sensor TOYOTA RAV4 1996 Service Repair Manual

ENGINE SPECIFICATIONS
Power Steering Pump Mounting Bracket-To-Cylinder Block Bolt32 (43)
Spark Plug13 (18)
Spark Plug Tube39 (53)
Stabilizer Bar Link-To-Lower Control Arm Nut
2-Door Vehicles33 (45)
4-Door Vehicles54 (73)
Stabilizer Bar-To-Frame Mount Bolt22 (30)
Starter Bolt29 (39)
Steering Gear Assembly-To-Front Suspension Crossmember Bolt/Nut 83 (113)
Stiffener Plate Bolt27 (37)
Throttle Body Bolt/Nut14 (19)
Tie Rod Nut41 (56)
Valve Cover Nut33 (45)
Wheel Lug Nut76 (103)
INCH Lbs. (N.m)
ABS Speed Sensor Bolt71 (8.0)
Clutch Release Cylinder Bolt106 (12.0)
Coolant By-Pass Pipe-To-Water Pump Nut82 (9.3)
Crankshaft Position Sensor Bolt71 (8.0)
Fuel Delivery Pipe-To-Cylinder Head Bolt115 (13.0)
No. 3 Timing Belt Cover Bolt69 (7.8)
Oil Baffle Plate-To-Cylinder Block Bolt/Nut48 (5.4)
Oil Cooler-To-Cylinder Block Nut78 (8.8)
Oil Pan Bolt/Nut48 (5.4)
Oil Pump Body Cover Bolt78 (8.8)
Oil Pump Pick-Up Tube Bolt/Nut48 (5.4)
Oil Pump-To-Cylinder Block Bolt78 (8.8)
Rear Plate-To-Cylinder Block Bolt82 (9.3)
Rear Seal Housing Bolt115 (13.0)
Thermostat Housing Nut78 (8.8)
Water Pump-To-Cylinder Block Bolt (5) 78 (8.8)
Water Pump-To-Water Pump Cover Bolt78 (8.8)
(1)Tighten bolts to specification in sequence. See Fig. 22 and Fig. 23 .
(2)Tighten bolts to specification in sequence. See Fig. 15 .
(3)Tighten nut to 115 INCH lbs. (13.0 N.m).
(4)Tighten bolts to specification in sequence. See Fig. 36 .
(5)Tighten bolts to specification in sequence. See Fig. 28 .

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:22:27 AMPage 59 © 2005 Mitchell Repair Information Company, LLC.

13. On all models, remove front wheels. Drain transaxle fluid. On models with Anti-Lock Brake System
(ABS), remove bolt and pull ABS speed sensor from front of axle carrier.
14. On all models, remove cotter pin and retainer from end of axle shaft. Loosen axle shaft nut while
applying brakes. Remove axle shaft nut.
15. Remove nut, and separate tie rod from steering knuckle. Disconnect stabilizer bar link from lower control
arm. Remove ball joint-to-lower control arm bolts/nuts.
16. Using soft-face hammer, tap axle shaft from hub assembly. Pull steering knuckle outward and separate
axle shaft from hub assembly.
17. On 2WD A/T models, remove axle shaft bearing bracket bolts for right (passenger-side) axle shaft. See
Fig. 10
or Fig. 11 . Remove right axle shaft assembly from transaxle and axle shaft bearing bracket.
18. On 2WD M/T models, remove snap ring and axle shaft retaining bolt from axle shaft bearing bracket for
right (passenger-side) axle shaft. See Fig. 10
or Fig. 11. Remove right axle shaft assembly from transaxle
and axle shaft bearing bracket.
19. On 2WD models, use hammer and brass drift or a slide hammer and Drive Shaft Remover Attachment
(09520-01010) to remove left (driver-side) axle shaft from transaxle. See Fig. 12
.
20. On 4WD models use hammer and brass drift or a slide hammer and Drive Shaft Remover Attachment
(09520-01010) to remove right (passenger-side) axle shaft from transaxle. See Fig. 12
. Use pry bar to
remove left (driver-side) axle shaft from transaxle. See Fig. 13
.
Fig. 10: Removing Right (Passenger
-Side) Axle Shaft (2WD A/T Models)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:31 AMPage 13 © 2005 Mitchell Repair Information Company, LLC.

Removal
1. Release fuel pressure. See FUEL PRESSURE RELEASE . Drain cooling system. Raise and support
vehicle. Remove right lower engine cover.
2. Disconnect control cables at throttle body. Remove air cleaner assembly and air cleaner case. Remove
accessory drive belt and generator. On 1997 models, remove distributor with spark plug wires. On 1998
models, remove front exhaust pipe.
3. On 1997 models, disconnect electrical connectors for oxygen sensors and remove exhaust manifold and
front catalytic converter. On 1998 models, disconnect oxygen sensor (except California) or Air/Fuel ratio
(A/F) sensor (California) and remove exhaust manifold and heat shield. On all models, remove sensors
from exhaust manifold and front catalytic converter, if equipped. See Fig. 14
.
4. On 1997 models, separate exhaust manifold and front catalytic converter and disconnect oil pressure
switch. On 1998 models, remove heat insulator from front exhaust pipe. Remove ignition coils with spark
plug wires attached. Disconnect oil pressure switch. See Fig. 14
.
5. On all models, disconnect necessary electrical connectors, coolant hoses and vacuum hoses from throttle
body, cylinder head and intake manifold. Remove coolant outlet, coolant by-pass pipe and gaskets. See
Fig. 14
.
6. Remove throttle body and gasket. Remove union bolt and disconnect fuel line at fuel filter. Remove EGR
valve and vacuum modulator. Remove EGR Vacuum Switching Valve (VSV) from side of cylinder head.
See Fig. 14
.
7. Remove intake manifold brace located between cylinder block and intake manifold. On A/T models,
disconnect control cable bracket from side of intake manifold. On all models, disconnect power steering
fluid reservoir, PCV hoses, cable brackets and control cables for access to valve cover.
8. Disconnect engine wiring harness protector at rear of timing belt cover for access to valve cover. When
disconnecting engine wiring harness protector, remove bolt on intake manifold side of engine first, and
then bolt on exhaust manifold side of engine.
9. Remove nuts, grommets, valve cover and gasket. Note location of grommets for reassembly reference, as
grommets must be installed in original location.
10. Remove bolts and disconnect engine wiring harness protector from rear side of intake manifold.
Disconnect electrical connectors at injectors, A/C compressor and crankshaft position sensor. Remove
engine wiring harness clamps from timing belt cover and generator drive belt adjusting bar.
11. Disconnect engine wiring harness protector from brackets on front side of intake manifold. Remove scuff
plate from passenger-side door opening and passenger-side kick panel. Remove center console trim panel
from passenger-side of center console.
12. Disconnect 2 electrical connectors from Engine Control Module (ECM), and 2 electrical connectors on
bracket. See Fig. 9
. Disconnect electrical connector for relay box located behind passenger-side kick
panel.
13. Disconnect engine wiring harness clamp located on engine wiring, near firewall. Pull engine wiring
harness out through firewall. Remove engine wiring harness from between cylinder head and intake
manifold. NOTE: On 4WD models, manufacturer recommends engine removal for servicing of
cylinder head and manifolds. See ENGINE. Proceed to appropriate step in
following procedure for servicing of cylinder head and manifolds.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:31 AMPage 17 © 2005 Mitchell Repair Information Company, LLC.

1. Remove timing belt, No. 2 idler pulley, crankshaft sprocket and oil pump sprocket. See TIMING BELT
under REMOVAL & INSTALLATION. Remove oil pan. See OIL PAN under REMOVAL &
INSTALLATION.
2. Remove oil pump pick-up tube, gasket and oil baffle plate. Disconnect electrical connector for crankshaft
position sensor located on from of oil pump housing. Remove bolt and crankshaft position sensor from
front of oil pump housing.
3. Remove oil pump-to-cylinder block bolts. Using soft-faced hammer, tap oil pump housing from cylinder
block. To disassemble oil pump, remove oil pump body cover bolts, oil pump body cover and "O" ring.
Disassemble oil pump components. See Fig. 40
. Remove oil pump oil seal and crankshaft front oil seal
(if necessary).
Fig. 40: Exploded View Of Oil Pump

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Inspection
1. Inspect components for damage. Coat relief valve with engine oil and ensure relief valve slides freely in
bore of oil pump housing. Replace relief valve and/or oil pump housing if relief fails to slide freely.
2. Install rotors in oil pump housing. Using feeler gauge, measure driven rotor-to-oil pump housing
clearance. Replace rotor assembly or oil pump housing if clearance exceeds specification. See OIL
PUMP SPECIFICATIONS .
3. Usin
g feeler gauge, measure rotor tip clearance between tip of drive rotor and tip of driven rotor. Tip of

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:31 AMPage 58 © 2005 Mitchell Repair Information Company, LLC.

Oil Cooler Relief Valve58 (79)
Oil Pump Sprocket Nut18 (24)
Oxygen Sensor-To-Exhaust Manifold Nut15 (20)
Oxygen Sensor-To-Front Catalytic Converter33 (45)
Power Steering Pump Bolt32 (43)
Power Steering Pump Mounting Bracket-To-Cylinder Block Bolt32 (43)
Spark Plug13 (18)
Spark Plug Tube39 (49)
Stabilizer Bar Link-To-Lower Control Arm Nut
3-Door Vehicles47 (64)
5-Door Vehicles83 (113)
Stabilizer Bar-To-Frame Mount Bolt22 (29)
Starter Bolt29 (39)
Steering Gear Assembly-To-Front Suspension Crossmember Bolt/Nut83 (113)
Stiffener Plate Bolt27 (37)
Throttle Body Bolt/Nut14 (19)
Tie Rod Nut36 (49)
Valve Cover Nut33 (44)
Wheel Lug Nut76 (103)
INCH Lbs. (N.m)
ABS Speed Sensor Bolt71 (8.0)
Clutch Release Cylinder Bolt106 (12.0)
Coolant By-Pass Pipe-To-Water Pump Nut82 (9.3)
Crankshaft Position Sensor Bolt71 (8.0)
Fuel Delivery Pipe-To-Cylinder Head Bolt115 (13.0)
No. 3 Timing Belt Cover Bolt69 (7.8)
Oil Baffle Plate-To-Cylinder Block Bolt/Nut48 (5.4)
Oil Cooler-To-Cylinder Block Nut78 (8.8)
Oil Pan Bolt/Nut48 (5.4)
Oil Pump Body Cover Bolt78 (8.8)
Oil Pump Pick-Up Tube Bolt/Nut48 (5.4)
Oil Pump-To-Cylinder Block Bolt78 (8.8)
Rear Plate-To-Cylinder Block Bolt82 (9.3)
Rear Seal Housing Bolt115 (13.0)
Thermostat Housing Nut78 (8.8)
Water Pump-To-Cylinder Block Bolt (5) 78 (8.8)
Water Pump-To-Water Pump Cover Bolt78 (8.8)
(1)Tighten bolts to specification in sequence. See Fig. 23 and Fig. 24 .
(2)Tighten bolts to specification in sequence. See Fig. 15 .

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:31 AMPage 62 © 2005 Mitchell Repair Information Company, LLC.

Fig. 2: Identifying Hub Components (Corolla Shown; Celica & RAV4 Similar)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
REMOVAL & INSTALLATION
FRONT AXLE HUB & WHEEL BEARING
Removal (Avalon, Camry, Camry Solara & Sienna)
1. Remove front wheel. Check wheel bearing backlash and deviation (rotational free play). See WHEEL
BEARING CHECKING under ADJUSTMENTS & INSPECTION.
2. Remove cotter pin and lock nut cap. Hold drive shaft from turning by applying brakes and remove drive
shaft lock nut. Remove brake caliper and disc and support calliper out of way.
3. Remove ABS speed sensor and wire harness clamp. Loosen 2 nuts on lower end of shock absorber (DO
NOT remove nuts).
4. Remove cotter pin and nut from tie rod end. Use tie rod separator to disconnect tie rod end from steering
knuckle. Remove 2 nuts and 1 bolt and disconnect lower ball joint from lower control arm. See Fig. 1
and
Fig. 3
.
5. Remove 2 nuts and bolts from lower end of shock absorber. Remove steering knuckle and axle hub from
vehicle.
6. Carefully pry off dust deflector. Mount assembly in vise and use separator tool to remove lower ball joint
from hub assembly. Use a slide hammer and attaching plate to remove axle hub.
7. Place axle hub on press and use appropriate support plates to press inner bearin
g race from axle hub.

1999 Toyota RAV4
1999-2000 SUSPENSION Front - Avalon, Camry, Camry Solara, Celica, Corolla, Echo, RAV4 & Sienna
Microsoft
Sunday, November 22, 2009 10:36:34 AMPage 3 © 2005 Mitchell Repair Information Company, LLC.

Removal (Celica, Corolla & RAV4)
1. Remove front wheel. On Celica, remove ABS speed sensor. Check wheel bearing backlash and deviation
(rotational free play). See WHEEL BEARING CHECKING
under ADJUSTMENTS & INSPECTION.
2. Remove cotter pin and lock nut cap. Hold drive shaft from turning by applying brakes and remove drive
shaft lock nut. Remove brake caliper and disc and support caliper out of way.
3. On Corolla and RAV4 with ABS, remove ABS speed sensor and wire harness clamp. On Corolla, remove
brake hose from shock absorber clamp. Loosen 2 nuts on lower end of shock absorber (DO NOT
remove).
4. On all models, remove cotter pin and nut from tie rod end. Use separator tool to disconnect tie rod end
from steering knuckle. On Celica, disconnect stabilizer bar link from lower control arm.
5. On all models, remove 2 nuts and 1 bolt and disconnect lower ball joint from lower control arm. Remove
2 nuts and bolts from lower end of shock absorber. Remove steering knuckle and axle hub from vehicle.
See Fig. 2
.
6. Mount assembly in vise. Carefully pry dust deflector from hub. Remove cotter pin and nut, and use
separator tool to remove lower ball joint from hub assembly. On Celica and Corolla, remove inner oil seal
from hub. On Corolla, remove inner snap ring.
7. On all models, use slide hammer and attaching plate to remove axle hub. Place axle hub on press and use
appropriate support plates to press inner bearing race from axle hub. Remove Torx bolts and remove dust
cover.
8. On Celica and Corolla, use a suitable extractor to remove outer oil seal from hub. On RAV4, use a
suitable extractor to remove inner and outer oil seals from hub. On all models, remove wheel bearing
snap ring, if equipped. Place inner race against outside of bearing and press wheel bearing from axle hub.
See Fig. 2
.
Installation
To install, reverse removal procedure. Use NEW snap ring after pressing in NEW wheel bearing. Use NEW
cotter pins. Ti
ghten bolts to specifications. See TORQUE SPECIFICATIONS.

1999 Toyota RAV4
1999-2000 SUSPENSION Front - Avalon, Camry, Camry Solara, Celica, Corolla, Echo, RAV4 & Sienna
Microsoft
Sunday, November 22, 2009 10:36:34 AMPage 5 © 2005 Mitchell Repair Information Company, LLC.

1. Remove front wheel. Check wheel bearing backlash and deviation (rotational free play). See WHEEL
BEARING CHECKING under ADJUSTMENTS & INSPECTION.
2. Using punch and hammer, unstake drive shaft lock nut. Apply brakes and remove lock nut. Remove 2
bolts, brake caliper and disc. Support brake caliper out of way.
3. Remove bolt, and disconnect ABS speed sensor. Remove clip and nut. Using separator, separate steering
knuckle from lower suspension arm. Remove cotter pin and nut, and using tie rod separator, disconnect
tie rod end.
4. Remove 2 nuts, bolts and steering knuckle with axle hub from shock absorber.
Installation
To install, reverse removal procedure. Use NEW snap ring after pressing in NEW wheel bearing. Use NEW
cotter pins. Tighten bolts to specifications. See TORQUE SPECIFICATIONS
.
SHOCK ABSORBER
Removal & Installation
1. Remove front wheel. Disconnect brake hose and ABS speed sensor clamp from shock absorber. On
Sienna, remove outer front cowl top panel. See Fig. 6
.
2. Remove 2 lower shock absorber nuts and bolts and disconnect shock absorber from steering knuckle.
Remove 3 upper shock absorber mounting nuts from inside engine compartment and remove shock
absorber with coil spring.
3. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE
SPECIFICATIONS . NOTE: On Camry, note mounting position of curved mounting plate on shock
absorber tower. Ensure it is reinstalled in same position.

1999 Toyota RAV4
1999-2000 SUSPENSION Front - Avalon, Camry, Camry Solara, Celica, Corolla, Echo, RAV4 & Sienna
Microsoft
Sunday, November 22, 2009 10:36:34 AMPage 8 © 2005 Mitchell Repair Information Company, LLC.

Fig. 13: Identifying Power Steering Gear Mounting Bolts (Sienna)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ApplicationFt. Lbs. (N.m)
ABS Speed Sensor Wire Harness Clamp Bolt
Avalon, Camry, Camry Solara, Echo & Sienna22 (30)
Brace Mounting Nuts
Corolla51 (69)
Brake Caliper Mounting Bolts-To-Steering Knuckle
Avalon, Camry, Camry Solara, RAV4 & Sienna79 (107)
Celica
199976 (103)
200079 (107)
Corolla & Echo65 (88)
Brake Hose Clamp Bolt
Avalon, Camry, Camry Solara, Corolla & Sienna22 (30)
Celica & RAV414 (19)
Drive Axle Nut

1999 Toyota RAV4
1999-2000 SUSPENSION Front - Avalon, Camry, Camry Solara, Celica, Corolla, Echo, RAV4 & Sienna
Microsoft
Sunday, November 22, 2009 10:36:34 AMPage 19 © 2005 Mitchell Repair Information Company, LLC.

38 (52)
"C"83 (113)
"D"116 (157)
"E"29 (39)
Corolla (2)
Front Bolts ("B")167 (226)
Rear Bolts ("D")45 (61)
Center Nuts ("E")42 (57)
Outer End Bolts ("C")109 (148)
Outer Rear Bolts ("A")129 (175)
RAV4
Outer152 (206)
Suspension Crossmember-To-Center Member Bolt & Nuts
Celica59 (80)
RAV4 (Nuts)85 (115)
Tie Rod End Nut36 (49)
INCH Lbs. (N.m)
ABS Speed Sensor Bolt
Avalon, Camry, Camry Solara, & Corolla71 (8.0)
Celica
199944 (5.0)
200071 (8.0)
Sienna69 (7.8)
ABS Speed Sensor Wire Harness Clamp Bolt
Celica
199944 (5.0)
200071 (8.0)
RAV448 (5.4)
Axle Hub Dust Cover Bolts74 (8.3)
Front Suspension Clamp (A/T Only)
RAV474 (8.3)
(1)See Fig. 8 .
(2)See Fig. 10 .

1999 Toyota RAV4
1999-2000 SUSPENSION Front - Avalon, Camry, Camry Solara, Celica, Corolla, Echo, RAV4 & Sienna
Microsoft
Sunday, November 22, 2009 10:36:34 AMPage 22 © 2005 Mitchell Repair Information Company, LLC.