TOYOTA RAV4 1996 Service Repair Manual

Fig. 34: Identifying TP Sensor Terminals (Corolla)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder
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Fig. 35: Identifying TP Sensor Terminals (Tacoma & 4Runner)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
THROTTLE OPENER
THROTTLE OPENER
Camry, Camry Solara, Celica, RAV4, Tacoma & 4Runner
For testing and adjustment procedures, see THROTTLE CONTROLS in SYSTEM & COMPONENT
TESTING - 4-CYLINDER article.
MISCELLANEOUS CONTROLS
PARK/NEUTRAL POSITION (PNP) SWITCH
For adjustment of PNP switch, see PARK/NEUTRAL POSITION (PNP) SWITCH under ENGINE SENSORS
& SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ApplicationFt. Lbs. (N.m)

1999 Toyota RAV4
1999 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder
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Valve Cover Bolt Or Nut
Camry, Camry Solara & Celica33 (45)
Corolla(1)
RAV433 (45)
Tacoma & 4Runner(2)
(1)Tighten bolts/nuts with washer to 80 INCH lbs. (9.0 N.m). Tighten bolts/nuts without washer to 97
INCH lbs. (11.0 N.m). Tighten bolts/nuts to specification in sequence. See Fig. 11
.
(2)Information is not available from manufacturer.

1999 Toyota RAV4
1999 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder
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1999-2000 STEERING
Power Rack & Pinion - Trucks
DESCRIPTION & OPERATION
System consists of a rack and pinion assembly, hydraulic power steering pump, hoses and control valves. On
some models an air control valve is used to increase idle speed when power steering pump is under load.
LUBRICATION
FLUID TYPE
Use Dexron-II or Dexron-III ATF fluid.
FLUID LEVEL CHECK
When fluid is at normal operating temperature, fluid level should be between HOT marks on fluid reservoir.
When fluid is cold, fluid level should be between COLD marks on fluid reservoir. Add as necessary.
HYDRAULIC SYSTEM BLEEDING
1. With engine off, check fluid level in power steering pump reservoir. See FLUID LEVEL CHECK
.
Raise and support vehicle. Turn wheels fully in both directions. Lower vehicle. Start engine and run at
idle.
2. Turn wheels fully to lock in one direction. Hold for a few seconds. Turn wheels fully to opposite lock.
Hold for a few seconds. Repeat process several times.
3. Check fluid. If there is no evidence of excess bubbles or foaming, bleeding is complete. If not, repeat
process until no bubbling is evident. Adjust fluid level as necessary.
ADJUSTMENTS
POWER STEERING PUMP BELT
Using belt tension gauge, measure belt tension. See BELT TENSION SPECIFICATIONS
table.
BELT TENSION SPECIFICATIONS
Application (1) Lbs. (kg)
RAV4
New95-145 (43-66)
Used (2) 60-100 (27-45)
Sienna
New150-185 (68-84)
Used (2) 95-135 (43-61)

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
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SYSTEMS TESTS
AIR CONTROL VALVE
Land Cruiser, RAV4, Tacoma & 4Runner
Start and fully warm up engine. Ensure A/C is off. With engine at idle, turn steering wheel to full LOCK
position until test is complete. Ensure engine RPM decreases when air control valve vacuum hose is pinched
shut. When hose is released, engine RPM should increase to normal. If system fails this test, check vacuum
hose, connections, and air control valve.
HYDRAULIC SYSTEM PRESSURE TEST
Pressure Test
1. Connect pressure to power steering pump high pressure line. Connect pressure gauge according to
manufacturer's instructions. Bleed air from hydraulic system. Check power steering fluid level. With
engine at idle, close pressure gauge valve for 2-3 seconds. DO NOT keep valve closed for more than 10
seconds. Note fluid minimum pressure. See HYDRAULIC PRESSURE
table.
2. Open pressure gauge valve fully. Note pressure with engine at 1000 RPM and at 3000 RPM. DO NOT
turn steering wheel. Pressure difference should be less than 71 psi (5 kg/cm2). If difference is greater than
specified, check flow control valve. If valve is okay, repair or replace power steering pump.
3. When steering wheel at full lock position and pressure valve open, again measure pressure. See
HYDRAULIC PRESSURE
table. If pressure is less than specified, steering gear has an internal leak.
Repair or replace steering gear.
HYDRAULIC PRESSURE
STEERING WHEEL TURNING FORCE
1. Center steering wheel. Check that free play of steering wheel does not exceed 1.58" (40 mm) on Land
Cruiser, or 1.18" (30 mm) on all other models. Remove steering wheel pad.
2. Attach INCH-lb torque wrench to steerin
g wheel nut. Start and idle engine. Using torque wrench, turn
Tacoma, Tundra & 4Runner
New135-180 (61-82)
Used (2) 85-120 (39-54)
(1)Land Cruiser uses automatic belt tensioner.
(2)Belt is used if it has been in operation for longer than 5 minutes.
ApplicationMinimum Pressure - Psi (kg/cm2 )
RAV41067 (75)
Sienna1138 (80)
Land Cruiser, Tacoma, Tundra & 4Runner1209 (85)

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
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and measure turning force. See STEERING EFFORT SPECIFICATIONS table. Repair or replace
power steering pump if force exceeds specifications.
STEERING EFFORT SPECIFICATIONS
REMOVAL & INSTALLATION
POWER STEERING PUMP
Removal (Land Cruiser)
1. Raise and support front of vehicle. Remove right and left engine under covers. Disconnect MAF
connector. Remove hose from air cleaner. Remove clamp, bolts and remove air cleaner assembly. Loosen
drive belt tensioner and remove drive belt.
2. Disconnect and plug return hose. Use drain pan to catch power steering fluid when connections are
released. Remove 3 bolts, and remove power steering pump.
Removal (RAV4)
1. Raise and support front of vehicle. Remove right and left engine under covers. Remove front exhaust
pipe. See Fig. 1
.
2. Remove stabilizer bar with link. Disconnect right and left lower control arms. See FRONT
- AVALON,
CAMRY, CAMRY SOLARA, CELICA, COROLLA, ECHO, RAV4 & SIENNA appropriate
FRONT SUSPENSION article in SUSPENSION.
3. Remove 2 power steering gear assembly set bolts and nuts. Remove front suspension crossmember
assembly. See Fig. 1
.
4. Disconnect 2 tube clamps and 2 vacuum hoses. Disconnect and plug return line. Use drain pan to catch
power steering fluid when connections are released.
5. Loosen top and bottom pump bolts and remove drive belt. Disconnect pressure feed tube. Remove 3
power steering pump bracket bolts. Remove pump assembly with bracket.
6. Remove union bolt and
gasket. Remove pressure feed line.
ApplicationINCH Lbs. (N.m)
RAV4 & Sienna52 (5.9)
Land Cruiser, Tacoma, Tundra & 4Runner43 (4.9)

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
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Fig. 1: Identifying Components For Removal Of Power Steering Pump & Gear (RAV4)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Sienna)

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
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1. Raise and support front of vehicle. Remove clip, and disconnect fluid return hose. Use drain pan to catch
power steering fluid when connections are released. Remove clamps and holders from pressure feed pipe.
Remove pressure feed pipe from power steering gear.
2. Loosen top and bottom pump bolts, and remove drive belt. Disconnect oil pressure switch connector.
Loosen bolt hidden behind power steering pump drive pulley until power steering pump can be removed
(bolt cannot be fully removed). See Fig. 2
.
3. Remove oil pressure switch from union bolt. Remove union bolt and gasket. Remove pressure feed line.
Fig. 2: Locating & Loosening Hidden Bolt Located Behind Power Steering Pump Drive Pulley (Sienna)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Tacoma & 4Runner 4-Cylinder)
1. Loosen power steering idle pulley bolt, then loosen belt adjusting bolt. Remove drive belt. Use 24-mm
spanner to hold pressure port union. Remove union bolt and gaskets. Remove pressure feed line from
pump.
2. Disconnect and plug return hose. Use drain pan to catch power steering fluid when connections are
released.
3. Remove pump bolts. Remove power steering pump.
Removal (Tacoma & 4Runner V6)

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
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Sunday, November 22, 2009 10:35:46 AMPage 5 © 2005 Mitchell Repair Information Company, LLC.

1. Remove air cleaner assembly. Disconnect and plug return hose. Use drain pan to catch power steering
fluid when connections are released.
2. Disconnect oil pressure switch connector. Remove oil pressure switch from pressure feed line. Remove
union bolt and gaskets. Disconnect pressure feed line from pump.
3. Loosen power steering pump adjusting bolts. Remove drive belt. Remove power steering pump mounting
bolts. Remove power steering pump.
Removal (Tundra)
1. Disconnect MAF connector. Remove hose from air cleaner. Remove clamp, bolts and remove air cleaner
assembly. On V8 engines, loosen drive belt tensioner and remove drive belt. On all models, disconnect
and plug return hose. Use drain pan to catch power steering fluid when connections are released.
2. On V6 models, disconnect oil pressure switch connector and remove oil pressure switch. On V8, remove
vacuum hoses. On all models, disconnect pressure feed line from pump. On V6 models, remove drive
belt. On all models, loosen power steering pump adjusting bolts. Remove power steering pump mounting
bolts. Remove power steering pump.
Installation (All Models)
To install, reverse removal procedure. Fill and bleed system. See HYDRAULIC SYSTEM BLEEDINGunder
LUBRICATION.
POWER RACK & PINION
Removal (Land Cruiser)
1. Place front wheels in straight-ahead position. Remove steering wheel and pad. Remove right and left
engine under covers. Disconnect both tie rod ends. See FRONT
- LAND CRUISER article in
SUSPENSION.
2. Drain engine oil. Remove oil filter assembly. Disconnect lower steering column shaft from steering gear.
Disconnect pressure and return lines from steering gear. Remove line clamps. Place matchmarks on tie
rod end and rack end. Remove both tie rods.
3. Remove power rack and pinion assembly mounting bolts and nuts. Remove rack and pinion assembly.
Installation
1. To install, reverse removal procedure, except install power feed and return line clamps to rack and pinion
assembly first.
2. After installation, place front wheels in straight-ahead position. Center steering wheel spiral cable, then
install steering wheel and pad. Check front wheel alignment.
Removal (RAV4)
1. Place front wheels in straight-ahead position. Remove steering wheel and pad.
2. Remove right and left engine under covers. Disconnect both tie rod ends. See FRONT
- AVALON,
CAMRY, CAMRY SOLARA, CELICA, COROLLA, ECHO, RAV4 & SIENNA article in

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
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SUSPENSION. Remove front exhaust pipe. Remove stabilizer bar with link.
3. Disconnect lower steering column shaft from steering gear. Disconnect pressure and return lines from
steering gear. Remove line clamps.
4. Disconnect right and left lower control arms. See FRONT
- AVALON, CAMRY, CAMRY SOLARA,
CELICA, COROLLA, ECHO, RAV4 & SIENNA article in SUSPENSION.
5. Remove power rack and pinion assembly mounting bolts and nuts. Securely suspend rack and pinion
assembly.
6. Remove front suspension crossmember. See Fig. 1
. Remove power rack and pinion assembly.
Installation
1. To install, reverse removal procedure, except install power feed and return line clamps to rack and pinion
assembly first.
2. After installation, place front wheels in straight-ahead position. Center steering wheel spiral cable, then
install steering wheel and pad. Check front wheel alignment.
Removal (Sienna)
1. Place front wheels in straight-ahead position. Remove steering wheel and pad. Disconnect both tie rod
ends. See FRONT
- AVALON, CAMRY, CAMRY SOLARA, CELICA, COROLLA, ECHO, RAV4
& SIENNA article in SUSPENSION.
2. Disconnect lower steering column shaft from steering gear. Remove nut holding tube clamp on rack
housing. Disconnect pressure and return lines from steering gear.
3. Disconnect, but DO NOT remove, stabilizer bar. See FRONT
- AVALON, CAMRY, CAMRY
SOLARA, CELICA, COROLLA, ECHO, RAV4 & SIENNA article in SUSPENSION.
4. Remove power rack and pinion assembly mounting bolts and nuts. Lift stabilizer bar to remove bolts.
Remove power rack and pinion assembly.
Installation
To install, reverse removal procedure, installing assembly from left side of vehicle. After installation, place
front wheels in straight-ahead position. Center steering wheel spiral cable, then install steering wheel and pad.
Check front wheel alignment.
Removal (Tacoma)
1. Place front wheels in straight-ahead position. Remove steering wheel and pad. On 4WD models, remove
engine under cover. Disconnect both tie rod ends.
2. Disconnect lower steering column shaft from steering gear. Disconnect pressure and return lines from
steering gear.
3. Remove power rack and pinion assembly mounting bolts and nuts. Remove power rack and pinion
assembly.
Installation

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
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