TOYOTA RAV4 1996 Service Repair Manual

EM1B9−02
P13638
Adhesive
S01764
S01763
S01648
− ENGINE MECHANICALCYLINDER HEAD
EM−55
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL OIL PRESSURE SWITCH
(a) Apply adhesive to 2 or 3 threads.
Adhesive:
Part No. 08833−00080, THREE BOND 1344 or equiva-
lent
(b) Install the oil pressure switch.
2. INSTALL INJECTORS AND DELIVERY PIPE (See page
SF−23)
3. INSTALL AIR HOSE FOR AIR ASSIST SYSTEM
Connect the air hose to the cylinder head port.
4. INSTALL INTAKE MANIFOLD
Install a new gasket and the intake manifold with the 6 bolts and
2 nuts. Uniformly tighten the bolts and nuts in several passes.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
5. INSTALL AIR TUBE
(a) Install the air tube and hose clamp with the 2 bolts.
(b) Connect the air hose to the intake manifold.
6. INSTALL CYLINDER HEAD AND INTAKE MANIFOLD
ASSEMBLY
(a) Place the cylinder head on the cylinder block.
(1) Place a new cylinder head gasket in position on the
cylinder block.
NOTICE:
Be careful of the installation direction.
(2) Place the cylinder head in position on the cylinder
head gasket.

S01799
1086 1 3 9
4257
S01796
90°
90°Painted Mark
S01786
Z00058
(3)
(2)
(1) EM−56
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
(b) Install the cylinder head bolts.
HINT:
The cylinder head bolts are tightened in 2 progressive
steps (steps (b) and (d)).
If any cylinder head bolt is broken or deformed, replace
it.
(1) Apply a light coat of engine oil on the threads and
under the heads of the cylinder head bolts.
(2) Install and uniformly tighten the 10 cylinder head
bolts and plate washers, in several passes, in the
sequence shown.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
If any one of the cylinder head bolts does not meet the torque
specification, replace the cylinder head bolt.
(3) Mark the front of the cylinder head bolt head with
paint.
(4) Retighten the cylinder head bolts 90° in the se-
quence shown above.
(5) Check that the painted mark is now at a 90° angle
to front.
7. INSTALL SPARK PLUG TUBES
(a) Clean the cylinder head tube holes of any residual adhe-
sive, oil or foreign particles. Remove any oil with kerosene
or gasoline.
(b) Screw the threads of the spark plug tube coated with
adhesive into the cylinder head.
(c) Using the spark plug tube nut and a 30 mm socket
wrench, tighten the spark plug tubes.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
8. ASSEMBLE EXHAUST CAMSHAFT
(a) Mount the hexagon wrench head portion of the camshaft
in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Install the camshaft gear spring (1), camshaft sub gear (2)
and wave washer (3).
HINT:
Align the pins on the gears with the spring ends.

P05618
Turn
ADrive Gear
Sub−Gear B
S01778
80 − 11 5°
Knock
Pin
S01790
EM3373
2 − 3 mm
(0.08 − 0.12 in.)
Seal
Packing
− ENGINE MECHANICALCYLINDER HEAD
EM−57
1996 RAV4 (RM447U)
(c) Using snap ring pliers, install the snap ring.
(d) Insert a service bolt A into the service hole of the camshaft
sub gear.
(e) Using a screwdriver, align the holes of the camshaft drive
gear and sub gear by turning camshaft sub gear clock-
wise, and install a service bolt B.
NOTICE:
Be careful not to damage the camshaft.
(f) Align the gear teeth of the drive gear and sub gear, and
tighten the service bolt B.
9. INSTALL CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being installed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, the follow-
ing steps should be carried out.
(a) Install the intake camshaft.
(1) Apply MP grease to the thrust portion of the cam-
shaft.
(2) Place the intake camshaft at 80 − 11 5° BTDC of
camshaft angle on the cylinder head.
HINT:
The above angle arrows the No. 1 and No. 3 cylinder cam lobes
of the intake camshaft to push their valve lifters evenly.
(3) Apply MP grease to a new oil seal lip.
(4) Install the oil seal as far as the deepest part of the
cylinder head.
(5) Apply seal packing to the No. 1 bearing cap as
shown.
Seal packing: Part No. 08826−00080 or equivalent

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.

S01805
S01793
9 10
3 45 6
1 2
7 8
EM7797
Seal Packing
S01649
S01645
− ENGINE MECHANICALCYLINDER HEAD
EM−59
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)
(9) Remove the service bolt B.
10. CHECK AND ADJUST VALVE CLEARANCE (See page
EM−5)
11. INSTALL SEMI−CIRCULAR PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the semi−circular plug grooves.
Seal packing: Part No. 08826−00080 or equivalent
(c) Install the 2 semi−circular plugs to the cylinder head.
12. INSTALL NO. 3 TIMING BELT COVER
Install the timing belt cover with the 3 bolts.
Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf)
13. TEMPORARILY INSTALL NO. 1 IDLER PULLEY AND
TENSION SPRING (See page EM−20)
14. INSTALL CAMSHAFT TIMING PULLEY AND TIMING
BELT (See page EM−20)
15. INSTALL ENGINE WIRE
(a) Install the engine wire protector to the 2 brackets on the
front side of the intake manifold.
(b) Connect the 4 injector connectors.
HINT:
The No. 1 and No. 3 injector connectors are brown, and the No.
2 and No. 4 injector connectors are gray.

S01647
S01432
P03283
: Seal Packing
S01658Marking 15°
15°
Z17351
12 EM−60
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
(c) Install the engine wire protector to the LH side of the in-
take manifold with the 2 bolts.
(d) Push in the engine wire through the cowl panel.
(e) Install the wire clamp to the bracket.
(f) Connect the 2 ECM connectors.
(g) Connect the 2 connectors to the connectors on the brack-
et.
(h) Connect the connector to the J/B No. 4.
(i) Install the RH floor carpet center cover.
(j) Install the RH cowl side trim.
(k) Install the RH scuff plate.
16. INST ALL 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 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 3 clamps to the No. 2 timing belt cover and
generator drive belt adjusting bar.
(g) Connect the crankshaft position sensor connector.
(h) w/ A/C:
Connect the A/C compressor connector.

S01791
S01644
S01806
− ENGINE MECHANICALCYLINDER HEAD
EM−61
1996 RAV4 (RM447U)
(i) Connect the PCV hose to the intake manifold.
(j) Install the accelerator cable bracket with the 2 bolts.
17. INSTALL VSV FOR EGR (See page SF−42)
18. CONNECT GROUND CABLE
Connect the ground cable to the intake manifold with the bolt.
19. CONNECT KNOCK SENSOR CONNECTOR
20. CONNECT PS IDLE−UP AIR HOSES TO AIR TUBE
21. A/T only:
CONNECT A/T THROTTLE CONTROL CABLE TO IN-
TAKE MANIFOLD
Connect the control cable to the clamp on the rear side of the
intake manifold.
22. INSTALL INTAKE MANIFOLD STAY
Install the intake manifold stay with the 2 bolts.
Torque: 42 N·m (425 kgf·cm, 31 ft·lbf)
23. INSTALL EGR VALVE AND VACUUM MODULATOR
(a) Install a new gasket and the EGR valve with the union nut
and 2 nuts.
Torque:
13 N·m (130 kgf·cm, 9 ft·lbf) for nut
59 N·m (600 kgf·cm, 43 ft·lbf) for union nut
(b) Install the vacuum modulator to the clamp on the intake
manifold.
(c) Connect the 2 vacuum hoses to the VSV for the EGR.
24. CONNECT FUEL INLET HOSE TO FUEL FILTER
Connect the inlet hose with 2 new gaskets and the union bolt.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)

S01560
(1)
(2)
(3)
P15451
ConnectNew
New
Gasket
O−Ring
S01594
S01368
EM−62
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
25. INSTALL HOSES AND GROUND STRAP
(a) Connect the vacuum sensor hose to the gas filter on the
intake manifold.
(b) Connect the brake booster vacuum hose to the intake
manifold.
(c) Connect the ground strap to the intake manifold.
26. INSTALL THROTTLE BODY (See page SF−33)
27. INSTALL WATER BYPASS PIPE
(a) Install a new gasket to the water pump cover.
(b) Install a new O−ring to the bypass pipe.
(c) Apply soapy water on the O−ring.
(d) Connect the water bypass pipe to the water pump cover.
(e) Install the bypass pipe with the 2 nuts and 2 bolts.
Torque:
9.3 N·m (95 kgf·cm, 82 in.·lbf) fot nut
19 N·m (195 kgf·cm, 14 ft·lbf) fot bolt
(f) Connect the engine wire protector with the nut.
(g) Connect the IAC valve water bypass hose to the water by-
pass pipe.
(h) Connect the heater water hose to the water bypass pipe.
(i) Connect the 2 oil cooler water bypass hoses to the oil
cooler.
(j) Install the oil cooler heat protector with the 2 nuts and bolt.
28. INSTALL WATER OUTLET
(a) Install a new gasket and the water outlet with the 2 nuts.
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
(b) Connect the radiator hose to the water outlet.
(c) Connect the water bypass pipe hose to the water outlet.
(d) Connect the heater water hose to the water outlet.
(e) Connect the IAC valve water bypass hose to the water
outlet.
(f) Connect the ECT sensor connector.
(g) Connect the ECT sender gauge connector.

P03469
Retainer
Cushion
New Gasket
S01823
Oxygen Sensor
(Bank 1 Sensor 1)
Oxygen Sensor (Bank 1 Sensor 2)
S01557
− ENGINE MECHANICALCYLINDER HEAD
EM−63
1996 RAV4 (RM447U)
29. CONNECT OIL PRESSURE SWITCH CONNECTOR
30. ASSEMBLE EXHAUST MANIFOLD AND FRONT TWC
(a) Place the cushion, retainer and a new gasket on the
TWC.
(b) Install the TWC to the exhaust manifold with the 3 bolts
and 2 nuts.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(c) Install the lower manifold heat insulator with the 5 bolts.
(d) Install the 2 TWC heat insulators with the 8 bolts.
31. INSTALL OXYGEN SENSOR (BANK 1 SENSOR 1) TO
EXHAUST MANIFOLD
Install a new gasket and the oxygen sensor with 2 new nuts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
32. INSTALL OXYGEN SENSOR (BANK 1 SENSOR 2) TO
FRONT TWC
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
33. INSTALL EXHAUST MANIFOLD AND FRONT TWC AS-
SEMBLY
(a) Install a new gasket, the exhaust manifold and TWC as-
sembly with the 6 nuts. Uniformly tighten the nuts in sev-
eral passes.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
(b) Install the RH exhaust manifold stay with the 2 bolts and
2 new nuts.
Torque: 42 N·m (452 kgf·cm, 31 ft·lbf)
(c) Install the upper manifold heat insulator with the 6 bolts.
(d) Connect the oxygen sensor (bank 1 sensor 1) connector.
(e) Connect the oxygen sensor (bank 1 sensor 2) connector.
34. INSTALL FRONT EXHAUST PIPE (See page EM−74)
35. INSTALL GENERATOR (See page CH−19)
36. INSTALL AIR CLEANER CASE AND CAP
37. CONNECT ACCELERATOR CABLE TO THROTTLE
BODY AND CABLE BRACKET
38. A/T only:
CONNECT THROTTLE CABLE TO THROTTLE BODY
AND CABLE BRACKET

EM−64
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
39. FILL WITH ENGINE COOLANT
40. START ENGINE AND CHECK FOR LEAKS
41. RECHECK ENGINE COOLANT LEVEL AND OIL LEV-
EL
42. INSTALL RH ENGINE UNDER COVER