engine TOYOTA RAV4 1996 Service Repair Manual

Fig. 4: Applying Sealant On Cylinder Head
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 10:23:30 AMPage 5 © 2005 Mitchell Repair Information Company, LLC.

Fig. 5: Aligning Valve Cover Grommets
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 10:23:30 AMPage 6 © 2005 Mitchell Repair Information Company, LLC.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:30 AMPage 7 © 2005 Mitchell Repair Information Company, LLC.

Fig. 6: Intake Valve Adjusting Shim Selection Chart
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 10:23:30 AMPage 8 © 2005 Mitchell Repair Information Company, LLC.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:30 AMPage 9 © 2005 Mitchell Repair Information Company, LLC.

Fig. 7: Exhaust Valve Adjusting Shim Selection Chart
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
REMOVAL & INSTALLATION
FUEL PRESSURE RELEASE
1. Remove driver-side rear seat and floor panel cover for access to electrical connector for electric fuel
pump.
2. Disconnect electrical connector for electric fuel pump. Start engine and allow engine to idle until engine
stalls. Turn ignition off.
3. Reconnect electrical connector for electric fuel pump. 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 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
.
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 necessar
y electrical connectors, coolant hoses, vacuum hoses and fuel lines for engine CAUTION: To prevent air bag deployment, disconnect negative battery cable and wait
at least 90 seconds before working on vehicle.
CAUTION: When battery is disconnected, vehicle computer and memory systems
may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle.
NOTE: For reassembly reference, label all electrical connectors, vacuum hoses and
fuel lines before removal. Also place mating marks on engine hood and other
major assemblies before removal.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:30 AMPage 10 © 2005 Mitchell Repair Information Company, LLC.

removal. Remove A/C compressor with hoses attached, and secure aside.
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
.
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.
Fig. 8: Identifying Relay Box, Electrical Connector & Engine Wiring Harness

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 10:23:30 AMPage 11 © 2005 Mitchell Repair Information Company, LLC.

Fig. 9: Identifying ECM & Electrical Connectors
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
9. Raise and support vehicle. Remove lower engine covers. On M/T models, remove clutch release cylinder
with hose attached, and secure aside. Remove starter. On 4WD models with M/T, disconnect oil cooler
lines at transaxle.
10. On A/T models, disconnect oil cooler lines at transaxle. Disconnect shift cable bracket from engine
mount crossmember.
11. On all models, disconnect control cables, oil cooler hoses and electrical connectors at transaxle. Remove
front exhaust pipe from between front catalytic converter on exhaust manifold and rear exhaust pipe.
12. On 4WD models, place reference marks on drive shaft flanges for reassembly reference. Remove drive
shaft flange bolts/nuts at rear axle. Remove drive shaft center support bearing bolts. Pull drive shaft from
transaxle. Remove drive shaft.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:31 AMPage 12 © 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.

Fig. 11: Removing Right (Passenger-Side) Axle Shaft (2WD M/T Models)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 12: Removing Left (Driver
-Side) Axle Shaft (2WD Models) Or Right (Passenger-Side) Axle
Shaft (4WD Models)

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:31 AMPage 14 © 2005 Mitchell Repair Information Company, LLC.