engine TOYOTA RAV4 1996 Service Repair Manual

4. Secure sub-gear to main gear on exhaust camshaft with a 6 x 1.0 x 18 mm service bolt "B". See Fig. 20 .
Before removing camshaft bearing cap bolts, ensure torsional spring force of sub-gear is secured by
service bolt "B".
Fig. 20: Securing Sub Gear
-To-Main Gear
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
NOTE: Camshaft bearing caps are numbered for location, and have an arrow on
top of cap. Front camshaft bearing cap on intake camshaft and rear
camshaft bearing cap on exhaust camshaft are not numbered. All other
camshaft bearing caps are numbered starting with No. 1 at timing belt end
of engine. Arrow on top of camshaft bearing cap must point toward timing
belt end of engine. See Fig. 21
.

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1999-2000 ENGINES 2.0L 4-Cylinder
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5. Remove bolts and rear camshaft bearing cap from exhaust camshaft. Remove bolts from No. 1, 2 and 4
camshaft bearing caps on exhaust camshaft in proper sequence. See Fig. 22
. DO NOT remove bolts from
No. 3 camshaft bearing cap at this time. Remove No. 1, 2 and 4 camshaft bearing caps from exhaust
camshaft. Fig. 21: Identifying Camshaft Bearing Caps

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

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Fig. 22: Exhaust Camshaft Bearing Cap Bolt Removal & Installation Sequence
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
6. Alternatel
y loosen bolts on No. 3 camshaft bearing cap on exhaust camshaft. Ensure exhaust camshaft is

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1999-2000 ENGINES 2.0L 4-Cylinder
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lifted upward as No. 3 camshaft bearing cap bolts are loosened.
7. If exhaust camshaft is not lifted upward, reinstall all camshaft bearing caps. Reposition intake camshaft
so knock pin is 10-45 degrees from vertical position. See Fig. 19
. Repeat steps 5) and 6) . Remove No. 3
camshaft bearing cap and exhaust camshaft.
Removal (Intake Side)
1. Remove distributor, if equipped. Rotate intake camshaft so knock pin is 80-115 degrees from vertical
position. See Fig. 19
. This aids in intake camshaft removal by using camshaft lobes on cylinders No. 1
and 3 to push on valve lifters.
2. Remove bolts, front camshaft bearing cap and oil seal from intake camshaft. Remove bolts from No. 1, 3
and 4 camshaft bearing caps on intake camshaft in proper sequence. See Fig. 23
. DO NOT remove bolts
from No. 2 camshaft bearing cap at this time. Remove No. 1, 3 and 4 camshaft bearing caps from intake
camshaft.

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Fig. 23: Intake Camshaft Bearing Cap Bolt Removal & Installation Sequence
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
3. Alternatel
y loosen bolts on No. 2 camshaft bearing cap on intake camshaft. Ensure intake camshaft is

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1999-2000 ENGINES 2.0L 4-Cylinder
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lifted upward as No. 2 camshaft bearing cap bolts are loosened.
4. If intake camshaft is not lifted upward, reinstall all camshaft bearing caps. Reposition intake camshaft so
knock pin is 80-115 degrees from vertical position. See Fig. 19
. Repeat steps 9) and 10) . Remove No. 2
camshaft bearing cap and intake camshaft.
5. If removing sub-gear from exhaust camshaft, mount camshaft in soft-jaw vise on hexagonal area of
camshaft. Install service bolt "A" in camshaft. See Fig. 24
.
Fig. 24: Removing & Installing Sub
-Gear On Main Gear
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
6. Using screwdriver, rotate sub-gear clockwise and remove service bolt "B". Remove snap ring, wave
washer, sub-gear and camshaft gear spring from exhaust camshaft. See Fig. 14
.
7. Note location of adjusting shims and valve lifters for reassembly reference. Remove adjusting shims and
valve lifters from cylinder head (if necessary).
Inspection
1. Inspect components for damage. Check camshaft journal diameter, lobe height and journal runout.
Replace camshaft if not within specification. See CAMSHAFT
table under ENGINE
SPECIFICATIONS. Install camshaft in cylinder head.
2. Using Plastigage, check camshaft oil clearance with camshaft bearing cap bolts tightened to specification
in sequence. See Fig. 22
and Fig. 23 . See TORQUE SPECIFICATIONS.

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3. Check camshaft end play with camshaft bearing cap bolts tightened to specification. Replace camshaft
and/or cylinder head if camshaft end play is not within specification. See CAMSHAFT
table under
ENGINE SPECIFICATIONS.
4. Install both camshafts in cylinder head without sub-gear installed on exhaust camshaft. Install and tighten
camshaft bearing cap bolts to specification in sequence. See Fig. 22
and Fig. 23 . See TORQUE
SPECIFICATIONS .
5. Using dial indicator, check gear backlash between gears on camshafts. Replace camshafts if gear backlash
exceeds specification. See CAMSHAFT
table under ENGINE SPECIFICATIONS.
6. Measure length of camshaft gear spring. Replace camshaft gear spring if distance is not within
specification. See CAMSHAFT
table under ENGINE SPECIFICATIONS. Measure valve lifter diameter
and bore diameter. Ensure oil clearance is within specification. Replace components if not within
specification. See VALVE LIFTERS
table under ENGINE SPECIFICATIONS.
Installation
1. If installing sub-gear on exhaust camshaft, install camshaft gear spring, sub-gear, wave washer and snap
ring on exhaust camshaft. Ensure pins on main gear and sub-gear engage with ends of camshaft gear
spring.
2. Install service bolt "A" on sub-gear. See Fig. 24
. Using screwdriver, rotate sub-gear clockwise and align
hole in sub-gear with hole on main gear. Install service bolt "B". Remove service bolt "A".
3. Install adjusting shims and valve lifters in original location on cylinder head (if removed). Ensure valve
lifters rotate smoothly in cylinder head.
4. Coat thrust surfaces of camshafts with multipurpose grease. To install intake camshaft, rotate intake
camshaft so knock pin is at 80-115 degrees from vertical position, and install into cylinder head. See Fig.
19 .
5. Coat seal lip of NEW oil seal for intake camshaft with grease. Install oil seal onto front of intake camshaft
until oil seal is fully seated in cylinder head. Apply sealant to front camshaft bearing cap for intake
camshaft. See Fig. 25
.

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1999-2000 ENGINES 2.0L 4-Cylinder
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Fig. 25: Applying Sealant To Front Camshaft Bearing Cap
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
6. Install front camshaft bearing cap for intake camshaft onto cylinder head. Install remaining camshaft
bearing caps for intake camshaft onto cylinder head in numerical sequence with arrow pointing toward
timing belt end of engine. See Fig. 21
.
7. Coat threads and bolt head-to-camshaft bearing cap contact surfaces of camshaft bearing cap bolts with
engine oil. Install and tighten camshaft bearing cap bolts to specification in sequence using several steps.
See Fig. 23
. See TORQUE SPECIFICATIONS .
8. To install exhaust camshaft, rotate intake camshaft so knock pin is 10-45 degrees from vertical position.
See Fig. 19
. Install exhaust camshaft so timing mark aligns with timing mark on intake camshaft. DO
NOT use assembly reference marks. See Fig. 26
. Ensure exhaust camshaft is fully seated in cylinder
head.
NOTE: It may be necessary to slightly rotate intake camshaft so exhaust camshaft
fully seats in cylinder head.

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Fig. 26: Aligning Camshaft Timing Marks
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
9. Install camshaft bearing caps for exhaust camshaft on cylinder head in numerical sequence with arrow
pointing toward timing belt end of engine. See Fig. 21
.
10. Coat threads and bolt head-to-camshaft bearing cap contact surfaces of camshaft bearing cap bolts with
engine oil. Install and tighten camshaft bearing cap bolts to specification in sequence using several steps.
See Fig. 22
. See TORQUE SPECIFICATIONS .
11. Remove service bolt "B" from camshaft gear. See Fig. 24
. Install No. 3 timing belt cover. Install and
tighten bolts to specification. See TORQUE SPECIFICATIONS
. Install timing belt using proper
procedure. See TIMING BELT
.
12. Check valve clearance. See VALVE CLEARANCE ADJUSTMENT
under ADJUSTMENTS. Apply
sealant in grooves on rear side of semi-circular plugs located on exhaust camshaft side of cylinder head.
Install semi-circular plugs in cylinder head.
13. Before installing gasket and valve cover, apply sealant at front and rear valve cover areas on cylinder
head. See Fig. 6
.
14. Using NEW gasket, install valve cover. Install grommets in original location with marking on grommet
aligned in designated area. See Fig. 7
. Install and tighten valve cover nuts to specification. See
TORQUE SPECIFICATIONS
.
15. If installing distributor, install NEW "O" ring on distributor. Coat "O" ring with engine oil.
16. Rotate crankshaft clockwise, as viewed from timing belt end of engine, so cylinder No. 1 is at TDC on
compression stroke and timing mark on crankshaft pulley aligns with "0" mark on timing belt cover.
C
ylinder No. 1 is front cylinder at timing belt end of engine.

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1999-2000 ENGINES 2.0L 4-Cylinder
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17. Ensure slot area on intake camshaft is vertically positioned. Rotate coupling on distributor so cutout
aligns with alignment mark on distributor housing.
18. Install distributor so center of flange on distributor is aligned with bolt hole on cylinder head. Install
distributor hold-down bolt(s). Adjust ignition timing.
CRANKSHAFT REAR OIL SEAL
Removal
Remove transaxle, clutch assembly (if equipped) and flywheel/drive plate. Using a knife, cut seal lip from oil
seal. Pry oil seal from rear seal housing. DO NOT damage sealing surfaces.
Installation
1. Ensure all sealing surfaces are clean. Apply grease to seal lip of new oil seal. Using Oil Seal Installer
(SST 09223-15030), install oil seal into rear seal housing until oil seal is even with surface of rear seal
housing.
2. Apply Loctite to flywheel/drive plate bolts. Install flywheel/drive plate. Install bolts and tighten to
specification using a crisscross pattern. See TORQUE SPECIFICATIONS
. To install remaining
components, reverse removal procedure.
WATER PUMP
Removal
1. Disconnect negative battery cable. Drain cooling system. Remove timing belt and idler pulley(s) as
needed for access to water pump. See TIMING BELT
.
2. Disconnect lower radiator hose from thermostat housing. Remove generator adjusting bracket. Remove
coolant b
y-pass pipe-to-water pump nuts. See Fig. 27. NOTE: On 4WD models, manufacturer recommends removing engine with transaxle for
transaxle removal. On 2WD models, transaxle may be removed with engine in
vehicle.

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
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