TOYOTA RAV4 1996 Service Repair Manual

EM0EI−02
S01653
21
S01367
− ENGINE MECHANICALVALVE CLEARANCE
EM−5
1996 RAV4 (RM447U)
VALVE CLEARANCE
INSPECTION
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1. DISCONNECT PS RESERVOIR
2. REMOVE CYLINDER HEAD COVER
(a) Disconnect the accelerator cable from the throttle body.
(b) Disconnect the accelerator cable from the clamp on the
intake manifold.
(c) Disconnect the accelerator cable from the clamp on the
generator bracket.
(d) Disconnect the A/T throttle control cable from the throttle
body.
(e) Disconnect the PCV hose from the air cleaner hose.
(f) Disconnect the PCV hose from the intake manifold.
(g) Disconnect the high−tension cords from the spark plugs.
(h) Remove the 2 bolts, and disconnect the accelerator cable
bracket from the intake manifold.
(i) Disconnect the engine wire protector from the 2 mounting
bolts of the No. 2 timing belt cover in the sequence shown.
(j) Remove the 4 nuts, grommets, cylinder head cover and
gasket.
HINT:
Arrange the grommets in the correct order, so that they can be
reinstalled into their original positions. This minimizes any pos-
sibility of oil leakage due to reuse of the grommets in different
positions.

P25455
Turn
P03443
1
1
2
2
1
13
3
P03442
2 233 44
44
P13927
Upward
Cam Lobe
Spark Plug SideNotch EM−6
− ENGINE MECHANICALVALVE CLEARANCE
1996 RAV4 (RM447U)
3. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley and align its groove with timing
mark ”0” of the No. 1 timing belt cover.
(b) Check that the valve lifters on the No.1 cylinder are loose
and valve lifters on the No.4 are tight.
If not, turn the crankshaft 1 revolution (360°) and align the mark
as above.
4. INSPECT VALVE CLEARANCE
(a) Check only the valves indicated.
Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
Record the out−of−specification valve clearance
measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake0.19 − 0.29 mm (0.007 − 0.011 in.)
Exhaust0.28 − 0.38 mm (0.011 − 0.015 in.)
(b) Turn the crankshaft 1 revolution (360°) and align the mark
as above (See procedure in step 3).
(c) Check only the valves indicated as shown. Measure the
valve clearance (See procedure in step (a)).
5. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.
Turn the crankshaft so that the cam lobe of the cam-
shaft on the adjusting valve points upward.
Position the notch of the valve lifter facing the spark
plug side.

P13988Spark Plug Side SST (A)
SST (B)
P13926
Magnetic
Finger
EM0494
P13989
SST (A)
SST (B)
− ENGINE MECHANICALVALVE CLEARANCE
EM−7
1996 RAV4 (RM447U)
Using SST (A), press down the valve lifter and place
SST (B) between the camshaft and valve lifter. Re-
move SST (A).
SST 09248−55040 (09248−05410, 09248−05420)
HINT:
Apply SST (B) at slight angle on the side marked with ”9”, at the
position shown in the illustration.
Remove the adjusting shim with a small screwdriver
and magnetic finger.
(b) Determine the replacement adjusting shim size by follow-
ing the Formula or Charts:
Using a micrometer, measure the thickness of the
removed shim.
Calculate the thickness of a new shim so that the
valve clearance comes within specified value.
T ........... Thickness of removed shim
A ........... Measured valve clearance
N ........... Thickness of new shim
Intake: N = T + (A − 0.24 mm (0.009 in.))
Exhaust: N = T + (A − 0.33 mm (0.013 in.))
Select a new shim with a thickness as close as pos-
sible to the calculated value.
HINT:
Shims are available in 17 sizes in increments of 0.05 mm
(0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.).
(c) Install a new adjusting shim.
Place a new adjusting shim on the valve lifter.
Using SST (A), press down the valve lifter and re-
move SST (B).
SST 09248−55040 (09248−05410, 09248−05420)
(d) Recheck the valve clearance.

V00867
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed,
and the measured clearance is 0.450 mm (0.0177 in.).
Replace the 2.800 mm (0.1102 in.) shim with a new No.11
shim.Adjusting Shim Selection Chart (Intake)
Intake valve clearance (Cold):
0.19 − 0.29 mm (0.007 − 0.011 in.)
2.500 (0.0984)
2.550 (0.1004)
2.600 (0.1024)
2.650 (0.1043)
2.700 (0.1063)
2.750 (0.1083)
2.800 (0.1102)
2.850 (0.1122)
2.900 (0.1142)2.950 (0.1161)
3.000 (0.1181)
3.050 (0.1201)
3.100 (0.1220)
3.150 (0.1240)
3.200 (0.1260)
3.250 (0.1280)
3.300 (0.1299) Shim
No.ThicknessShim
No.Thickness
4
5
6
7
8 3 2
1
910
11
12
13
14
15
16
17
HINT: New shims have the thickness in millimeters
imprinted on the face.
Installed shim thickness
Measured clearancemm (in.)
mm (in.)
New shim thickness
mm (in.)
EM−8
− ENGINE MECHANICALVALVE CLEARANCE
1996 RAV4 (RM447U)

V00868
2.500 (0.0984)
2.550 (0.1004)
2.600 (0.1024)
2.650 (0.1043)
2.700 (0.1063)
2.750 (0.1083)
2.800 (0.1102)
2.850 (0.1122)
2.900 (0.1142)2.950 (0.1161)
3.000 (0.1181)
3.050 (0.1201)
3.100 (0.1220)
3.150 (0.1240)
3.200 (0.1260)
3.250 (0.1280)
3.300 (0.1299) Shim
No.ThicknessShim
No.Thickness
4
5
6
7
8 3 2
1
910
11
12
13
14
15
16
17
HINT: New shims have the thickness in millimeters
imprinted on the face.
Adjusting Shim Selection Chart (Exhaust)
Exhaust valve clearance (Cold):
0.28 − 0.38 mm (0.011 − 0.015 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed,
and the measured clearance is 0.450 mm (0.0177 in.).
Replace the 2.800 mm (0.1102 in.) shim with a new No.9
shim.
Installed shim thickness
Measured clearancemm (in.)
mm (in.)
New shim thickness mm (in.)
− ENGINE MECHANICALVALVE CLEARANCE
EM−9
1996 RAV4 (RM447U)

P03518
: Seal Packing
P01655
Marking
30°
Z17351
2 1 EM−10
− ENGINE MECHANICALVALVE CLEARANCE
1996 RAV4 (RM447U)
6. REINSTALL CYLINDER HEAD COVER
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head as shown in the
illustration.
Seal packing: Part No. 08826−00080 or equivalent
(c) Install the gasket to the cylinder head cover.
(d) Install the head cover with the 4 grommets and nuts. Uni-
formly tighten the nuts in several passes.
Torque: 23 N·m (230 kgf·cm, 17 ft·lbf)
HINT:
Install the grommets so that their markings are as shown in the
illustration.
(e) Install the engine wire protector to the 2 mounting bolts of
the No. 2 timing belt cover in the sequence shown.
(f) Connect the high−tension cords to the spark plugs.
(g) Install the accelerator cable bracket with the 2 bolts.
(h) Connect the accelerator cable to the throttle body.
(i) Connect the accelerator cable to the clamp on the intake
manifold.
(j) Connect the accelerator cable to the clamp on the gener-
ator bracket.
(k) Connect the A/T throttle control cable to the throttle body.
(l) Connect the PCV hose to the air cleaner hose.
(m) Connect the PCV hose to the intake manifold.
7. CONNECT PS RESERVOIR

EM0EJ−01
S01354
TOYOTA
Hand−held Tester
S01261
DLC1
TE1
E1SST
S01272
− ENGINE MECHANICALIGNITION TIMING
EM−11
1996 RAV4 (RM447U)
IGNITION TIMING
INSPECTION
1. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
2. CONNECT TOYOTA HAND−HELD TESTER OR OBD II
SCAN TOOL
(a) Remove the fuse cover on the instrument panel.
(b) Connect the TOYOTA hand−held tester or OBD II scan
tool to the DLC3.
(c) Please refer to the TOYOTA hand−held tester or OBD II
scan tool operator’s manual for further details.
3. CONNECT TIMING LIGHT TO ENGINE
4. INSPECT IGNITION TIMING
(a) Using SST, connect terminals TE1 and E1 of the DLC1.
SST 09843−18020
(b) Using a timing light, check the ignition timing.
Ignition timing:
8 − 12° BTDC @ idle
(Transmission in neutral position)
(c) Remove the SST from the DLC1.
SST 09843−18020
5. FURTHER CHECK IGNITION TIMING
Ignition timing:
0 − 10° BTDC @ idle
(Transmission in neutral position)
HINT:
The timing mark moves in a range between 0° and 10°
6. DISCONNECT TIMING LIGHT FROM ENGINE
7. DISCONNECT TOYOTA HAND−HELD TESTER OR
OBD II SCAN TOOL

EM0EK−01
EM−12
− ENGINE MECHANICALIDLE SPEED
1996 RAV4 (RM447U)
IDLE SPEED
INSPECTION
1. INITIAL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All pipes and hoses of air induction system connected
(d) All vacuum lines properly connected
(e) SFI system wiring connectors fully plugged
(f) All operating accessories switched OFF
(g) Ignition timing check correctly
(h) Transmission in neutral position
(i) Air conditioning switched OFF
2. CONNECT TOYOTA HAND−HELD TESTER OR OBD II SCAN TOOL (See page EM−11)
3. INSPECT IDLE SPEED
(a) Race the engine speed at 2,500 rpm for approx. 90 seconds.
(b) Check the idle speed.
Idle speed (w/ Cooling fan OFF): 750 ± 50 rpm
If the idle speed is not as specified, check the IAC valve and air intake system.
4. DISCONNECT TOYOTA HAND−HELD TESTER OR OBD II SCAN TOOL

EM0EL−02
− ENGINE MECHANICALTIMING BELT
EM−13
1996 RAV4 (RM447U)
TIMING BELT
COMPONENTS

EM−14
− ENGINE MECHANICALTIMING BELT
1996 RAV4 (RM447U)