1996 TOYOTA RAV4 heater

Rear Combination Light (PMMA/PP)
Roof Side Inner Garnish (TSOP)
Air Conditioner Unit (PP)
Heater Blower (PP)
Rear Bumper Side Seal (PE)
Cowl Side Trim Board (PP)
Deck Trim Side Panel (TSOP) Front Door Outside Scuff Plate (PP/PE)
Back Door Outside Handle (PC) Rear Door Outside Scuff Plate (PP/PE)
Rear Bumper Piece (TSOP)
Licence Plate Light (PC)
Reflex Reflector (PMMA/ABS)
HINT:
wResin material differs with model.
/ Made up of 2 or more kinds of materials.
PLASTIC BODY PARTSPPœ6

CO0BE−01
S01292Drain Plug CO−2
− COOLINGCOOLANT
1996 RAV4 (RM447U)
REPLACEMENT
1. DRAIN ENGINE COOLANT
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
(b) Loosen the radiator drain plug (on the left side of the ra-
diator lower tank) and engine drain plug (on the left rear
of the cylinder block), and drain the coolant.
(c) Close the drain plugs.
Torque: Engine drain plug
25 N·m (250 kgf·cm, 18 ft·lbf)
2. FILL ENGINE COOLANT
(a) Slowly fill the system with coolant.
Use a good brand of ethylene−glycol base coolant
and mix it according to the manufacture’s direc-
tions.
Using coolant which includes more than 50 % ethyl-
ene−glycol (but not more than 70 %) is recom-
mended.
NOTICE:
Do not use an alcohol type coolant.
The coolant should be mixed with demineralized wa-
ter or distilled water.
Capacity (w/ Heater):
M/T: 8.0 liters (8.5 US qts, 7.0 lmp. qts)
A/T: 7.7 liters (8.1 US qts, 6.8 lmp. qts)
(b) Install radiator cap.
(c) Start the engine, and bleed the cooling system.
(d) Refill the radiator reservoir with coolant until it reaches the
”FULL” line.
3. CHECK ENGINE COOLANT FOR LEAKS

CO0BO−02
Z00570
Radiator Cap Tester
Radiator Cap30° or More
S01265
Radiator Cap Tester CO−14
− COOLINGRADIATOR
1996 RAV4 (RM447U)
ON−VEHICLE INSPECTION
1. REMOVE RADIATOR CAP
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
2. INSPECT RADIATOR CAP
NOTICE:
If the radiator cap has contaminations, always rinse
it with water.
When performing steps (a) and (b) below, keep the ra-
diator cap tester at an angle of over 30°above the hor-
izontal.
(a) Using a radiator cap tester, slowly pump the tester and
check that air is coming from the vacuum valve.
Pump speed:
1 push/(3 seconds or more)
NOTICE:
Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the radiator
cap.
(b) Pump the tester and measure the relief valve opening
pressure.
Pump speed:
1 push within 1 second
NOTICE:
This pump speed is for the first pump only (in order to close
the vacuum valve). After this, the pump speed can be re-
duced.
Standard opening pressure:
74 − 103 kPa (0.75 − 1.05 kgf/cm
2, 10.7 − 14.9 psi)
Minimum opening pressure:
59 kPa (0.6 kgf/cm
2, 8.5 psi)
HINT:
Use the tester’s maximum reading as the opening pressure.
If the opening pressure is less than minimum, replace the radia-
tor cap.
3. INSPECT COOLING SYSTEM FOR LEAKS
(a) Fill the radiator with coolant and attach a radiator cap tes-
ter.
(b) Warm up the engine.
(c) Pump it to 118kPa (1.2 kgf/cm
2, 17.1 psi), and check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator or water pump
for leaks. If no external leaks are found, check the heater core,
cylinder block and cylinder head.
4. REINSTALL RADIATOR CAP

S01823
Oxygen Sensor
(Bank 1 Sensor 1)
Oxygen Sensor (Bank 1 Sensor 2)
P03152
S01368
S01365
S01594
EM−34
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
10. REMOVE OXYGEN SENSOR (BANK 1 SENSOR 1)
FROM EXHAUST MANIFOLD
11. REMOVE OXYGEN SENSOR (BANK 1 SENSOR 2)
FROM FRONT TWC
12. SEPARATE EXHAUST MANIFORD AND FRON TWC
(a) Remove the 5 bolts and lower manifold heat insulator.
(b) Remove the 8 bolts and 2 TWC heat insulators.
(c) Remove the 3 bolts, 2 nuts, TWC, gasket retainer and
cushion.
13. DISCONNECT OIL PRESSURE SWITCH CONNECTOR
14. REMOVE WATER OUTLET
(a) Disconnect the ECT sensor connector.
(b) Disconnect the ECT sender gauge connector.
(c) Disconnect the radiator hose from the water outlet.
(d) Disconnect the water bypass pipe hose from the water
outlet.
(e) Disconnect the heater water hose from the water outlet.
(f) Remove the 2 nuts, water outlet and gasket.
15. REMOVE WATER BYPASS PIPE
(a) Remove the bolt, 2 nuts and oil cooler heat protector.
(b) Disconnect the IAC valve water bypass hose from the wa-
ter bypass pipe.
(c) Disconnect the heater water hose from the water bypass
pipe.
(d) Disconnect the 2 oil cooler water bypass hoses from the
oil cooler.
(e) Remove the nut and disconnect the wire protector.
(f) Remove the 2 bolts and 2 nuts.
(g) Disconnect the water bypass pipe from the water pump
cover, and remove the water bypass pipe.
(h) Remove the gasket and O−ring.
16. REMOVE THROTTLE BODY (See page SF−30)

S01560
(1)
(2)
(3)
P15451
ConnectNew
New
Gasket
O−Ring
S01594
S01368
EM−62
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
25. INSTALL HOSES AND GROUND STRAP
(a) Connect the vacuum sensor hose to the gas filter on the
intake manifold.
(b) Connect the brake booster vacuum hose to the intake
manifold.
(c) Connect the ground strap to the intake manifold.
26. INSTALL THROTTLE BODY (See page SF−33)
27. INSTALL WATER BYPASS PIPE
(a) Install a new gasket to the water pump cover.
(b) Install a new O−ring to the bypass pipe.
(c) Apply soapy water on the O−ring.
(d) Connect the water bypass pipe to the water pump cover.
(e) Install the bypass pipe with the 2 nuts and 2 bolts.
Torque:
9.3 N·m (95 kgf·cm, 82 in.·lbf) fot nut
19 N·m (195 kgf·cm, 14 ft·lbf) fot bolt
(f) Connect the engine wire protector with the nut.
(g) Connect the IAC valve water bypass hose to the water by-
pass pipe.
(h) Connect the heater water hose to the water bypass pipe.
(i) Connect the 2 oil cooler water bypass hoses to the oil
cooler.
(j) Install the oil cooler heat protector with the 2 nuts and bolt.
28. INSTALL WATER OUTLET
(a) Install a new gasket and the water outlet with the 2 nuts.
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
(b) Connect the radiator hose to the water outlet.
(c) Connect the water bypass pipe hose to the water outlet.
(d) Connect the heater water hose to the water outlet.
(e) Connect the IAC valve water bypass hose to the water
outlet.
(f) Connect the ECT sensor connector.
(g) Connect the ECT sender gauge connector.

EM0EV−02
A04063
N·m (kgf·cm, ft·lbf) : Specified torque
 Non−reusable part
29 (300, 22)
Hold Down ClampHold Down Clamp
BatteryEngine Hood
Battery Tray
Lower Radiator
HosePS Pump
w/ BracketCharcoal Canister
Battery Tray
IAT Sensor ConnectorAir Cleaner Cap
 Gasket
 Gasket
Fuel Inlet Hose
Fuel Filter
Water Inlet
Upper Radiator
Hose
Heater Hose
PS Pump Drive Belt
Generator Drive
Belt
Accelerator Cable
Generator
Generator Drive Belt
Adjusting Bar
Air Filter
EVAP VSV Connector
Air Cleaner Case
Radiator
Reservoir
Relay Block No. 2
Upper Cover
Relay Block No. 2
Wire Harness
A/C Compressor
Type B Type A
Type B Type A
− ENGINE MECHANICALENGINE UNIT
EM−65
1996 RAV4 (RM447U)
ENGINE UNIT
COMPONENTS

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.

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