TOYOTA RAV4 1996 Service Repair Manual

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Sun Roofs
Microsoft
Sunday, November 22, 2009 10:58:31 AMPage 111 © 2005 Mitchell Repair Information Company, LLC.

Fig. 78: Power Sun Roof System Wiring Diagram (1999-2000 Sienna)

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Sun Roofs
Microsoft
Sunday, November 22, 2009 10:58:31 AMPage 112 © 2005 Mitchell Repair Information Company, LLC.

TOYOTA
2.0L 4-Cylinder - RAV4
MANUFACTURER'S SUGGESTED SCHEDULED MAINTENANCE
For 1996-97 model years, the manufacturer recommends the belt be replaced every 60,000 miles for severe
service operating conditions. For 1998 model year, the manufacturer recommends the belt be replaced every
90,000 miles for severe service operating conditions. For 1999-00 model years, the manufacturer recommends
the belt be replaced every 90,000 miles or 72 months.
REMOVAL & INSTALLATION
TIMING BELT
Removal
1. Disconnect negative battery cable. Disconnect power steering reservoir, and remove reservoir bracket.
Disconnect wire harness bracket for Data Link Connector No. 1. Remove generator and generator
bracket.
2. Remove ABS actuator. Raise and support vehicle. Remove right front wheel. Remove right engine
undercover. Remove power steering drive belt. Slightly jack up engine and remove right engine mounting
insulator.
3. Remove spark plugs. Remove crankshaft pulley. See Fig. 1
. Remove right engine mounting bracket.
Remove No. 2 timing belt cover. See Fig. 2
. Temporarily install crankshaft pulley with pulley bolt. Set
No. 1 cylinder to TDC on compression stroke. See Fig. 3
.
4. Loosen mounting bolt of No. 1 idler pulley and shift pulley toward left as far as it will go to relieve belt
tension. See Fig. 4
. Temporarily tighten idler pulley. Remove crankshaft pulley and No. 1 timing belt
cover.
5. If reusing timing belt, mark direction of rotation on belt. Also place match marks on belt and camshaft
pulle
y. See Fig. 5 . Remove timing belt from engine. NOTE: Always turn crankshaft clockwise.

1999 Toyota RAV4
TOYOTA 2.0L 4-Cylinder - RAV4

1999 Toyota RAV4
TOYOTA 2.0L 4-Cylinder - RAV4
Microsoft
Sunday, November 22, 2009 10:24:26 AMPage 1 © 2005 Mitchell Repair Information Company, LLC.
Microsoft
Sunday, November 22, 2009 10:24:33 AMPage 1 © 2005 Mitchell Repair Information Company, LLC.

Fig. 1: Exploded View Of Timing Belt & Components

1999 Toyota RAV4
TOYOTA 2.0L 4-Cylinder - RAV4
Microsoft
Sunday, November 22, 2009 10:24:26 AMPage 2 © 2005 Mitchell Repair Information Company, LLC.

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 2: Removing No. 2 Timing Belt Cover

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
TOYOTA 2.0L 4-Cylinder - RAV4
Microsoft
Sunday, November 22, 2009 10:24:26 AMPage 3 © 2005 Mitchell Repair Information Company, LLC.

Fig. 3: Setting No. 1 Cylinder To TDC
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
TOYOTA 2.0L 4-Cylinder - RAV4
Microsoft
Sunday, November 22, 2009 10:24:26 AMPage 4 © 2005 Mitchell Repair Information Company, LLC.

Fig. 4: Loosening No. 1 Idler Pulley Mounting Bolt
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
TOYOTA 2.0L 4-Cylinder - RAV4
Microsoft
Sunday, November 22, 2009 10:24:26 AMPage 5 © 2005 Mitchell Repair Information Company, LLC.

Fig. 5: Aligning Matching Marks Of Timing Belt & Cams
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Inspection
1. Inspect idler pulleys for smoothness. Ensure free length of tension spring is 1.653" (42.0 mm). See Fig.
6 . Spring tension should be 8.5 lbs. (3.85 kg) at length of 1.988". If not as specified, replace spring.
Inspect timin
g belt cover gaskets. Replace if gaskets are cracked or peeling.

1999 Toyota RAV4
TOYOTA 2.0L 4-Cylinder - RAV4
Microsoft
Sunday, November 22, 2009 10:24:26 AMPage 6 © 2005 Mitchell Repair Information Company, LLC.

Fig. 6: Measuring Tensioner Spring Free Length
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Installation
1. Ensure that No. 1 cylinder is set to TDC on compression stroke by temporarily installing No. 1 timing
belt cover and crankshaft pulley. Align groove with timing mark "0" on No. 1 timing belt cover. Ensure
that camshaft and timing belt match marks are aligned. Remove crankshaft pulley and timing belt cover.
Install timing belt. If reusing old belt, ensure rotation direction and mating marks are in correct position.
2. Install timing belt guide on crankshaft with cup side facing out. Install No. 1 timing belt cover, crankshaft
pulley, and crankshaft pulley bolt. Loosen No. 1 idler pulley 1/2 turn to tension timing belt. Slowly turn
crankshaft pulley 2 revolutions from TDC to TDC.
3. Check that each pulley aligns with timing marks as shown. See Fig. 5
. Slowly turn crankshaft pulley 1-
7/8 revolutions and align groove with mark at 45 degrees BTDC (for No. 1 cylinder) of No. 1 timing belt
cover. See Fig. 7
. Tighten No. 1 idler pulley mounting bolt to specification.
4. Place right engine mounting bracket in position, but do not install bolts. Install No. 2 timing belt cover.
Disconnect engine wire protector between cylinder head cover and No. 3 timing belt cover. Install No. 2
timing belt cover. Install engine wire to No. 2 timing belt cover. Install engine wire protector to mounting
bolts of No. 2 timing belt cover.
5. Remove crankshaft pulley. Install engine mounting bracket-to-engine bolts and tighten to specification.
Install crankshaft pulley, and tighten pulley bolt to specification. See TORQUE SPECIFICATIONS
.
To complete installation, reverse removal procedure. Ad
just drive belts to proper tension.

1999 Toyota RAV4
TOYOTA 2.0L 4-Cylinder - RAV4
Microsoft
Sunday, November 22, 2009 10:24:26 AMPage 7 © 2005 Mitchell Repair Information Company, LLC.

Fig. 7: Locating 45 Degree BTDC Mark
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ApplicationFt. Lbs. (N.m)
Camshaft Timing Pulley Bolt40 (54)
Crankshaft Pulley Bolt80 (108)
Generator Bracket Bolts31 (42)
Engine Mount Bracket-To-Engine Bolts38 (52)
Engine Mount Insulator-To-Body Bolts38 (52)
Engine Mount Insulator-To-Bracket Nut27 (37)
No. 1 Idler Pulley Mounting Bolt31 (42)
Wheel Lug Nut76 (103)
INCH Lbs. (N.m)
Water Pump Bolts78 (8.8)

1999 Toyota RAV4
TOYOTA 2.0L 4-Cylinder - RAV4
Microsoft
Sunday, November 22, 2009 10:24:27 AMPage 8 © 2005 Mitchell Repair Information Company, LLC.