1996 TOYOTA RAV4 radiator

HINT: For symbols, capital letters indicate right side of vehicle,
small letters indicate left side of vehicle (Seen from rear).
K-k
1386
(54.57)552
(21.73)C-K
or
c-k
1494
(58.82)C-k
or
c-K
(Three-Dimensional Distance)
mm (in.)
Hole dia.
6 (0.24) nut
10 (0.39)
10 (0.39)
6 (0.24) nut
10 (0.39) Name
Cooler condenser installation nut
Radiator support extension standard hole
Radiator support standard hole
Front bumper support installation nut
Front apron to cowl side member standard hole Symbol
G, g
H, h
I, i
J
K, k Hole dia.
6 (0.24) nut
11 (0.43)
6 (0.24) nut
13 (0.51)
18 (0.71) Name
Front fender installation nut
Front spring support hole - inner
Front fender installation nut
Cowl top panel center mark
Front side member standard hole
Front side member standard hole Symbol
A, a
B, b
C, c
D, d
E, e
F, f
BODY DIMENSION DRAWINGS
ENGINE COMPARTMENT
BODY DIMENSIONSDIœ3

LOCATION OF PLASTIC BODY PARTS
Quarter Vent Duct (PP)
Rear Door Outside Handle (PC)
Front Door Outside Handle (PC)
Outer Rear View Mirror (AAS)
Instrument Panel Safety Pad (PP)
Cowl TopVentilator Louver (PP)
Radiator Grill (ABS)
Quarter Outside Moulding
(TSOP)
Rear Door Outside Moulding (TSOP) Front Bumper Cover (TSOP)
Front Turn Signal Light (PMMA/PP)
Front Door Outside Moulding (TSOP)
Front Fender Moulding (TSOP)
HINT:
wResin material differs with model.
/ Made up of 2 or more kinds of materials.
PLASTIC BODY PARTSPPœ4

Center Pillar Lower Garnish (PP/PE)
Center Pillar Garnish (PP)
Back Door Trim Board (PP)
Front Pillar Garnish (PP)
Front Fender Liner (PE)
Quater Panel Mudguard (TPU)
Side Turn Signal Light (SAN/ABS)
Washer Jar (PP)
Front Fender Mudguard (TPU)
Radiator Reserve Tank (PP)
Engine Under Cover (PE)
HINT:
wResin material differs with model.
/ Made up of 2 or more kinds of materials.
PLASTIC BODY PARTSPPœ5

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.

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

CO0BG−02
S01613
P15462
P15546
1
3
2
P15463
Disconnect
− COOLINGWATER PUMP
CO−5
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE RH ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. REMOVE TIMING BELT (See page EM−15)
4. DISCONNECT LOWER RADIATOR HOSE FROM
WATER INLET
5. REMOVE TIMING BELT TENSION SPRING AND NO.2
IDLER PULLEY
6. REMOVE GENERATOR DRIVE BELT ADJUSTING
BAR
(a) Disconnect the crankshaft position sensor connector
clamp.
(b) Remove the bolt and adjusting bar.
7. REMOVE WATER PUMP AND WATER PUMP COVER
ASSEMBLY
(a) Remove the 2 nuts holding the water pump to the water
bypass pipe.
(b) Remove the 3 bolts in the sequence shown.
(c) Disconnect the water pump cover from the water bypass
pipe, and remove the water pump and water pump cover
assembly.
(d) Remove the gasket and 2 O−ring from the water pump
and water bypass pipe.

CO0BI−03
P13480
New O−Ring
New Gasket
P15547
New O−Ring
P15464
Connect
Z16489
3
1
2 CO−8
− COOLINGWATER PUMP
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL WATER PUMP TO WATER PUMP COVER
Install a new gasket and the water pump with the 3 bolts.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
2. INSTALL WATER PUMP AND WATER PUMP COVER
ASSEMBLY
(a) Install new O−ring and gasket to water pump cover.
(b) Install a new O−ring to the water bypass pipe.
(c) Apply soapy water to the O−ring on the water bypass
pipe.
(d) Connect the water pump cover to the water bypass pipe.
Do not install the nuts yet.
(e) Install the water pump with the 3 bolts. Tighten the bolts
in the sequence shown.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
(f) Install the 2 nuts holding the water pump cover to the wa-
ter bypass pipe.
Torque: 9.3 N·m (95 kgf·cm, 82 in.·lbf)
3. INSTALL GENERATOR DRIVE BELT ADJUSTING BAR
(a) Install the adjusting bar with the bolt.
Torque: 27 N·m (275 kgf·cm, 20 ft·lbf)
(b) Connect the crankshaft position sensor connector clamp.
4. INSTALL NO.2 IDLER PULLEY AND TIMING BELT
TENSION SPRING
5. CONNECT LOWER RADIATOR HOSE
6. INSTALL TIMING BELT (See page EM−20)
7. FILL WITH ENGINE COOLANT
8. START ENGINE AND CHECK FOR COOLANT LEAKS
9. INSTALL RH ENGINE UNDER COVER

CO0BN−01
− COOLINGRADIATOR
CO−13
1996 RAV4 (RM447U)
RADIATOR
ON−VEHICLE CLEANING
Using water or a steam cleaner, remove any mud or dirt from the radiator core.
NOTICE:
If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. (i.e. Main-
tain a distance between the cleaner nozzle and radiator core.)