1996 TOYOTA RAV4 set clock

AT0953
SST
AX05A−02
AT3306
Hold
Lock
Free
Turn
D00776
AT4184
AX−20
− AUTOMATIC TRANSAXLE (A241E)TORQUE CONVERTER CLUTCH AND DRIVE PLATE
1996 RAV4 (RM447U)
TORQUE CONVERTER CLUTCH
AND DRIVE PLATE
INSPECTION
1. INSPECT ONE−WAY CLUTCH
(a) Install SST into the inner race of the one−way clutch.
SST 09350−32014 (09351−32010)
(b) Install SST so that it fits in the notch of the converter clutch
hub and outer race of the one−way clutch.
SST 09350−32014 (09351−32020)
(c) With the torque converter clutch standing on its side,the
clutch locks when turned counterclockwise, and rotates
freely and smoothly clockwise.
If necessary, clean the converter clutch and retest the clutch.
Replace the converter clutch if the clutch still fails the test.
2. MEASURE DRIVE PLATE RUNOUT AND INSPECT
RING GEAR
Set up a dial indicator, measure the drive plate runout.
Maximum runout: 0.20 mm (0.0079 in.)
If the runout is not within the specification or if the ring gear is
damaged, replace the drive plate. If installing a new drive plate,
note the orientation of spacers and tighten the bolts.
Torque: 83 N·m (850 kgf·cm, 61 ft·lbf)
3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE
RUNOUT
Temporarily mount the torque converter clutch to the drive
plate. Set up a dial indicator, measure the torque converter
clutch sleeve runout.
Maximum runout: 0.30 mm (0.0118 in.)
If the runout is not within the specification, try to correcting by
reorienting the installation of the converter clutch.

AT0952
SST
AX04W−01
AT0953
SST
AT3306
Hold
Lock
Free
Turn
AT2821
AX−22
− AUTOMATIC TRANSAXLE (A540H)TORQUE CONVERTER CLUTCH AND DRIVE PLATE
1996 RAV4 (RM447U)
TORQUE CONVERTER CLUTCH
AND DRIVE PLATE
INSPECTION
1. INSPECT ONE−WAY CLUTCH
(a) Install SST into the inner race of the one−way clutch.
SST 09350−32014 (09351−32010)
(b) Install SST so that it fits in the notch of the converter clutch
hub and outer race of the one−way clutch.
SST 09350−32014 (09351−32020)
(c) With the torque converter clutch standing on its side, the
clutch locks when turned counterclockwise, and rotates
freely and smoothly clockwise.
If necessary, clean the converter clutch and retest the clutch.
Replace the converter clutch if the clutch still fails the test.
2. MEASURE DRIVE PLATE RUNOUT AND INSPECT
RING GEAR
(a) Set up a dial indicator and measure the drive plate runout.
(b) Check the damage of the ring gear.
Maximum runout: 0.20 mm (0.0079 in.)
If the runout is not within the specification, or ring gear is dam-
aged replace the drive plate.
Torque: 83 N·m (850 kgf·cm, 61 ft·lbf)

Z10844
Z15867
UP
DOWN
BE−54
− BODY ELECTRICALPOWER WINDOW CONTROL SYSTEM
1996 RAV4 (RM447U)
(2) Attach a current−measuring probe to terminal 6 of
the wire harness.
(3) Turn the ignition switch ON and set the power win-
dow switch in the down position.
(4) As the window goes down, check that the current is
approximately 7 amperes.
(5) Check that the current increases up to approxi-
mately 14.5 amperes or more when the window
stops going down.
HINT:
The circuit breaker opens some 4 − 40 seconds after the win-
dow stops going down, so that check must be made before the
circuit breaker operates.
If operation is not as specified, replace the master switch.
7. INSPECT FRONT POWER WINDOW SWITCH CONTI-
NUITY
Switch positionTester connectionSpecified condition
UP1 − 2, 3 − 4Continuity
OFF1 − 2, 3 − 5Continuity
DOWN1 − 4, 3 − 5Continuity
If continuity is not as specified, replace the switch.
8. 5 Door models:
INSPECT REAR POWER WINDOW SWITCH CONTI-
NUITY
Switch positionTester connectionSpecified condition
UP1 − 2, 3 − 4Continuity
OFF1 − 2, 4 − 5Continuity
DOWN2 − 3, 4 − 5Continuity
If continuity is not as specified, replace the switch.
9. Driver ’s door of 3 door models:
INSPECT POWER WINDOW MOTOR OPERATION
(a) Connect the positive (+) lead from the battery to terminal
1 and the negative (−) lead to terminal 2, check that the
motor turns counterclockwise.

Fuse BlockEngine ECU R/B No. 5 J/B No. 1J/B No. 4 ABS ECUDaytime Running
Light Relay (*1) Door Look Control RelayA/C Amplifier J/B No. 3
4. ECU (ELECTRONIC CONTROL UNIT)
Locations of ECUs
Many ECUs are mounted in this vehicle.
Take the following precautions during body repair to prevent damage to the ECUs.

Before starting electric welding operations, disconnect the negative (-) terminal cable from the battery.
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio
systems will be cancelled. So before starting work, make a record of the contents memorized by each
memory system. Then when work is finished, reset the clock and audio systems as before.
When the vehicle has tilt and telescopic steering, power seat and outside rear view mirror, which are all
equipped with memory function, it is not possible to make a record of the memory contents.
So when the operation is finished, it will be necessary to explain this fact to the customer, and request
the customer to adjust the features and reset the memory.

Do not expose the ECUs to ambient temperatures above 80°C (176°F).
NOTICE: If it is possible the ambient temperature may reach 80 °C (176 °F) or more, remove the ECUs
from the vehicle before starting work.

Be careful not to drop the ECUs and not to apply physical shocks to them.
4. COMPONENTS ADJACENT TO THE BODY PANELS
Various types of component parts are mounted directly on or adjacently to the body panels.
Strictly observe the following precautions to prevent damaging these components and the body panels
during handling.

Before repairing the body panels, remove their components or apply protective covers over the comœ
ponents.

Before prying components off using screwdriver or a scraper, etc., attach protective tape to the tool
tip or blade to prevent damaging the components and the body paint.

Before removing components from the outer surface of the body, attach protective tape to the body to
ensure no damage to painted areas.
HINT: Apply touch-up paint to any damaged paint surfaces.

Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side.
INTRODUCTIONINœ8

S01770
S01772
9
10 3
45
61
27
8
S01776
10 − 45°
Knock
Pin
S01773
Assembly
Timing Reference
Mark
Mark EM−58
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
(6) Install the bearing caps in their proper locations.
(7) Apply a light coat of engine oil on the threads and
under the heads of the bearing cap bolts.
(8) Install and uniformly tighten the 10 bearing cap
bolts, in several passes, in the sequence shown.
Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)
(b) Install the exhaust camshaft.
(1) Set the knock pin of the intake camshaft at 10 − 45°
BTDC of camshaft angle.
HINT:
The above angle allows the No. 2 and No. 4 cylinder cam lobes
of the exhaust camshaft to push their valve lifters evenly.
(2) Apply MP grease to the thrust portion of the cam-
shaft.
(3) Engage the exhaust camshaft gear to the intake
camshaft gear by matching the timing marks on
each gear.
(4) Roll down the exhaust camshaft onto the bearing
journals while engaging gears with each other.
NOTICE:
There are also assembly reference marks on each gear as
shown in the illustration. Do not use these marks.
(5) Turn the intake camshaft clockwise or counterclock-
wise a little until the exhaust camshaft sits in the
bearing journals evenly without rocking the cam-
shaft on the bearing journals.
NOTICE:
It is very important to replace the camshaft in the bearing
journals evenly while tightening bearing caps in the subse-
quent steps.

11 5
SRS
NOTICE: When inspecting or repairing the SRS, perform the operation in accordance with the following
precautionary instructions and the procedure and precautions in the Repair Manual for the applicable model
year.

Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic trouble
codes become the most important source of information when troubleshooting.
When troubleshooting the supplemental restraint system, always inspect the diagnostic trouble codes before
disconnecting the battery.

Work must be started after 90 seconds from the time the ignition SW is turned to the LOCKº position and the
negative (-) terminal cable is disconnected from the battery.
(The supplemental restraint system is equipped with a back-up power source so that if work is started within
90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be activated.)
When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio
systems will be canceled. So before starting work, make a record of the contents memorized by each memory
system. When work is finished, reset the clock and audio system as before and adjust the clock.
To avoid erasing the memory of each memory system, never use a back-up power supply from outside the
vehicle.

When removing the steering wheel pad or handling a new steering wheel pad, keep the pad upper surface
facing upward. Also, lock the lock lever of the twin lock type connector at the rear of the pad and take care
not to damage the connector.
(Storing the pad with its metallic surface up may lead to a serious accident if the SRS inflates for some reason.)

Always store a removed or new front passenger airbag assembly with the airbag door facing up. Storing the
airbag assembly with the airbag door facing down could cause a serious accident if the airbag inflates.

Store the steering wheel pad where the ambient temperature remains below 935C (2005F), without high
humidity and away from electrical noise.

Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.

Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag sensor
assembly.

Before repairing the body, remove the airbag sensor if during repair shocks are likely to be applied to the
sensors due to vibration of the body or direct tapping with tools or other parts.

Do not reuse a steering wheel pad or front airbag sensors.
After evaluating whether the center airbag sensor assembly is damaged or not, decide whether or not to reuse
it. (See the Repair Manual for the method for evaluating the center airbag sensor assembly.)

When troubleshooting the supplemental restraint system, use a high-impedance (Min. 10kW/V) tester.

The wire harness of the supplemental restraint system is integrated with the instrument panel wire harness
assembly.
The vehicle wiring harness exclusively for the airbag system is distinguished by corrugated yellow tubing, as
are the connectors.

Do not measure the resistance of the airbag squibs.
(It is possible this will deploy the airbag and is very dangerous.)

If the wire harness used in the supplemental restraint system is damaged, replace the whole wire harness
assembly.

INFORMATION LABELS (NOTICES) are attached to the periphery of the SRS components. Follow the
instructions on the notices.

IG0J9−01
B11573
B11574
− IGNITIONDISTRIBUTOR
IG−13
1996 RAV4 (RM447U)
INSTALLATION
1. SET NO. 1 CYLINDER TO DTC/COMPRESSION
Turn the crankshaft clockwise, and position the slit of the intake
camshaft as shown in the illustration.
2. INSTALL DISTRIBUTOR
(a) Install a new O−ring to the housing.
(b) Apply a light coat of engine oil on the O−ring.
(c) Align the cutout of the coupling with the line of the hous-
ing.
(d) Insert the distributor, aligning the center of the flange with
that of bolt hole on the cylinder head.
(e) Tighten the hold−down bolt.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
3. CONNECT HIGH−TENSION CORDS TO SPARK
PLUGS
Firing order:
1 − 3 − 4 − 2
4. CONNECT HIGH−TENSION CORD TO IGNITION COIL
5. CONNECT DISTRIBUTOR CONNECTOR
6. INSTALL AIR CLEANER CAP ASSEMBLY

S01910
Ohmmeter
Vacuum IDL
E2
0.60 mm
S01910
Ohmmeter
Vacuum IDL
E20.50 or
0.70 mm SF−32
− SFITHROTTLE BODY
1996 RAV4 (RM447U)
(b) Apply vacuum to the throttle opener.
(c) Insert a 0.60 mm (0.024 in.) thikness gauge between the
throttle stop screw and stop lever.
(d) Connect the test probe of an ohmmeter to the terminals
IDL and E2 of the sensor.
(e) Gradually turn the sensor clockwise untill the ohmmeter
deflects, and secure it with the 2 set screws.
(f) Recheck the continuity between terminals IDL and E2.
Clearance between
lever and stop screwContinuity (IDL − E2)
0.50 mm (0.020 in.)Continuity
0.70 mm (0.028 in.)No continuity