1996 TOYOTA RAV4 İdle

Z17555
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part
 Precoated partOutput Shaft AssemblyInput Shaft Assembly
 Tapered Roller Bearing
Outer Race
Reverse Idler Gear ShaftReverse Idler Gear
Thrust Washer
Rear Bearing Retainer
Needle Roller Bearing 5th Driven Gear
Synchronizer Pull RingKey Spring
Middle Synchronizer
Ring
Snap Ring Output Shaft
Lock Nut5th Gear
No.3 Clutch Hub
No.3 Hub Sleeve Key Spring Outer Synchronizer RingInner Synchronizer RingSnap Ring
Spacer x7Shim
 Lock Bolt
29 (300, 22)
42 (430, 31)
123 (1,250, 90)
Snap Ring 
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−15
1996 RAV4 (RM447U)

Q06190
Q01615
Q00056
Q05815
FIPG
MT0669
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−19
1996 RAV4 (RM447U)
18. REMOVE SNAP RING
(a) Using a snap ring expander, remove the input shaft rear
bearing snap ring.
(b) Using 2 screwdrivers and a hammer, remove the 2 snap
rings.
19. REMOVE STRAIGHT SCREW PLUG, SEAT, SPRING
AND LOCKING BALL
(a) Using a hexagon wrench (6 mm), remove the plug.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Using a magnetic finger, remove the seat, spring and
locking ball.
20. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
21. REMOVE TRANSMISSION CASE
Remove the 17 bolts and tap the case with a plastic hammer.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
22. REMOVE SHIM
HINT:
At the time of reassembly, please refer to the following item.
Install the previously selected shim by adjusting output shaft
preload.
(See page MX−27)

MT0693
SST
Q06375
Z17557
Matchmarks
Q01614
Q08124
MX−20
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
23. REMOVE OUTPUT SHAFT REAR TAPER ROLLER
BEARING OUTER RACE
Using SST and a hammer, remove the output shaft rear taper
roller bearing outer race.
SST 09316−60011 (09316−00011)
24. REMOVE TRANSMISSION OIL PIPE
(a) Remove the gasket from the oil pipe.
(b) Remove the 2 bolts and oil pipe.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
25. REMOVE REVERSE SHIFT ARM BRACKET AS-
SEMBLY
Remove the bolt and pull off the reverse shift arm and bracket.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
26. REMOVE REVERSE IDLER GEAR AND SHAFT
Pull out the shaft, remove the reverse idler gear and thrust
washer.
HINT:
At the time of reassembly, please refer to the following item.
Align the matchmarks, as shown.
27. REMOVE STRAIGHT SCREW PLUG, LOCKING BALL
AND SPRING
(a) Using a hexagon wrench (6 mm), remove the 2 plugs.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Using a magnetic finger, remove the 2 seats, springs and
balls.
28. REMOVE NO.1, NO.2 SHIFT FORKS AND SHIFT HEAD
SET BOLT
Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)
29. REMOVE NO.1 SHIFT FORK SHAFT
Pull up the No.3 shift fork shaft, remove the No.1 shift fork shaft.
HINT:
At the time of reassembly, please refer to the following item.
When it is difficult to push the fork shaft through the reverse shift
fork, pull up the No.3 shift fork shaft.

S01834
Gasket
SST (Union)
SST
Fuel Inlet Hose Gasket
SST (Union)
S01835
301 − 347 kPa
S01836
For 5 Minutes After Engine has Stopped
147 kPa
or More SF−6
− SFIFUEL PUMP
1996 RAV4 (RM447U)
(f) Install the fuel inlet hose and SST (pressure gauge) to the
fuel filter outlet with the 3 gaskets and SST (union bolt).
SST 09268−45012
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(g) Wipe off any splattered gasoline.
(h) Connect the TOYOTA hand−held tester to the DLC3.
(i) Reconnect the negative (−) terminal cable to the battery.
(j) Turn the ignition switch ON.
(k) Measure the fuel pressure.
Fuel pressure:
301 − 347 kPa (3.1 − 3.5 kgf/cm
2, 44 − 50 psi)
If pressure is high, replace the fuel pressure regulator.
If pressure is low, check these parts:
Fuel hoses and connections
Fuel pump
Fuel filter
Fuel pressure regulator
(l) Remove the TOYOTA hand−held tester from the DLC3.
(m) Start the engine.
(n) Measure the fuel pressure at idle.
Fuel pressure:
301 − 347 kPa (3.1 − 3.5 kgf/cm
2, 44 − 50 psi)
(o) Stop the engine.
(p) Check that the fuel pressure remains as specified for 5
minutes after the engine has stopped.
Fuel pressure:
147 kPa (1.5 kgf/cm
2, 21 psi) or more
If pressure is not as specified, check the fuel pump, pressure
regulator and/or injectors.
(q) After checking fuel pressure, disconnect the negative (−)
terminal cable from the battery and carefully remove the
SST to prevent gasoline from splashing.
SST 09268−45012
(r) Reconnect the fuel inlet hose with 2 new gaskets and the
union bolt.
Torque: 29 N·m (300 kgf·cm, 21 ft·lbf)
(s) Reconnect the negative (−) terminal cable to the battery.
(t) Check for fuel leakage (See page SF−1).
(u) Reinstall the engine comportment R/B No.2 and air clean-
er assembly.
3. CHECK FUEL PUMP
(a) Remove the LH rear seat assembly.
(b) Remove the floor service hole cover.

S01898
SF0QO−03
S01946
P
E
R
S00037
Ohmmeter
Throttle Position Sensor
VC
VTA
E2
S01901
Disconnect
Plug
− SFITHROTTLE BODY
SF−27
1996 RAV4 (RM447U)
THROTTLE BODY
ON−VEHICLE INSPECTION
1. INSPECT THROTTLE BODY
(a) Check that the throttle linkage moves smoothly.
(b) Check the vacuum at each port.
Start the engine.
Check the vacuum with your finger.
Port nameAt idleOther than idle
PNo vacuumVacuum
ENo vacuumVacuum
RNo vacuumNo vacuum
2. INSPECT THROTTLE POSITION SENSOR
(a) Apply vacuum to the throttle opener.
(b) Disconnect the sensor connector.
(c) Using an ohmmeter, measure the resistance between
each terminal.
Clearance between
lever and stop screwBetween
terminalsResistance
0 mm (0 in.)VTA − E20.2 − 5.7 kΩ
Throttle valve fully
openVTA − E22.0 − 10.2 kΩ
−VC − E22.5 − 5.9 kΩ
(d) Reconnect the sensor connector.
3. INSPECT AND ADJUST THROTTLE OPENER
4. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
5. CHECK IDLE SPEED
Idle speed: 700 ± 50 rpm
6. CHECK AND ADJUST THROTTLE OPENER SETTING
SPEED
(a) Disconnect the vacuum hose from the throttle opener,
and plug the hose end.
(b) Maintain the engine at 2,500 rpm.
(c) Release the throttle valve.
(d) Check that the throttle opener is set.
Throttle opener setting speed:
1,300 − 1,500 rpm (w/ cooling fan OFF)

SF0QT−02
S01261
SST DLC1
E1 TE1
S01904
RSC
RSO+B
Ohmmeter
IAC Valve SF−34
− SFIIDLE AIR CONTROL (IAC) VALVE
1996 RAV4 (RM447U)
IDLE AIR CONTROL (IAC) VALVE
ON−VEHICLE INSPECTION
1. INSPECT IAC VALVE OPERATION
(a) Initial conditions:
Engine at normal operating temperature
Idle speed check correctly
Transmission in neutral position
(b) Using SST, connect terminals TE1 and E1 of the DLC1.
SST 09843−18020
(c) Maintain engine speed in the range between 900 − 1,300
rpm for 5 seconds. Check that it returns to idle speed.
If the engine speed operation is not as specified, check the IAC
valve, wiring and ECM.
(d) Remove the SST.
SST 09843−18020
2. INSPECT IAC VALVE RESISTANCE
NOTICE:
”Cold” and ”Hot” in these sentences express the tempera-
ture of the coils themselves. ”Cold” is from −10°C (14°F) to
50°C (122°F) and ”Hot” is from 50°C (122°F) to 100°C
(212°F).
(a) Disconnect the IAC valve connector.
(b) Using an ohmmeter, measure the resistance between ter-
minal +B and other terminals (RSC, RSO).
Resistance:
Cold: 17.0 − 24.5 Ω
Hot: 21.5 − 28.5 Ω
If resistance is not as specified, replace the IAC valve.
(c) Reconnect the IAC valve connector.

SF0QU−02
− SFIIDLE AIR CONTROL (IAC) VALVE
SF−35
1996 RAV4 (RM447U)
COMPONENTS

SF0QV−03
S01895
SF−36
− SFIIDLE AIR CONTROL (IAC) VALVE
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE THROTTLE BODY (See page SF−30)
2. REMOVE IAC VALVE
Remove the 4 screws, IAC valve and gasket.
HINT:
At the time of installation, plaese refer to the following items.
Place a new gasket on the throttle body.