1996 TOYOTA RAV4 gas tank

AX0T8−01
Z18886
RH Drive Shaft
LH Drive Shaft  Snap Ring
64 (650, 47)
 Cotter Pin
Lock Cap
216 (2,200, 159)
 Gasket
49 (500, 36)
7.0 (75, 65 in.·lbf)
62 (630, 46)
48 (490, 35)
Front Exhaust PipeEngine Mounting
Center MemberPS Gear Assembly
Front Suspension Crossmember
Assembly with Stabilizer Bar
RH Engine Under Cover
LH Engine Under Cover
137 (1,400, 101)
206 (2,100, 152)
127 (1,300, 94)
72 (730, 53)

73 (740, 54)
N·m (kgf·cm, ft·lbf)
: Specified torque
 Non−reusable part
113 (1,150 83)
 Cotter Pin
 Gasket
35 (360, 26)
64 (650, 47)
64 (650, 47)
19 (194, 14)
25 (250, 18)
46 (470, 34)
27 (280, 20)
25 (250, 18)
9.0 (95, 78 in.·lbf)
64 (650, 47)
9.0 (95, 78 in.·lbf)
37 (380, 27)
13 (135, 10)
39 (400, 29)64 (650, 47)
 GasketStarterEngine Wire
Clamp Plug for Line
Pressure Test
Shift Control
Cable ClipRear End Plate Stiffener Platex 6 Torque Converter
ClutchEngine Coolant Reservoir TankABS RelayAir Intake Connector
Air Cleaner
Case Assembly AX−14
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE UNIT
1996 RAV4 (RM447U)
AUTOMATIC TRANSAXLE UNIT
COMPONENTS

− DIAGNOSTICSENGINE
DI−15
1996 RAV4 (RM447U) DTC No.
(See Page)
Detection ItemTrouble AreaMILMemory
P0172
(DI−48)System too Rich
(Fuel Trim)
Fuel line pressure
Injector blockage, leak
Oxygen sensor malfunction
Manifold absolute pressure sensor
Engine coolant temp. sensor
 *1
P0300
(DI−51)Random / Multiple
Cylinder Misfire DetectedIgnition system
Injector
Fuel line pressure
EGR
Compression pressure
Valve clearance not to specification
Valve timing
Manifold absolute pressure sensor
Engine coolant temp. sensor
 *2P0301
P0302
P0303
P0304
(DI−51)Misfire Detected
− Cylinder 1
− Cylinder 2
− Cylinder 3
− Cylinder 4
P0325
(DI−56)Knock Sensor 1 Circuit
MalfunctionOpen or short in knock sensor 1 circuit
Knock sensor 1 (looseness)
ECM
 *1
P0335
(DI−59)Crankshaft Position Sensor
”A” Circuit Malfunction
Open or short in crankshaft position sensor circuit
Crankshaft position sensor
Starter
ECM
 *1
P0336
(DI−62)Camshaft Position Sensor
Circuit Range / PerformanceDistributor
ECM malfunction (for back up) *1
P0340
(DI−63)Camshaft Position Sensor
Circuit Malfunction
Open or short in camshaft position sensor circuit
Camshaft position sensor
Starter
ECM
 *1
P0401
(DI−65)Exhaust Gas Recirculation
Flow Insufficient Detected
EGR valve stuck close
Open or short in VSV circuit for EGR
Vacuum or EGR hose disconnected
Manifold absolute pressure sensor
EGR VSV open or close malfunction
ECM
 *1
P0402
(DI−71)Exhaust Gas Recirculation
Flow Excessive Detected
EGR valve stuck open
Vacuum or EGR hose is connected to wrong post
Manifold absolute pressure sensor
ECM
 *1
P0420
(DI−73)Catalyst System Efficiency
Below ThresholdThree−way catalytic converter
Open or short in oxygen sensor circuit
Oxygen sensor
 *1
P0440
(DI−76)Evaporative Emission Control
System Malfunction
Vapor pressure sensor
Fuel tank cap incorrectly installed
Fuel tank cap cracked or damaged
Vacuum hose cracked, holed, blocked, damaged or
disconnected
Hose or tube cracked, holed, damaged or loose
Fuel tank cracked, holed, or damaged
Charcoal canister cracked, holed or damaged
 *1
*1: MIL lights up
*
2: MIL lights up or blinking

EC05E−01
− EMISSION CONTROLEMISSION CONTROL SYSTEM
EC−1
1996 RAV4 (RM447U)
EMISSION CONTROL SYSTEM
PURPOSE
The emission control systems are installed to reduce the amount of HC, CO and NOx exhausted from the
engine ((3), (4) and (5)), to prevent the atmospheric release of blow−by gas−containing HC (1) and evapo-
rated fuel containing HC being released from the fuel tank (2).
The function of each system is shown in the following table.
SystemAbbreviationFunction
(1) Positive Crankcase Ventilation
(2) Evaporative Emission Control
(3) Exhaust Gas Recirculation
(4) Three−Way Catalytic Converter
(5) Sequential Multiport Fuel Injection*PCV
EVAP
EGR
TWC
SFIReduces HC
Reduces evaporated HC
Reduces NOx
Reduces HC, CO and NOx
Injects a precisely timed, optimum amount of fuel for reduced
exhaust emissions
Remark: * For inspection and repair of the SFI system, refer to the SFI section in this manual.

EC05I−03
EC3069Check Valve (Vacuum Valve)Gasket
S01428
S01451
Port E
Port D
Port A
Compressed
Air
Port B
S01452
Port C Port D Port A
Compressed
Air
Port B
− EMISSION CONTROLEVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
EC−5
1996 RAV4 (RM447U)
EVAPORATIVE EMISSION (EVAP)
CONTROL SYSTEM
INSPECTION
1. VISUALLY INSPECT LINES AND CONNECTIONS
Look for loose connections, sharp bends or damage.
2. VISUALLY INSPECT FUEL TANK
Look for deformation, cracks or fuel leakage.
3. VISUALLY INSPECT FUEL TANK CAP
Check if the cap and/or gasket are deformed or damaged.
If necessary, repair or replace the cap.
4. DISCONNECT EVAP HOSES FROM CHARCOAL CAN-
ISTER
5. VISUALLY INSPECT CHARCOAL CANISTER
Look for cracks or damage.
6. CHECK FOR CLOGGED FILTER, AND STUCK CHECK
VALVE AND DIAPHRAGM
(a) Install a plug to port E.
(b) While holding port B closed, blow air (1.76 kPa, 18
gf/cm
2, 0.26 psi) into port A and check that air flows from
port D.
(c) While holding port B and port D closed, blow air (1.76 kPa,
18 gf/cm
2, 0.26 psi) into port A and check that air does not
flow from port C.

MX05N−02
Q10400
Air Intake Connector
Engine Coolant
Reservoir Tank Clutch Release Cylinder
and Line
Vehicle Speed
Sensor Connector
Back−Up Light Switch
Connector
Control Cable
Clip
Ground Cable
Transaxle Case Protector
Tie Rod End RH Drive Shaft
Stiffener PlateNo.2 Rear
End Plate
 Snap Ring
 Cotter Pin LH Drive
Shaft
PS Gear Assembly
Engine Mounting
Center Member
RH Engine
Under Cover
LH Engine Under CoverFront Suspension Crossmember
Assembly with Stabilizer BarClipAir Cleaner Case
Assembly
with Air Hose
Snap Ring
Engine
Wire
Clamp
 Cotter Pin
Lock Cap Starter
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part
 
4.9 (50, 43 in.·lbf)
12 (120, 9)
29 (300, 22)
35 (360, 26)32 (330, 24)46 (470, 34)
64 (650, 47)
35 (360, 26)
64 (650, 47)
12 (120, 9)
64 (650, 47)
25 (250, 18)
25 (250, 18)
9.0 (95, 78 in.·lbf)
37 (380, 27)
39 (400, 29)
9.0 (95, 78 in.·lbf)
29 (300, 22)
37 (380, 27)49 (500, 36)
113 (1,150, 83)
137 (1,400, 101)
206 (2,100, 152)
216 (2,200, 159)
113 (1,150, 83)
64 (650, 47)
48 (490, 35)
80 (820, 59)
115 (1,170, 85)
127 (1,300, 94)
62 (630, 46)
Front Exhaust Pipe
 GasketClip
Washer
MX−2
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
1996 RAV4 (RM447U)
MANUAL TRANSAXLE UNIT (2WD)
COMPONENTS

SF0QM−02
3.5 (35, 31 in.·lbf)
S01936
Fuel Vent Tube
w/ Gauge Assembly
Fuel return Vent tubeFuel Suction w/ Pump
& Gauge Tube Assembly
Fuel Tank Inlet PipeGasketFuel Tank Cap
3.5 (35, 31 in.·lbf)
 Gasket
1.8 (18, 16 in.·lbf)1.8 (18, 16 in.·lbf)
 Gasket
 Gasket Gasket
 Gasket
EVAP Vent Tube
Fuel Cut Off Valvex 7
x 8
x 5
x 5
3.5 (35, 31 in.·lbf)

Fuel Tank
Breather Tube
Breather Hose
Fuel
Tank
Filler Pipe
Fuel Inlet HoseFiller Pipe ProtectorFiller Pipe Shield
Fuel Main Tube
Protector Fuel Tank Protector
Center Exhaust Pipe
 Gasket
Fuel Tank Band
39 (390, 29)
39 (390, 29)
 Gasket
49 (500, 36)21 (210, 15)
74 (750, 54)
37 (375, 27)
Propeller Shaft Assembly4WD
Protector
ProtectorProtector
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part
− SFIFUEL TANK AND LINE
SF−25
1996 RAV4 (RM447U)
FUEL TANK AND LINE
COMPONENTS
CAUTION:
Always use new gaskets when replacing the fuel tank or component parts.
Apply the proper torque to all parts tightened