1996 TOYOTA RAV4 coolant level

CO0BD−01
− COOLINGCOOLANT
CO−1
1996 RAV4 (RM447U)
COOLANT
INSPECTION
1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR
The engine coolant level should be between the ”LOW” and ”FULL” lines, when engine is cold.
If low, check for leaks and add engine coolant up to the ”FULL” line.
2. CHECK ENGINE COOLANT QUALITY
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator
are still hot, as fluid and steam can be blown out under pressure.
(b) There should not be any excessive deposits of rust or scale around the radiator cap or radiator filler
hole, and the coolant should be free from oil.
If excessively dirty, replace the coolant.
(c) Reinstall the radiator cap.

CO0BM−02
P13611
Protrusion
Jiggle
Valve5° 5° CO−12
− COOLINGTHERMOSTAT
1996 RAV4 (RM447U)
INSTALLATION
1. PLACE THERMOSTAT IN WATER PUMP
(a) Install a new gasket to the thermostat.
(b) Align the jiggle valve of the thermostat with the protrusion
of the water inlet, and insert the thermostat in the water
inlet.
HINT:
The jiggle valve may be set within 5° of either side of the pre-
scribed position.
2. INSTALL WATER INLET AND THERMOSTAT
Install the water inlet and thermostat with the 2 nuts.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
3. INSTALL OIL FILTER (See page LU−2)
4. FILL WITH ENGINE COOLANT
5. START ENGINE AND CHECK FOR LEAKS
6. CHECK ENGINE OIL LEVEL

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

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

28
G ELECTRICAL WIRING ROUTING
Position of Parts in Engine Compartment
*1 : w/ A/C
*2 : w/o A/C
A 1 A/C Condenser Fan Motor E 1 Electronically Controlled Transmission Solenoid
A 2 A/C Magnetic Clutch and Lock Sensor E 2 Engine Coolant Temp. Sensor
A 3 A/C Triple Pressure SW (A/C Dual and Single
Pressure SW) F 1 Front Side Marker Light LH
A 4 A/C Water Temp. SW F 2 Front Side Marker Light RH
A 5 A/T Fluid Temp. SW F 3 Front Turn Signal Light LH and Front Parking
A 6 ABS Actuator Light LH
A 7 ABS Actuator F 4 Front Turn Signal Light RH and Front Parking
A 8 ABS Relay Light RH
A 9 ABS Relay F 5 Front Washer Motor
A 10 ABS Speed Sensor Front LH F 6 Front Wiper Motor
A 11 ABS Speed Sensor Front RH F 7 Fusible Link Block
B 1 Back-Up Light SW (M/T) G 1 Generator
B 2 Brake Fluid Level Warning SW G 2Generator
C 1 Center Diff. Lock Warning Buzzer SW H 1 Headlight LH
C 2 Crankshaft Position Sensor H 2 Headlight RH
C 3 Cruise Control Actuator H 3 Horn
D 1 Data Link Connector 1

159
FAN MOTOR OPERATION
WHEN THE IGNITION SW IS TURNED ON, CURRENT FROM THE ECU-IG FUSE FLOWS TO THE FAN NO. 1 RELAY (COIL SIDE) AND
THE FAN NO. 2 RELAY (COIL SIDE) "TERMINAL 2 OF THE A/C SINGLE PRESSURE SW "TERMINAL 3 "TERMINAL 2 OF THE A/C
WATER TEMP. SW "TERMINAL 1 "GROUND, AND THE FAN NO. 1 RELAY AND THE FAN NO. 2 RELAY ARE TURNED ON.
AT THE SAME TIME THAT THIS CURRENT FLOWS, CURRENT FROM THE ECU-IG FUSE FLOWS TO THE E/G MAIN RELAY (COIL
SIDE) "GROUND, AND THE E/G MAIN RELAY IS TURNED ON. AS A RESULT, CURRENT FROM THE ALT FUSE FLOWS TO THE CDS
FA N FUSE AND RDI FAN FUSE.
*LOW SPEED OPERATION
WHEN THE IGNITION SW IS TURNED ON AND THE A/C IS ACTIVATED, CURRENT FLOWS FROM THE MG/C RELAY (POINT SIDE) "
THE FAN NO. 3 RELAY (COIL SIDE) "GROUND, AND THE FAN NO. 3 RELAY IS TURNED ON. AS A RESULT, CURRENT FROM THE
CDS FAN FUSE FLOWS TO TERMINAL 2 OF THE A/C CONDENSER FAN MOTOR "TERMINAL 1 "THE FAN NO. 2 RELAY (POINT
SIDE) "THE FAN NO. 3 RELAY (POINT SIDE) "TERMINAL 2 OF THE RADIATOR FAN MOTOR "TERMINAL 1 "GROUND, AND
BOTH OF THE FAN MOTORS, WITH THE RESULT THAT THE FANS ARE ACTIVATED AT LOW SPEED.
IF THE ENGINE COOLANT TEMPERATURE IS APPROX. 90
C (194
F) OR LESS, AND THE REFRIGERANT PRESSURE IS APPROX.
15.5 KG/CM
2 (1323 KPA, 191.7 PSI) OR LESS, BOTH THE A/C WATER TEMP. SW AND THE A/C SINGLE PRESSURE SW ARE CLOSED,
SO THAT THE FAN NO. 1 RELAY AND THE FAN NO. 2 RELAY ARE TURNED ON. AS A RESULT, BOTH OF THE FAN MOTOR OPERATE
AT LOW SPEED.
*HIGH SPEED OPERATION
WHEN, DURING A/C OPERATION, THE REFRIGERANT PRESSURE BECOMES HIGHER THAN ORDINARY LEVEL (APPROX. 15.5
KG/CM
2 (1323 PSI. 191.7 KPA)), THE A/C SINGLE PRESSURE SW IS TURNED OFF. AS A RESULT, THE FAN NO. 1 RELAY AND THE
FAN NO. 2 RELAY ARE TURNED OFF, AND THE CURRENT FLOWS FROM THE RDI FAN FUSE TO FAN NO. 1 RELAY (POINT SIDE) "
TERMINAL 2 OF THE RADIATOR FAN MOTOR "TERMINAL 1 "GROUND, AND CURRENT FROM THE CDS FAN FUSE FLOWS TO
TERMINAL 2 OF THE A/C CONDENSER FAN MOTOR "TERMINAL 1 "THE FAN NO. 2 RELAY (POINT SIDE) "GROUND, AND TO
BOTH OF THE FAN MOTORS IN PARALLEL, THUS CAUSING THE FAN MOTORS TO OPERATE AT HIGH SPEED.
NOTE THAT, BECAUSE THE CURRENT FLOWS IN THE SAME MANNER EVEN IF THE COOLANT TEMPERATURE IS APPROX. 90
C
(194
F) OR HIGHER, THE FAN MOTORS STILL OPERATE AT HIGH SPEED.
A 3 A/C SINGLE PRESSURE SW
2-3 : OPEN ABOVE APPROX. 15.5 KG/CM2 (191.7 PSI, 1323 KPA)
CLOSE BELOW APPROX. 12.5 KG/CM2 (142 PSI, 980 KPA)A 4 A/C WATER TEMP. SW
1-2 : OPEN ABOVE APPROX. 90
C (194
F)
CLOSED BELOW APPROX. 83
C (181.4
F)
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
A 128F 728R 129
A 328F 831
A 428J 131
: RELAY BLOCKS
CODESEE PAGERELAY BLOCKS (RELAY BLOCK LOCATION)
223R/B NO. 2 (ENGINE COMPARTMENT LEFT)
625R/B NO. 6 (ENGINE COMPARTMENT LEFT)
: JUNCTION BLOCK AND WIRE HARNESS CONNECTOR
CODESEE PAGEJUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION)
1A20INSTRUMENT PANEL WIRE AND J/B NO.1 (LOWER FINISH PANEL)
1E20FUSE BLOCK ASSY WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
: CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS
CODESEE PAGEJOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION)
IB236ENGINE ROOM MAIN WIRE AND INSTRUMENT PANEL WIRE (RIGHT KICK PANEL)
: GROUND POINTS
CODESEE PAGEGROUND POINTS LOCATION
EA34RADIATOR RIGHT
EB34RADIATOR LEFT
SYSTEM OUTLINE
SERVICE HINTS

LU06C−02
LU−20
− LUBRICATIONOIL COOLER
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL OIL COOLER
(a) Clean the oil cooler contact surface on the oil cooler
mounting.
(b) Install a new O−ring to the oil cooler.
(c) Temporarily install the oil cooler with the nut.
(d) Apply a light coat of engine oil on the threads and under
the head of the relief valve.
(e) Install the plate washer and union bolt.
Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)
(f) Tighten the nut.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
(g) Connect the 2 water bypass hoses to the oil cooler.
2. INSTALL OIL FILTER
3. INSTALL WATER BYPASS HOSE HEAT PROTECTOR
Install the heat protector with the bolt and 2 nuts.
4. INSTALL EXHAUST MANIFOLD AND FRONT TWC AS-
SEMBLY (See page EM−55)
5. INSTALL OIL DIPSTICK
6. INSTALL GENERATOR (See page CH−19)
7. INSTALL FRONT EXHAUST PIPE (See page EM−55)
8. FILL WITH ENGINE COOLANT
9. START ENGINE AND CHECK FOR LEAKS
10. CHECK ENGINE OIL LEVEL
11. INSTALL RH ENGINE UNDER COVER