TOYOTA RAV4 1996 Service Repair Manual

EM0EM−03
S01283
B
SST
A
S01358
Oil Pump
S01630
SST
SST
− ENGINE MECHANICALTIMING BELT
EM−15
1996 RAV4 (RM447U)
REMOVAL
1. DISCONNECT PS RESERVOIR AND REMOVE RES-
ERVOIR BRACKET
2. DISCONNECT WIRE HARNESS BRACKET FOR DLC1
3. REMOVE GENERATOR (See page CH−7)
4. REMOVE GENERATOR BRACKET
5. w/ ABS:
REMOVE NO. 3 ABS ACTUATOR BRACKET (See page
BR−40)
6. REMOVE RH FRONT WHEEL
7. REMOVE RH ENGINE UNDER COVER
8. REMOVE PS PUMP DRIVE BELT
(a) Loosen the bolt A.
(b) Using SST and a deep socket wrench, loosen the bolt B.
SST SST09249−63010
(c) Remove the drive belt.
9. SLIGHTLY JACK UP ENGINE
Attach the jack to the oil pan, and raise the engine enough to
remove the weight from the engine mounting on the right side.
10. REMOVE RH ENGINE MOUNTING INSULATOR
11. REMOVE SPARK PLUGS
12. REMOVE CRANKSHAFT PULLEY
(a) Using SST (and bolt), remove the pulley bolt.
SST 09213−54015 (91651−60855 for type A),
09330−00021
Bolt: Part No. 91121−40665 for type B
HINT:
Either of 2 types of pulley may be used, each with its own
bolt size, type A and type B.
When using bolt type B, a plate washer must be inserted
between the bolt and SST.

S01655
SST
S01284
SST
S01624
S01597
S01651
EM−16
− ENGINE MECHANICALTIMING BELT
1996 RAV4 (RM447U)
(b) Using SST, remove the pulley.
SST 09950−50010 (09951−05010, 09952−05010,
09953−05010, 09953−05020,
09954−05020 for type A,
09954−05010 for type B)
13. REMOVE RH ENGINE MOUNTING BRACKET
Using SST, remove the 3 bolts and mounting bracket.
SST 09249−63010
14. REMOVE NO. 2 TIMING BELT COVER
(a) Disconnect the engine wire from the timing belt cover.
(b) Remove the 4 bolts and timing belt cover.
15. TEMPORARILY INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley,
and slide on the pulley.
(b) Temporarily install the pulley bolt.
16. 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 hole of the camshaft timing pulley is
aligned with the timing mark of the bearing cap.
If not, turn the crankshaft 1 revolution (360°).
17. REMOVE TIMING BELT FROM CAMSHAFT TIMING
PULLEY
HINT:
When re−using timing belt:
Place matchmarks on the timing belt and camshaft timing
pulley, and place matchmark on timing belt to match the end of
the No. 1 timing belt cover.

S01650
S01656
SST
SST
S01620
P25458
S01614
SST
− ENGINE MECHANICALTIMING BELT
EM−17
1996 RAV4 (RM447U)
(a) Loosen the mounting bolt of the No. 1 idler pulley and shift
the pulley toward the left as far as it will go, and temporari-
ly tighten it.
(b) Remove the timing belt from the camshaft timing pulley.
18. REMOVE CAMSHAFT TIMING PULLEY
Using SST, remove the pulley bolt and timing pulley.
SST 09249−63010, 09960−10010 (09962−01000,
09963−01000)
19. REMOVE CRANKSHAFT PULLEY
HINT:
When re−using timing belt:
Remove the pulley without turning it.
20. REMOVE NO. 1 TIMING BELT COVER
(a) Disconnect the engine wire from the timing belt cover.
(b) Remove the 4 bolts and timing belt cover.
21. REMOVE TIMING BELT GUIDE
22. REMOVE TIMING BELT
HINT:
(When re−using timing belt): Draw a direction arrow on the tim-
ing belt (in the direction of engine revolution), and place match-
marks on the timing belt and crankshaft timing pulley.
23. REMOVE NO. 1 IDLER PULLEY AND TENSION
SPRING
24. REMOVE NO. 2 IDLER PULLEY
25. REMOVE CRANKSHAFT TIMING PULLEY
If the pulley cannot be removed by hand, use SST to remove
the timing pulley.
SST 09950−50010 (09951−05010, 09952−05010,
09953−05010, 09953−05020, 09954−05010)
NOTICE:
Do not scratch the angle sensor of the timing pulley.

S01636
SST EM−18
− ENGINE MECHANICALTIMING BELT
1996 RAV4 (RM447U)
26. REMOVE OIL PUMP PULLEY
Using SST, remove the nut and pulley.
SST 09960−10010 (09962−01000, 09963−00600)

EM0EN−02
EM3336
No!
EM3295
P15243Free Length
− ENGINE MECHANICALTIMING BELT
EM−19
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT TIMING BELT
NOTICE:
Do not bend, twist or turn the timing belt inside out.
Do not allow the timing belt to come into contact with
oil, water or steam.
Do not utilize timing belt tension when installing or re-
moving the mounting bolt of the camshaft timing
pulley.
If there are any defects as shown in the illustration, check these
points:
(a) Premature parting
Check for proper installation.
Check the timing cover gasket for damage and
proper installation.
(b) If the belt teeth are cracked or damaged, check to see if
either camshaft or water pump is locked.
(c) If there is noticeable wear or cracks on the belt face,
check to see if there are nicks on the side of the idler
pulley lock.
(d) If there is wear or damage on only one side of the belt,
check the belt guide and the alignment of each pulley.
(e) If there is noticeable wear on the belt teeth, check the tim-
ing cover for damage, correct gasket installation, and for
foreign material on the pulley teeth.
If necessary, replace the timing belt.
2. INSPECT IDLER PULLEYS
Check that the idler pulley turns smoothly.
If necessary, replace the idler pulley.
3. INSPECT TENSION SPRING
(a) Measure the free length of tension spring.
Free length: 46.0 mm (1.811 in.)
If the free length is not as specified, replace the tension spring.
(b) Measure the tension of the tension spring at the specified
installed length.
Installed tension (at 50.5 mm (1.988 in.)):
22 − 27 N (2.25 − 2.75 kgf, 5.0 − 6.1 lbf)
If the installed tension is not as specified, replace the tension
spring.

EM0EO−03
S01634
SST
S01637
Inward
Sensor
S01625
35 mm
S01654
42 mm
S01657
Pry
Move EM−20
− ENGINE MECHANICALTIMING BELT
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL OIL PUMP PULLEY
(a) Align the cutouts of the pulley and shaft, and slide on the
pulley.
(b) Using SST, install the nut.
SST 09960−10010 (09962−01000, 09963−00600)
Torque: 24 N·m (245 kgf·cm, 18 ft·lbf)
2. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the timing pulley set key with the key groove of the
pulley.
(b) Install the timing pulley, facing the sensor side inward.
NOTICE:
Do not scratch the sensor part of the crankshaft timing
pulley.
3. INSTALL NO. 2 IDLER PULLEY
(a) Install the pulley with the bolt.
Torque: 42 N·m (425 kgf·cm, 31 ft·lbf)
HINT:
Use a bolt 35 mm (1.38 in.) in length.
(b) Check that the idler pulley moves smoothly.
4. TEMPORARILY INSTALL NO. 1 IDLER PULLEY AND
TENSION SPRING
(a) Align the bracket pin hole with the pivot pin.
(b) Install the pulley with the bolt. Do not tighten the bolt yet.
HINT:
Use a bolt 42 mm (1.65 in.) in length.
(c) Install the tension spring.
(d) Pry the pulley toward the left as far as it will go and tighten
the bolt.
(e) Check that the idler pulley moves smoothly.

S01621
S01623
S01622
S07327Length = 660 mm (25.98 in.)
− ENGINE MECHANICALTIMING BELT
EM−21
1996 RAV4 (RM447U)
5. TEMPORARILY INSTALL TIMING BELT
NOTICE:
The engine should be cold.
(a) Using the crankshaft pulley bolt, turn the crankshaft and
position the key groove of the crankshaft timing pulley up-
ward.
(b) Remove any oil or water on the crankshaft pulley, oil
pump pulley, water pump pulley, No. 1 idler pulley and No.
2 idler pulley, and keep them clean.
(c) Install the timing belt on the crankshaft timing pulley, oil
pump pulley, No. 1 idler pulley, water pump pulley and No.
2 idler pulley.
HINT:
When re−using timing belt:
Align the points marked during removal, and install the belt with
the arrow pointing in the direction of engine revolution.
6. INSTALL TIMING BELT GUIDE
Install the guide, facing the cup side outward.
7. INSTALL NO. 1 TIMING BELT COVER
(a) Check that the timing belt cover gaskets has no cracks or
peeling, etc.
If the gasket has cracks or peeling, etc., replace it using these
steps:
Using a screwdriver and gasket scraper, remove all
the old gasket material.
Thoroughly clean all components to remove all the
loose material.
Remove the backing paper from a new gasket and
install the gasket evenly to the part of the timing belt
cover shaded black in the illustration.
After installing the gasket, press down on it so that
the adhesive firmly sticks to the timing belt cover.
(b) Install the timing belt cover with the 4 bolts.
(c) Install the engine wire to the timing belt cover.

S01627
SST
Fulcrum
Length SST
S01628
SST
S01598
EM−22
− ENGINE MECHANICALTIMING BELT
1996 RAV4 (RM447U)
8. TEMPORARILY INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley,
and slide on the pulley.
(b) Temporarily install the pulley bolt.
9. INSTALL CAMSHAFT TIMING PULLEY
(a) Align the camshaft knock pin with the knock pin groove of
the pulley, and slide on the timing pulley.
(b) Using SST, install the bolt.
SST 09249−63010, 09960−10010 (09962−01000,
09963−01000)
Torque:
54 N·m (550 kgf·cm, 40 ft·lbf)
37 N·m (380 kgf·cm, 27 ft·lbf) for SST
HINT:
Use a torque wrench with a fulcrum length of 340 cm (13.39 in.).
10. 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) Using SST, turn the camshaft, and align the hole of the
camshaft timing pulley with the timing mark of the bearing
cap.
SST 09960−10010 (09962−01000, 09963−01000)
11. INSTALL TIMING BELT
HINT:
When re−using timing belt:
Check that the matchmark on the timing belt matches the end
of the No. 1 timing belt cover. If the matchmark does not align,
align as follows:

S01638
Turn
Pull
S01600
Hold
Turn
S01604
Pull
Turn
S01601
TurnHold
S01652
− ENGINE MECHANICALTIMING BELT
EM−23
1996 RAV4 (RM447U)
When matchmark is misaligned clockwise:
Align the matchmark by pulling the timing belt up on the
water pump pulley side while turning the crankshaft pulley
counterclockwise.
When matchmark is misaligned clockwise:
After aligning the matchmark, hold the timing belt, turn the
crankshaft pulley clockwise, and align its groove with tim-
ing mark ”0” of the No. 1 timing belt cover.
When matchmark is misaligned counterclockwise:
Align the matchmark by pulling the timing belt up on the
No.1 idler pulley side while turning the crankshaft pulley
clockwise.
When matchmark is misaligned counterclockwise:
After aligning the matchmark, hold the timing belt, turn the
crankshaft pulley counterclockwise, and align its groove
with timing mark ”0” of the No. 1 timing belt cover.
(a) Remove any oil or water on the camshaft timing pulley,
and keep it clean.
(b) Align the matchmarks of the timing belt and camshaft tim-
ing pulley.
(c) Install the timing belt, and check the tension between the
crankshaft timing pulley and camshaft timing pulley.
12. CHECK VALVE TIMING
(a) Loosen the No. 1 idler pulley bolt 1/2 turn.

S01602
Turn
S01597
S01603
Turn
S01238
P25229
Length = 735 mm (28.94 in.)
Length = 230 mm (9.06 in.) EM−24
− ENGINE MECHANICALTIMING BELT
1996 RAV4 (RM447U)
(b) Slowly turn the crankshaft pulley 2 revolutions from TDC
to TDC.
NOTICE:
Always turn the crankshaft clockwise.
(c) Check that each pulley aligns with the timing marks as
shown in the illustration.
If the timing marks do not align, remove the timing belt and rein-
stall it.
(d) Slowly turn the crankshaft pulley 1 and 7/8 revolutions,
and align its groove with the mark at 45 ° BTDC (for No.
1 cylinder) of the No.1 timing belt cover.
NOTICE:
Always turn the crankshaft clockwise.
(e) Torque the mounting bolt of the No.1 idler pulley.
Torque: 42 N·m (425 kgf·cm, 31 ft·lbf)
13. PLACE RH ENGINE MOUNTING BRACKET IN POSI-
TION
HINT:
Do not install the bolts.
14. INSTALL NO. 2 TIMING BELT COVER
(a) Check that the timing belt cover gaskets has no cracks or
peeling, etc.
If the gasket has cracks or peeling, etc., replace it using these
steps:
Using a screwdriver and gasket scraper, remove all
the old gasket material.
Thoroughly clean all components to remove all the
loose material.