engine TOYOTA RAV4 1996 Service Repair Manual

1. Remove driver-side rear seat and floor panel cover for access to fuel pump electrical connector.
2. Disconnect fuel pump electrical connector. Start engine and allow engine to idle until engine stalls. Turn
ignition off.
3. Reconnect fuel pump electrical connector. Reinstall floor panel cover and driver-side rear seat.
4. Disconnect negative battery cable. Place an approved gasoline container under fuel line. Cover fuel line
connection with shop towel.
5. Slowly loosen fuel line connection to release fuel pressure. Once fuel pressure is released, fuel system
components may be serviced.
ENGINE
Removal
1. Engine and transaxle are removed as an assembly from bottom of engine compartment. Release fuel
pressure. See FUEL PRESSURE RELEASE
. Remove hood, battery and battery tray. Drain cooling
system, and engine and transaxle oil.
2. Disconnect control cables at throttle body. Remove air cleaner assembly and air cleaner case. Remove
bolts, and disconnect relay box from body. Relay box is located near driver-side strut tower. See Fig. 8
.

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
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Fig. 8: Identifying Relay Box, Electrical Connector & Engine Wiring Harness
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
3. Remove upper cover from relay box. Disconnect electrical connector from relay box. See Fig. 8
. Remove
nuts, and disconnect engine wiring harness from relay box.
4. Remove charcoal canister. Remove accessory drive belt and generator. Disconnect upper and lower
radiator hoses. Remove thermostat housing from front of engine.
5. Disconnect necessary electrical connectors, coolant hoses, vacuum hoses and fuel lines for engine
removal.
6. Remove scuff plate from passenger-side door opening and passenger-side kick panel. Remove center
console trim panel from passenger-side of center console. See Fig. 9
.
Fig. 9: Identifying ECM & Electrical Connectors

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

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
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Sunday, November 22, 2009 10:22:26 AMPage 11 © 2005 Mitchell Repair Information Company, LLC.

7. 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.
8. Disconnect engine wiring harness clamp located on engine wiring harness, near firewall. Pull engine
wiring harness out through firewall.
9. Raise and support vehicle. Remove lower engine covers. On M/T models, remove clutch release cylinder
with hose attached, and secure aside. Disconnect transaxle control cables from transaxle. Remove starter
and transaxle ground cable. On A/T, and 4WD vehicles with M/T, disconnect transaxle oil cooler hoses.
10. On A/T models, disconnect transaxle control cable from front suspension crossmember and engine mount
center member. Disconnect connectors, plug wires, strap and hoses from top of engine. On 4WD M/T,
disconnect ground strap from engine cowl. Disconnect differential lock control solenoid connector.
11. Using 14-mm deep socket wrench, remove 2 bolts holding front exhaust pipe to front TWC. Remove 2
bolts and 2 nuts holding front exhaust pipe to TWC. Remove front exhaust pipe and 2 gaskets.
12. Disconnect A/C compressor connector. Remove 2 bolts, nut and stud bolt. Disconnect A/C compressor
from engine, and secure aside. On 4WD vehicles, remove rear drive shaft. On all models, remove front
drive shaft.
13. Remove front wheel and engine undercover. On M/T vehicles drain gear oil. On A/T models, drain
transmission fluid. On vehicles with ABS, remove bolt and ABS speed sensor. Remove cotter pin, lock
cap and lock nut.
14. Disconnect tie rod from steering knuckle. Disconnect stabilizer bar link from lower control arm.
Disconnect lower ball joint from lower control arm.
15. Using soft-face hammer, tap axle shaft from hub assembly. Pull steering knuckle outward and separate
axle shaft from hub assembly.
16. On 2WD A/T models, remove axle shaft bearing bracket bolts for right (passenger-side) axle shaft. See
Fig. 10
. Remove right axle shaft assembly from transaxle and axle shaft bearing bracket.

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:22:26 AMPage 12 © 2005 Mitchell Repair Information Company, LLC.

Fig. 10: Removing Right (Passenger-Side) Axle Shaft (2WD A/T Models)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
17. 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. 11
. Remove right axle shaft assembly from transaxle and axle
shaft bearin
g bracket.

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
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Sunday, November 22, 2009 10:22:26 AMPage 13 © 2005 Mitchell Repair Information Company, LLC.

Fig. 11: Removing Right (Passenger-Side) Axle Shaft (2WD M/T Models)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
18. On 2WD models, use hammer and brass drift or a slide hammer and Drive Shaft Remover Attachment
(09520-01010) to remove left (drive
r-side) axle shaft from transaxle. See Fig. 12 .

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
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Sunday, November 22, 2009 10:22:26 AMPage 14 © 2005 Mitchell Repair Information Company, LLC.

Fig. 12: Removing Left (Driver-Side) Axle Shaft (2WD Models) Or Right (Passenger-Side) Axle
Shaft (4WD Models)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
19. 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 (drive
r-side) axle shaft from transaxle. See Fig. 13.

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:22:26 AMPage 15 © 2005 Mitchell Repair Information Company, LLC.

Fig. 13: Removing Left (Driver-Side) Axle Shaft (4WD Models)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
20. Remove stabilizer bar-to-frame mount bolts. Remove stabilizer bar with mounting brackets and
insulators. Remove 2 steering gear assembly-to-front suspension crossmember bolts/nuts located at each
end of steering gear assembly.
21. Support engine with hoist. Remove engine mount crossmember-to-front suspension crossmember nuts.
Front suspension crossmember mounts between both lower control arms.
22. Support front suspension crossmember with floor jack. Remove front suspension crossmember bolts and
front suspension crossmember.
23. Remove front (exhaust manifold side) engine mount-to-engine mount crossmember bolts. Remove engine
mount crossmember-to-body bolts. Remove engine mount crossmember.
24. Remove power steering pump with hoses attached, and secure aside. Remove left (transaxle side) engine
mounting bracket-to-engine mount bolts/nuts. Remove right (timing belt side) engine mounting bracket-
to-engine mount bolts/nuts. Lower engine from engine compartment.
Installation

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
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Sunday, November 22, 2009 10:22:26 AMPage 16 © 2005 Mitchell Repair Information Company, LLC.

1. Install engine in engine compartment. Loosely install right (timing belt side) engine mounting bracket-to-
engine mount bolts/nuts.
2. Install and tighten left (transaxle side) engine mounting bracket-to-engine mount bolts/nuts to
specification. See TORQUE SPECIFICATIONS
. Tighten right (timing belt side) engine mounting
bracket-to-engine mount bolts/nuts to specification.
3. Install power steering pump. Install and tighten bolts to specification. See TORQUE
SPECIFICATIONS . Install engine mount crossmember with front (exhaust manifold side) engine
mount-to-engine mount crossmember bolts and engine mount crossmember-to-body bolts loosely
installed. DO NOT tighten bolts at this time
4. Install front suspension crossmember on body with bolts loosely installed. Loosely install engine mount
crossmember-to-front suspension crossmember nuts and steering gear assembly-to-front suspension
crossmember bolts/nuts. DO NOT tighten bolts/nuts at this time.
5. Install and tighten front suspension crossmember bolts to specification. See TORQUE
SPECIFICATIONS .
6. Tighten steering gear assembly-to-front suspension crossmember bolts/nuts and then engine mount
crossmember-to-front suspension crossmember nuts to specification. See TORQUE
SPECIFICATIONS .
7. Tighten front (exhaust manifold side) engine mount-to-engine mount crossmember bolts and then engine
mount crossmember-to-body bolts to specification. See TORQUE SPECIFICATIONS
.
8. To install remaining components, reverse removal procedure. Before installing axle shafts coat axle shaft
seals in transaxle with grease.
9. On all axle shafts except right (passenger-side) axle shaft on 2WD models, install NEW snap ring on end
of axle shaft. Position snap ring on end of axle shaft with opening facing downward.
10. Install axle shaft by lightly tapping axle shaft into transaxle. Ensure axle shaft moves inward and outward
approximately .079-.120" (2.00-3.00 mm) and cannot be pulled from transaxle.
11. On 2WD M/T models, when installing right (passenger-side) axle shaft, install NEW axle shaft retaining
bolt. Tighten axle shaft retaining bolt to specification. See TORQUE SPECIFICATIONS
.
12. On 4WD models, ensure reference marks on drive shaft flanges are aligned. Ensure mounting bracket on
drive shaft center support bearing is straight and perpendicular to drive shaft before tightening bolts to
specification.
13. Use NEW gasket and NEW nuts when installing front exhaust pipe on catalytic converter. Ensure all
bolts/nuts are loosely installed before tightening to specification.
14. Adjust fluid levels and control cables. On 2WD models with A/T, use Dexron-II ATF. On 4WD models
with A/T, use Type "T" ATF. On all M/T models, use SAE 75-90 GL-5 gear oil.
CYLINDER HEAD & MANIFOLDS NOTE: All axle shafts, except right (passenger-side) axle shaft on 2WD models,
use a snap ring on end of axle shaft. Ensure NEW snap ring is installed.
NOTE: On 4WD models, manufacturer recommends engine removal for servicing of
cylinder head and manifolds. See ENGINE
.

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:22:26 AMPage 17 © 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.
3. Remove front exhaust pipe. Remove exhaust manifold and heat insulator assembly. Disconnect oxygen
sensor (except California) or Air/Fuel (A/F) ratio sensor (California), and remove exhaust manifold and
heat shield. Remove sensors from exhaust manifold and front catalytic converter, if equipped.
4. Remove heat insulator from front exhaust pipe. Remove throttle body and gasket. Remove ignition coils
with spark plug wires attached.
5. Disconnect necessary electrical connectors, coolant hoses and vacuum hoses from cylinder head and
intake manifold. Remove coolant outlet, coolant by-pass pipe and gaskets.
6. Disconnect hoses and ground strap. Remove union bolt, and disconnect fuel line at fuel filter. Remove
EGR valve and vacuum modulator. Disconnect power steering idle-up hoses from air tube.
7. Remove 2 bolts and accelerator cable bracket. Disconnect PCV hoses, cable brackets and control cables
for access to valve cover. Disconnect engine wiring harness protector at rear of timing belt cover for
access to valve cover. Remove nuts, grommets, valve cover and gasket. Note location of grommets for
reassembly reference, as grommets must be installed in original location.
8. Remove bolts, and disconnect engine wiring harness protector from left 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.
9. Remove scuff plate from passenger-side door opening and passenger-side kick panel. Remove right side
cowl side trim and floor carpet center cover. 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.
10. 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.
11. Disconnect timing belt from camshaft timing pulley. Remove camshaft timing pulley. Remove No. 1 idler
pulley and tension spring. See TIMING BELT
. Remove 3 bolts and timing belt cover. See Fig. 14 .
After removing timing belt from camshaft sprocket, support timing belt so belt does not come off
crankshaft sprocket.

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:22:26 AMPage 18 © 2005 Mitchell Repair Information Company, LLC.

Fig. 14: Exploded View Of Camshaft & Cylinder Head Components
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
12. Remove camshafts. See CAMSHAFT

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:22:26 AMPage 19 © 2005 Mitchell Repair Information Company, LLC.