timing belt TOYOTA RAV4 1996 Service User Guide

7. Ensure all sprockets and idler pulleys are clean. Install timing belt on crankshaft sprocket, oil pump
sprocket, water pump sprocket, No. 1 idler pulley and then No. 2 idler pulley.
8. Install timing belt guide with cupped side away from crankshaft sprocket and flat side toward timing belt.
Install No. 1 timing belt cover.
9. Remove crankshaft pulley bolt. Align crankshaft pulley key groove with key in crankshaft. Install
crankshaft pulley. Temporarily install and tighten crankshaft pulley bolt.
10. If using new timing belt, go to step 15 . If reusing timing belt, ensure reference mark placed on timing
belt aligns with upper edge of No. 1 timing belt cover when timing mark on crankshaft pulley aligns with
"0" mark on No. 1 timing belt cover. If reference mark is aligned, proceed to step 15 .
11. If reference mark is below surface of No. 1 timing belt cover, pull upward on water pump side of timing
belt while rotating crankshaft pulley counterclockwise. Align reference mark with surface of No. 1 timing
belt cover.
12. After aligning matchmark, hold timing belt and rotate crankshaft pulley clockwise so timing mark on
crankshaft pulley aligns with "0" mark on No. 1 timing belt cover.
13. If reference mark is above surface of No. 1 timing belt cover, pull upward on No. 1 idler pulley side of
timing belt while rotating crankshaft pulley clockwise. Align reference mark with surface of No. 1 timing
belt cover.
14. After aligning matchmark, hold timing belt and rotate crankshaft pulley counterclockwise so timing mark
on crankshaft pulley aligns with "0" mark on No. 1 timing belt cover.
15. Install timing belt on camshaft sprocket. If reusing timing belt, ensure reference mark on timing belt
aligns with reference mark placed on camshaft sprocket. Ensure tension exists on timing belt between
crankshaft and camshaft sprockets.
16. Loosen No. 1 idler pulley bolt 1/2 turn. Rotate crankshaft pulley 2 full revolutions clockwise from TDC
to TDC. DO NOT rotate crankshaft counterclockwise.
17. Ensure timing mark on crankshaft pulley aligns with "0" mark on No. 1 timing belt cover, and hole in
camshaft sprocket aligns with alignment mark on camshaft bearing cap. See Fig. 17
. If timing marks are
not aligned, remove timing belt and reinstall.
18. Rotate crankshaft clockwise 1 7/8 revolutions and align crankshaft pulley "0" mark with 45-degree
Before Top Dead Center (BTDC) mark on No. 1 timin
g belt cover. See Fig. 18 . installed in original direction of rotation.

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1999-2000 ENGINES 2.0L 4-Cylinder
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Fig. 18: Aligning Crankshaft Pulley With 45-Degree BTDC Mark
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
19. Tighten No. 1 idler pulley bolt to specification. See TORQUE SPECIFICATIONS
. Install right (timing
belt side) engine mounting bracket on front of cylinder block with bolts loosely installed. DO NOT
tighten bolts at this time.
20. Install No. 2 timing belt cover. Install engine wire harness and engine wire harness protector on rear of
No. 2 timing belt cover. When installing engine wire harness protector, install bolt on exhaust manifold
side of engine first, and then bolt on intake manifold side of engine.
21. Remove crankshaft pulley bolt and crankshaft pulley. Tighten right (timing belt side) engine mounting
bracket-to-cylinder block bolts to specification. See TORQUE SPECIFICATIONS
.
22. Reinstall crankshaft pulley. Install and tighten crankshaft pulley bolt to specification. See TORQUE
SPECIFICATIONS .
23. Install right (timing belt side) engine mount on body and mounting bracket on cylinder block. Tighten
right (timing belt side) engine mount-to-body bolts to specification. See TORQUE
SPECIFICATIONS .
24. Tighten right (timing belt side) mounting bracket-to-engine mount bolts/nuts to specification. See
TORQUE SPECIFICATIONS
. To install remaining components, reverse removal procedure. On
models with ABS, bleed brake system after install ABS actuator. See HYDRAULIC SYSTEM
BLEEDING in appropriate article in BRAKES.

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1999-2000 ENGINES 2.0L 4-Cylinder
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VALVE LIFTER
Removal
Remove camshaft. See CAMSHAFT . Note location of adjusting shims and valve lifters for reassembly
reference. Remove adjusting shims and valve lifters from cylinder head.
Inspection
Inspect components for damage. 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
To install, reverse removal procedure. Ensure components are installed in original location and valve lifters
rotate smoothly in cylinder head. If camshaft, adjusting shims or valve lifters are replaced, check valve
clearance. See VALVE CLEARANCE ADJUSTMENT
under ADJUSTMENTS.
CAMSHAFT
Removal (Exhaust Side)
1. Remove timing belt and camshaft sprocket. See TIMING BELT . Remove No. 3 timing belt cover. See
Fig. 14
.
2. Disconnect power steering fluid reservoir, PCV hoses, cable brackets and control cables for access to
valve cover. Disconnect spark plug wires from spark plugs. Remove nuts, grommets, valve cover and
gasket. Note location of grommets for reassembly reference, as grommets must be installed in original
location.
3. For servicing of exhaust camshaft, rotate intake camshaft so knock pin is 10-45 degrees from vertical
position. See Fig. 19
. This aids in exhaust camshaft removal by using camshaft lobes on cylinders No. 2
and 4 to push on valve lifters. CAUTION: Camshafts must be properly positioned to lift camshaft straight from
cylinder head to prevent damage to cylinder head and camshaft. DO
NOT pry or force camshafts from cylinder head or component
damage will result.

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1999-2000 ENGINES 2.0L 4-Cylinder
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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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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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1999-2000 ENGINES 2.0L 4-Cylinder
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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.

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1999-2000 ENGINES 2.0L 4-Cylinder
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Piston & Rod Assembly
1. Ensure connecting rod and connecting rod cap are marked with matching cylinder number for reassembly
reference. Piston, connecting rod and connecting rod must be installed with front mark toward timing belt
end of engine. See Fig. 31
.
2. Before disassembling piston and connecting rod, try to move piston back and forth on piston pin. Replace
piston and piston pin as a set, if any movement is felt.
3. Remove 2 compression rings using a piston ring expander. Remove 2 oil rings and oil ring expander by
hand. Using Piston Pin Remover/Replacer (09221-25026), press piston pin from piston, and remove
connecting rod. See Fig. 32
.
4. Ensure piston pin diameter is within specification. See PISTONS, PINS & RINGS
table under ENGINE
SPECIFICATIONS. Ensure connecting rod bend, twist and piston pin bore diameter (connecting rod
small end) are within specification. See CONNECTING RODS
table under ENGINE
SPECIFICATIONS.
5. If piston pin bore diameter is not within specification, replace connecting rod assembly. See
CONNECTING RODS
table under ENGINE SPECIFICATIONS.
6. Using hand pressure, ensure nut rotates easily on connecting rod bolt. If nut fails to rotate easily, use
caliper to measure connecting rod bolt outside diameter .59" (15.0 mm) from end of bolt. Standard
connecting rod bolt outside diameter is .3094-.3150" (7.860-8.000 mm). Replace connecting rod bolt and
nut assembly if bolt outside diameter is less than .2992" (7.600 mm).
7. Pistons with different diameters are used. Piston diameter is identified by size mark ("1", "2" or "3")
stamped on top of piston. See Fig. 30
.
Fig. 30: Identifying Piston Size Marks

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
8. To determine piston diameter, measure piston skirt diameter .91-1.024" (23-26 mm) from top of piston, at
90-de
gree angle to piston pin. Ensure piston diameter is within size mark specification. See PISTONS,

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1999-2000 ENGINES 2.0L 4-Cylinder
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Fig. 34: Positioning Piston Rings
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Rod Bearings
1. Ensure connecting rod and connecting rod cap are marked with matching cylinder number for reassembly
reference. Ensure connecting rod is installed so front mark (protrusion) at center of connecting rod is
toward timing belt end of engine. Front mark (protrusion) on connecting rod cap must also face timing
belt end of engine. See Fig. 31
.
2. Connecting rod cap and rod bearing are stamped with size mark ("1", "2" or "3"). See Fig. 35
. Ensure
size marks on connecting rod cap and rod bearing are same.
3. Rod bearing thickness is determined by size mark. See ROD BEARING SPECIFICATIONS
table.
4. Ensure nut rotates easily on connecting rod bolt. If nut fails to rotate easily, use caliper to measure
connecting rod bolt outside diameter at .59" (15.0 mm) from end of bolt. Replace connecting rod bolt and
nut as an assembly if bolt outside diameter is less than .2992" (7.600 mm).
5. Install connecting rod cap with front mark (protrusion) toward timing belt end of engine. See Fig. 31
.
Coat threads of connecting rod bolts and nut-to-connecting rod cap surface with engine oil before
tightening nuts to specification. See TORQUE SPECIFICATIONS
.
6. Ensure bearing oil clearance and connecting rod side play are within specification. See CRANKSHAFT,
MAIN & CONNECTING ROD BEARINGS and CONNECTING RODS tables under ENGINE
SPECIFICATIONS.
NOTE: If replacing rod bearing, ensure size mark on replacement rod bearing is
same as size mark on original rod bearing.

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1999-2000 ENGINES 2.0L 4-Cylinder
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ROD BEARING SPECIFICATIONS
Fig. 35: Identifying Connecting Rod Cap & Rod Bearing Size Marks

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Crankshaft & Main Bearings
1. Main bearing caps are numbered on top of cap for location reference. No. 1 main bearing cap is at timing
belt end of engine and No. 5 is at flywheel/drive plate end of engine. Ensure arrow on top of main bearing
cap points toward timing belt end of engine.
2. Remove main bearing cap bolts in sequence. See Fig. 36
. Remove main bearing caps, crankshaft, thrust
bearings and main bearings.
3. Cylinder block main bearing bore inside diameter is identified by main bearing bore size mark ("1", "2"
or "3") stamped on cylinder block. See Fig. 37
. Front size mark indicates No. 1 main bearing bore and
rear size mark indicates No. 5 main bearing bore.
4. Crankshaft main bearing journal diameter is identified by main bearing journal size mark ("0", "1" or "2")
located on crankshaft counterweight. See Fig. 37
.
5. Ensure crankshaft runout, journal diameter, taper and out-of-round are within specification. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
table under ENGINE
Bearing Size MarkBearing Thickness - In. (mm)
"1".0584-.0586 (1.484-1.488)
"2".0586-.0587 (1.488-1.492)
"3".0587-.0589 (1.492-1.496)

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1999-2000 ENGINES 2.0L 4-Cylinder
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