1996 TOYOTA RAV4 engine oil

EM−64
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
39. FILL WITH ENGINE COOLANT
40. START ENGINE AND CHECK FOR LEAKS
41. RECHECK ENGINE COOLANT LEVEL AND OIL LEV-
EL
42. INSTALL RH ENGINE UNDER COVER

EM1BA−02
S01374
Cover
Connector EM−68
− ENGINE MECHANICALENGINE UNIT
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE BATTERY
2. REMOVE ENGINE HOOD
3. REMOVE ENGINE UNDER COVERS
4. DRAIN ENGINE COOLANT
5. DRAIN ENGINE OIL
6. DRAIN TRANSAXLE OIL
7. REMOVE AIR CLEANER CAP AND CASE
8. DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY, CABLE BRACKET AND CLAMPS
9. DISCONNECT ENGINE WIRE FROM RELAY BLOCK
NO. 2
(a) Remove the 2 bolts, and disconnect the relay block No.
2 from the body.
(b) Remove the upper cover.
(c) Disconnect the connector.
(d) Remove the 2 nuts and disconnect the engine wire.
10. REMOVE CHARCOAL CANISTER
11. REMOVE GENERATOR (See page CH−7)
12. REMOVE RADIATOR UPPER AND LOWER HOSES
13. REMOVE WATER INLET
Remove the 2 nuts and water inlet.
14. DISCONNECT HEATER HOSES
15. DISCONNECT FUEL INLET HOSE
CAUTION:
Catch leaking fuel in a container.
16. M/T only:
REMOVE STARTER (See page ST−4)
17. DISCONNECT GROUND CABLE
Remove the bolt and disconnect the ground cable on the trans-
axle.

S01351
Buck−up Light
Connector M/T only
S01797
M/T
A/T
S01785
A/T only
− ENGINE MECHANICALENGINE UNIT
EM−69
1996 RAV4 (RM447U)
18. M/T only:
DISCONNECT CLUTCH RELEASE CYLINDER FROM
TRANSAXLE
(a) Disconnect the back−up light switch connector.
(b) Remove the clamp, and disconnect the tube from the
bracket.
(c) Remove the bolt, and disconnect the bracket from the
transaxle.
(d) Remove the clamp bolt, and disconnect the tube from the
transaxle.
(e) Remove the 2 bolts, and disconnect the release cylinder
from the transaxle.
19. DISCONNECT TRANSAXLE CONTROL CABLE(S)
FROM TRANSAXLE
20. A/T only:
DISCONNECT TRANSAXLE CONTROL CABLE FROM
FRONT SUSPENSION CROSSMEMBER AND ENGINE
MOUNTING CENTER MEMBER
Remove the 2 bolts, and disconnect the control cable from the
crossmember and center member.
21. A/T and 4WD w/ M/T:
DISCONNECT TRANSAXLE OIL COOLER HOSES

S01432
S01285
S01347
EM−70
− ENGINE MECHANICALENGINE UNIT
1996 RAV4 (RM447U)
22. DISCONNECT CONNECTORS, CORD, STRAP AND
HOSES
(a) Disconnect the vapor pressure sensor connector.
(b) Disconnect the igniter connector.
(c) Disconnect the ignition coil connector.
(d) Disconnect the noise filter connector.
(e) Disconnect the high−tension cord from the ignition coil.
(f) Disconnect the MAP sensor connector.
(g) Disconnect the MAP sensor vacuum hose from the gas
filter on the intake manifold.
(h) Disconnect the brake booster hose from the intake man-
ifold.
(i) 4WD M/T:
Disconnect the differential lock control solenoid connec-
tor.
(j) Disconnect the ground strap from the cowl.
23. DISCONNECT ENGINE WIRE FROM CABIN
(a) Remove the RH scuff plate.
(b) Remove the RH cowl side trim.
(c) Remove the RH floor carpet center cover.
(d) Disconnect the 2 ECM connectors.
(e) Disconnect the 2 connectors from the connectors on the
bracket.
(f) Disconnect the connector from the J/B No. 4.
(g) Disconnect the wire clamp from the bracket.
(h) Pull out the engine wire from the cabin.
24. REMOVE FRONT EXHAUST PIPE
(a) Using a 14 mm deep socket wrench, remove the 2 bolts
holding the front exhaust pipe to the front TWC.
(b) Remove the 2 bolts and 2 nuts holding the front exhaust
pipe to the TWC w/ pipe.
(c) Remove the front exhaust pipe and 2 gaskets.
25. DISCONNECT A/C COMPRESSOR FROM ENGINE
(a) Disconnect the A/C compressor connector.
(b) Remove the 2 bolts, nut and stud bolt, and disconnect the
A/C compressor from the engine.
HINT:
Suspend the A/C compressor securely.
26. 4WD only:
REMOVE PROPELLER SHAFT (See page PR−3)
27. REMOVE FRONT DRIVE SHAFT (See page SA−20)
28. REMOVE STABILIZER (See page SA−40)

S01797
M/T
A/T
S01785
A/T Only
S01351
M/T Only
Back−up Light
Connector EM−78
− ENGINE MECHANICALENGINE UNIT
1996 RAV4 (RM447U)
14. CONNECT CONNECTORS, CORD, STRAP AND
HOSES
(a) Connect the vapor pressure sensor connector.
(b) Connect the igniter connector.
(c) Connect the ignition coil connector.
(d) Connect the noise filter connector.
(e) Connect the high−tension cord to the ignition coil.
(f) Connect the MAP sensor connector.
(g) Connect the MAP sensor vacuum hose to the gas filter on
intake manifold.
(h) Connect the brake booster hose to the intake manifold.
(i) 4WD M/T:
Connect the differential lock control solenoid connector.
(j) Connect the ground strap to the cowl.
15. A/T and 4WD w/ M/T:
CONNECT TRANSAXLE OIL COOLER HOSES
16. CONNECT TRANSAXLE CONTROL CABLE(S) TO
TRANSAXLE
17. A/T only:
INSTALL TRANSAXLE CONTROL CABLE TO FRONT
SUSPENSION CROSSMEMBER AND ENGINE
MOUNTING CENTER MEMBER
18. M/T only:
INSTALL CLUTCH RELEASE CYLINDER
(a) Install the release cylinder with the 2 bolts.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
(b) Install the bracket with the bolt, and install the tube to the
bracket with the clamp.
(c) Install the tube with the clamp and bolt.
(d) Connect the back−up light switch connector.
19. CONNECT GROUND CABLE
Connect the ground cable onto the transaxle.
20. M/T only:
INSTALL STARTER (See page ST−19)
21. CONNECT FUEL INLET HOSE TO FUEL FILTER
Connect the inlet hose with 2 new gaskets and the union bolt.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
22. CONNECT HEATER HOSES
23. INSTALL WATER INLET
Install the water inlet with the 2 nuts.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
24. INSTALL RADIATOR UPPER AND LOWER HOSES

S01374
Cover
Connector
− ENGINE MECHANICALENGINE UNIT
EM−79
1996 RAV4 (RM447U)
25. INSTALL GENERATOR (See page CH−19)
26. INSTALL CHARCOAL CANISTER
27. CONNECT ENGINE WIRE TO RELAY BOX NO. 2
(a) Connect the engine wire to the relay block No.2 with the
2 nuts.
(b) Connect the connector.
(c) Install the upper cover.
(d) Connect the relay block No. 2 to the body with the 2 bolts.
28. INSTALL ACCELERATOR CABLE TO THROTTLE
BODY, CABLE BRACKET AND CLAMPS
29. INSTALL AIR CLEANER CASE AND CAP
30. INSTALL BATTERY
31. FILL WITH TRANSAXLE OIL
32. FILL WITH ENGINE OIL
33. FILL WITH ENGINE COOLANT
34. START ENGINE AND CHECK FOR LEAKS
35. PERFORM ENGINE ADJUSTMENT
36. CHECK FRONT WHEEL ALIGNMENT
37. INSTALL ENGINE UNDER COVERS
38. INSTALL ENGINE HOOD
39. ROAD TEST VEHICLE
Check for abnormal noises, shock slippage, correct shift points
and smooth operation.
40. RECHECK ENGINE COOLANT AND OIL LEVELS

P15297
M/T
EM1BB−02
P15299
A/T
P13432
P15304
RH Engine
Mounting
Bracket
PS Pump
Bracket
S01580
1
3
2
− ENGINE MECHANICALCYLINDER BLOCK
EM−81
1996 RAV4 (RM447U)
DISASSEMBLY
1. M/T:
REMOVE FLYWHEEL
Remove the 8 bolts and flywheel.
2. A/T:
REMOVE DRIVE PLATE
Remove the 8 bolts, front plate, drive plate and rear spacer.
3. REMOVE REAR END PLATE
Remove the bolt and end plate.
4. INSTALL ENGINE TO ENGINE STAND FOR DIS-
ASSEMBLY
5. REMOVE RH ENGINE MOUNTING BRACKET
Remove the 3 bolts and mounting bracket.
6. REMOVE PS PUMP BRACKET
Remove the 3 bolts and PS pump bracket.
7. REMOVE TIMING BELT AND PULLEYS (See page
EM−15)
8. REMOVE CYLINDER HEAD (See page EM−33)
9. REMOVE OIL PAN AND OIL PUMP (See page LU−7)
10. REMOVE GENERATOR DRIVE BELT ADJUSTING
BAR, WATER PUMP AND WATER PUMP COVER AS-
SEMBLY
(a) Remove the bolt and adjusting bar.
(b) Remove the 3 bolts in the sequence shown, remove the
water pump, water pump cover assembly and O−ring.
11. REMOVE OIL COOLER (See page LU−18)

S01631
SST
P05527
P13434
P13435
P13436
EM−82
− ENGINE MECHANICALCYLINDER BLOCK
1996 RAV4 (RM447U)
12. REMOVE KNOCK SENSOR
Using SST, remove the knock sensor.
SST 09816−30010
13. REMOVE REAR OIL SEAL RETAINER
Remove the 6 bolts, retainer and gasket.
14. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while mov-
ing the connecting rod back and forth.
Standard thrust clearance:
0.160 − 0.312 mm (0.0063 − 0.0123 in.)
Maximum thrust clearance: 0.35 mm (0.0138 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly. If necessary, replace the crankshaft.
15. REMOVE CONNECTING ROD CAPS AND CHECK OIL
CLEARANCE
(a) Check the matchmarks on the connecting rod and cap to
ensure correct reassembly.
(b) Remove the 2 connecting rod cap nuts.