1996 TOYOTA RAV4 gasoline

CodeMaterial
nameHeat*
resistant
temperature
limit °C (°F)Resistance to
alcohol or gasolineNotes
AASAcrylonitrile
Acrylic Styrene80
(176)Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease.)Avoid gasoline and
organic or aromatic
solvents.
ABSAcrylonitrile
Butadiene Styrene80
(176)Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease.)Avoid gasoline and
organic or aromatic
solvents.
AESAcrylonitrile
Ethylene Styrene80
(176)Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease).Avoid gasoline and
organic or aromatic
solvents.
BMCBulk
Moulding
Compound150
(302)Alcohol and gasoline are
harmless.Most solvents are
harmless.
CABCellulose
Acetate80
(176)Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease).Avoid gasoline and
organic or aromatic
solvents.
EPDM100
(212) Ethylene
PropyleneAlcohol is harmless.
Gasoline is harmless if applied
only for short time in small
amounts.Most solvents are
harmless but avoid
dipping in gasoline,
solvents, etc.
PAPolyamide
(Nylon)80
(176)Alcohol and gasoline are
harmless.Avoid battery acid.
PBTPolybutylene
Terephthalate160
(320)Alcohol and gasoline are
harmless.Most solvents are
harmless.
PC
Polycarbonate120
(248)Alcohol is harmless.Avoid gasoline brake
fluid, wax, wax removers
and organic solvents.
Avoid alkali.
PE
Polyethylene80
(176)Alcohol and gasoline are harmless.Most solvents are
harmless.
PETPolyethylene
Terephthalate75
(167)Alcohol and gasoline are
harmless.Avoid dipping in water.
HANDLING PRECAUTIONS
1. The repair procedure for plastic body parts must conform with the type of plastic material.
2. Plastic body parts are identified by the codes in the following chart.
3. When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding,
painting etc.), consideration must given to the property of the plastic.
*Temperatures higher than those listed here may result in material deformation during repair.
PLASTIC BODY PARTSPPœ2

CodeMaterial
nameHeat*
resistant
temperature
limit °C (°F)Resistance to
alcohol or gasolineNotes
PMMAPolymethyl
Methacrylate80
(176)Alcohol is harmless if applied
only for short time in small
amounts.Avoid dipping or immersœ
ing in alcohol, gasoline,
solvents, etc.
POMPolyoxymethylene
(Polyacetal)100
(212)Alcohol and gasoline are
harmless.Most solvents are
harmless.
PP
Polypropylene80
(176)Alcohol and gasoline are
harmless.Most solvents are
harmless.
PPOModified
Polyphenylene
Oxide100
(212)Alcohol is harmless.Gasoline is harmless if
applied only for quick
wiping to remove
grease.
PS
Polystyrene60
(140)Alcohol and gasoline are harmœ
less if applied only for short time
in small amounts.Avoid dipping or immersœ
ing in alcohol, gasoline,
solvents, etc.
PUR
Polyurethane80
(176)Alcohol is harmless if applied only
for very short time in small amounts
(e.g., quick wiping to remove
grease.)Avoid dipping or immersœ
ing in alcohol, gasoline,
solvents, etc.
PVCPolyvinylchloride
(Vinyl)80
(176)Alcohol and gasoline are harmless if
applied only for short time in small
amounts (e.g., quick wiping to remove
grease).Avoid dipping or immersœ
ing in alcohol, gasoline,
solvents, etc.
SANStyrene
Acrylonitrile80
(176)Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease.)Avoid dipping or immersœ
ing in alcohol, gasoline,
solvents etc.
SMCSheet
Moulding
Compound180
(356)Alcohol and gasoline are
harmless.Avoid alkali.
TPOThermoplastic
Olefine80
(176)Alcohol is harmless.
Gasoline is harmless if applied
only for short time in small
amounts.Most solvents are harmœ
less but avoid dipping in
gasoline, solvents,
etc.
TPUThermoplastic
Polyurethane80
(176)Alcohol is harmless if applied
only for very short time in small
amounts (e.g., quick wiping to
remove grease).Avoid dipping or immersœ
ing in alcohol, gasoline,
solvents, etc.
TSOPTOYOTA
Super
Olefine Polymer80
(176)Alcohol and gasoline are
harmless.Most solvents are
harmless.
UPUnsaturated
Polyester11 0
(233)Alcohol and gasoline are
harmless.Avoid alkali.
*Temperatures higher than those listed here may result in material deformation during repair.
PLASTIC BODY PARTSPPœ3

IG0317IG0151P25066A06618
1.1 − 1.3 mm
(0.043 − 0.051 in.)
A00404
”10 (+)
#30 (+)#40 (+) ON
#20 (+)
− DIAGNOSTICSENGINE
DI−53
1996 RAV4 (RM447U)
INSPECTION PROCEDURE
1 Check spark plug and spark of misfiring cylinder.
PREPARATION:
(a) Disconnect the high−tension cord from spark plug.
(b) Remove spark plug.
CHECK:
(a) Check the carbon deposits on electrode.
(b) Check electrode gap.
OK:
(1) No large carbon deposit present.
Not wet with gasoline or oil.
(2) Electrode gap: 1.1 − 1.3 mm (0.043 − 0.051 in.)
PREPARATION:
(a) Install the spark plug to the high − tension cord.
(b) Disconnect injector connector.
(c) Ground spark plug.
CHECK:
Check if spark occurs while engine is being cranked.
NOTICE:
To prevent excess fuel being injected from the injectors
during this test, do not crank the engine for more than 5 −
10 seconds at a time.
OK:
Spark jumps across electrode gap.
NG Replace or check ignition system (See page
IG−1).
OK
2 Check voltage of ECM terminal for injector of failed cylinder.
PREPARATION:
(a) Remove side trim cover (See page SF−61).
(b) Turn ignition switch ON.
CHECK:
Measure voltage between applicable terminal of ECM connec-
tor and body ground.
OK:
Voltage: 9 − 14 V
OK Go to step 4
NG

S01799
1086 1 3 9
4257
S01796
90°
90°Painted Mark
S01786
Z00058
(3)
(2)
(1) EM−56
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
(b) Install the cylinder head bolts.
HINT:
The cylinder head bolts are tightened in 2 progressive
steps (steps (b) and (d)).
If any cylinder head bolt is broken or deformed, replace
it.
(1) Apply a light coat of engine oil on the threads and
under the heads of the cylinder head bolts.
(2) Install and uniformly tighten the 10 cylinder head
bolts and plate washers, in several passes, in the
sequence shown.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
If any one of the cylinder head bolts does not meet the torque
specification, replace the cylinder head bolt.
(3) Mark the front of the cylinder head bolt head with
paint.
(4) Retighten the cylinder head bolts 90° in the se-
quence shown above.
(5) Check that the painted mark is now at a 90° angle
to front.
7. INSTALL SPARK PLUG TUBES
(a) Clean the cylinder head tube holes of any residual adhe-
sive, oil or foreign particles. Remove any oil with kerosene
or gasoline.
(b) Screw the threads of the spark plug tube coated with
adhesive into the cylinder head.
(c) Using the spark plug tube nut and a 30 mm socket
wrench, tighten the spark plug tubes.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
8. ASSEMBLE EXHAUST CAMSHAFT
(a) Mount the hexagon wrench head portion of the camshaft
in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Install the camshaft gear spring (1), camshaft sub gear (2)
and wave washer (3).
HINT:
Align the pins on the gears with the spring ends.

IG0J3−02
− IGNITIONIGNITION SYSTEM
IG−1
1996 RAV4 (RM447U)
IGNITION SYSTEM
ON−VEHICLE INSPECTION
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).
1. INSPECT IGNITERS AND SPARK TEST
Check that the spark occurs.
(1) Disconnect the high−tension cord (from the ignition
coil) from the distributor cap.
(2) Hold the end approx. 12.5 mm (0.50 in.) from the
body ground.
(3) See if spark occurs while engine is being cranked.
NOTICE:
To prevent gasoline from being injected from injectors dur-
ing this test, crank the engine for no more than 5 − 10 se-
conds at time.
If the spark does not occur, perform the test as follows:

S05308
16mm Plug
Wrench
Z00032
IG0152
IG−4
− IGNITIONIGNITION SYSTEM
1996 RAV4 (RM447U)
(c) Using a 16 mm plug wrench, remove the 4 spark plugs.
(d) Visually check the spark plug for thread damage and insu-
lator damage.
If abnormal, replace the spark plug.
Recommended spark plug:
DENSOPK20R11
NGKBKR6EP−11
(e) Inspect the electrode gaps.
Maximum electrode gap for used spark plug:
1.3 mm (0.051 in.)
If the gap is greater than maximum, replace the spark plug.
Correct electrode gap for new spark plug:
1.1 mm (0.043 in.)
NOTICE:
If adjusting the gap of a new spark plug, bend only the base
of the ground electrode. Do not touch the tip. Never attempt
to adjust the gap on the used plug.
(f) Clean the spark plugs.
If the electrode has traces of wet carbon, allow it to dry and then
clean with a spark plug cleaner.
Air pressure: Below 588 kPa (6 kgf/cm
2, 85 psi)
Duration: 20 seconds or less
HINT:
If there are traces of oil, remove it with gasoline before using the
spark plug cleaner.
(g) Using a 16 mm plug wrench, install the 4 spark plugs.
Torque: 18 N·m (180 kgf·cm, 13 ft·lbf)
(h) Reconnect the high−tension cords from the spark plugs.
4. INSPECT IGNITION COILS
(a) Disconnect the ignition coil connector.
(b) Disconnect the high−tension cord from ignition coil.
(c) Inspect the primary coil resistance.
Using an ohmmeter, measure the resistance between the
positive (+) and negative (−) terminals.
Primary coil resistance:
Cold0.36 − 0.55 Ω
Hot0.45 − 0.65 Ω
If the resistance is not as specified, replace the ignition coil.

LU061−02
S01264
SST
LU0555
S01266
LU−2
− LUBRICATIONOIL AND FILTER
1996 RAV4 (RM447U)
REPLACEMENT
CAUTION:
Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In addi-
tion, used engine oil contains potentially harmful
contaminants which may cause skin cancer.
Care should be taken, therefore, when changing en-
gine oil to minimize the frequency and length of time
your skin is exposed to used engine oil. Protective
clothing and gloves that cannot be penetrated by oil
should be worn. The skin should be thoroughly
washed with soap and water, or use water−less hand
cleaner, to remove any used engine oil. Do not use
gasoline, thinners, or solvents.
In order to preserve the environment, used oil and
used oil filters must be disposed of only at desig-
nated disposal sites.
1. DRAIN ENGINE OIL
(a) Remove the oil filler cap.
(b) Remove the oil drain plug, and drain the oil into a contain-
er.
2. REPLACE OIL FILTER
(a) Using SST, remove the oil filter.
SST 09228−06501
(b) Check and clean the oil filter installation surface.
(c) Lubricate the filter rubber gasket with clean engine oil.
(d) Lightly tighten the oil filter by hand until the rubber gasket
contacts the seat of the filter mounting.

R10664
SST
R10757
Z12363
1 − 2 mm
(0.04 − 0.08 in.) SA−88
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
(a) Install 2 new snap rings to the side gear shafts.
(b) Using SST, install the 2 side gear shafts until it contacts
the pinion shaft.
SST 09520−24010
HINT:
Check that the shaft is fully inserted by confirming the noise it
should make when it is tapped.
28. 2 Pinion Differential:
INSTALL SIDE GEAR SHAFTS
(a) Install the 2 side gear shafts to the differential case.
(b) Install 2 new snap rings to the 2 side gear shafts.
29. INSTALL DIFFERENTIAL CARRIER COVER
(a) Clean contacting surfaces of any residual FIPG material
using gasoline or alcohol.
(b) Apply FIPG to the carrier.
FIPG:
Part No.08826−00090, THREE BOND 1281 or equiva-
lent
HINT:
Install the carrier cover within 3 minutes after applying FIPG.
(c) Torque the 8 bolts.
Torque: 47 N·m (475 kgf·cm, 34 ft·lbf)