Engine TOYOTA RAV4 1996 Service Repair Manual

covered.
EMISSION SYSTEM PERFORMANCE WARRANTY (CALIFORNIA)
For a period of 3 years or 50,000 miles, manufacturer will make all necessary repairs and adjustments to ensure
vehicle passes a required Smog Check inspection.
EMISSION SYSTEM DEFECT WARRANTY (CALIFORNIA)
Warrants vehicle to be free of defects in materials or workmanship that may cause it to fail to conform with
applicable California emission regulations for a period of 5 years or 50,000 miles, whichever occurs first.
Certain emission-related parts are covered for repair or replacement for 7 years or 70,000 miles, whichever
occurs first. See copy of warranty for specific components covered.
FUSES & CIRCUIT BREAKERS
Fuse box is located below instrument panel to left of steering column on all vehicles. An additional fuse and
relay box located in the engine compartment.

1999 Toyota RAV4
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Fig. 6: Engine Compartment Fuse Box Identification (USA) - 1997
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
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Fig. 7: Engine Compartment Fuse Box Identification (Canada) - 1997
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
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Fig. 8: Engine Compartment Fuse Box Identification - 1997
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
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Fig. 12: Engine Compartment Fuse Box Identification (USA) - 1998
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
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Fig. 13: Engine Compartment Fuse Box Identification (Canada) - 1998
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
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Fig. 14: Engine Compartment Fuse Box Identification - 1998
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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1999 MANUAL TRANSMISSIONS
Toyota E250 & E250F 5-Speed Overhaul
APPLICATION
TRANSAXLE APPLICATIONS
IDENTIFICATION
Transmission type is identified by ID label located on driver-side door post.
DESCRIPTION
Transaxle design incorporates transmission, center differential, front differential and transfer case (4WD
models). Transmission is shifted by a pair of push-pull cables. These cables provide positive shift feel and
absorb transmission and engine vibrations. The E250F utilizes a full-time transfer case with a limited slip
viscous coupling. Both the E250 and E250F have a center differential, which compensates for difference
between the rotational speed of the front and rear wheels.
ADJUSTMENTS
LUBRICATION
Remove filler plug from side of transmission. Fluid should be level with bottom of filler opening. If fluid is low,
fill until level is correct. Use SAE 75W/90 API GL-4 or GL-5 gear oil for 2WD models, or SAE 75W/90 API
GL-5 gear oil for 4WD models. Capacity is 4.1 qts. (3.9L) for 2WD models, or 5.3 qts. (5.0L) for 4WD models.
ON-VEHICLE SERVICE
AXLE SHAFTS
See appropriate AXLE SHAFTS article in AXLE SHAFTS & TRANSFER CASES.
TROUBLE SHOOTING
See GENERAL TROUBLE SHOOTING article.
Vehicle ApplicationTransaxle Model
RAV4
2WDE250
4WDE250F
NOTE: No adjustments are necessary.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
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1999 ENGINE PERFORMANCE
On-Vehicle Adjustments - 4-Cylinder
ENGINE MECHANICAL
Before performing any on-vehicle adjustments to fuel or ignition systems, ensure engine mechanical condition
is okay.
VALVE CLEARANCE
Camry, Camry Solara, Celica & RAV4
1. Disconnect spark plug wires from spark plugs and valve cover. Disconnect necessary hoses, control
cables and engine wiring clamps for removal of valve cover.
2. Disconnect engine wiring protector from rear of upper timing belt cover for access to valve cover if
necessary. Engine wiring protector is attached to bolts for upper timing belt cover. Remove engine wiring
protector from upper timing belt cover bolt on intake side of engine first, and then from upper timing belt
cover bolt on exhaust side of engine.
3. Note location of grommets between valve cover nuts and valve cover for installation reference. Grommets
should be installed in original location to prevent oil leakage. Remove valve cover nuts, grommets, valve
cover and gasket.
4. Rotate crankshaft clockwise (viewed from timing belt end of engine) until timing mark (groove) on
crankshaft pulley aligns with "0" mark on timing belt cover and cylinder No. 1 is at TDC on compression
stroke. Cylinder No. 1 is front cylinder at timing belt end of engine.
5. Ensure valve lifters on cylinder No. 1 are loose and valve lifters on cylinder No. 4 are tight. If valve
lifters are not as specified, rotate crankshaft clockwise one full revolution (360 degrees) and realign
crankshaft pulley timing mark (groove) with "0" mark on timing belt cover.
6. With cylinder No. 1 at TDC on compression stroke, use feeler gauge to check valve clearance between
valve lifter and camshaft on specified valves. Perform STEP 1. See Fig. 1
. Record valve clearance.
7. To check remaining valves, rotate crankshaft clockwise one full revolution (360 degrees) and realign
crankshaft pulley timing mark (groove) with "0" mark on timing belt cover. Using feeler gauge, measure
valve clearance on specified valves. Perform STEP 2. See Fig. 1
. Record valve clearance.
8. Ensure valve clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS
(CAMRY, CAMRY SOLARA, CELICA & RAV4)table. NOTE: Check and adjust valve clearance with engine cold.

1999 Toyota RAV4
1999 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

1999 Toyota RAV4
1999 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder
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Fig. 1: Identifying Cylinder Numbers & Checking Valve Clearance (Camry, Camry Solara, Celica
& RAV4)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
VALVE CLEARANCE SPECIFICATIONS (CAMRY, CAMRY SOLARA, CELICA & RAV4)
9. If valve clearance requires adjustment, rotate crankshaft so camshaft lobe on valve to be adjusted is facing
upward, away from valve lifter. Rotate valve lifter so notch on valve lifter is toward spark plug.
10. Valve Clearance Ad
juster (SST 09248-55040) is used to remove adjusting shim. Using SST "A" of valve
Application(1) In. (mm)
Intake.007-.011 (.19-.29)
Exhaust.011-.015 (.29-.38)
(1)Adjust valve clearance with engine cold.

1999 Toyota RAV4
1999 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder
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