Generator TOYOTA RAV4 1996 Service Owner's Guide

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Generators & Regulators
Microsoft
Sunday, November 22, 2009 10:13:08 AMPage 31 © 2005 Mitchell Repair Information Company, LLC.

Fig. 15: Charging System Wiring Diagram (Tacoma)

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Generators & Regulators
Microsoft
Sunday, November 22, 2009 10:13:08 AMPage 32 © 2005 Mitchell Repair Information Company, LLC.

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Generators & Regulators
Microsoft
Sunday, November 22, 2009 10:13:08 AMPage 33 © 2005 Mitchell Repair Information Company, LLC.

Fig. 16: Charging System Wiring Diagram (2000 Tundra)

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Generators & Regulators
Microsoft
Sunday, November 22, 2009 10:13:08 AMPage 34 © 2005 Mitchell Repair Information Company, LLC.

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Generators & Regulators
Microsoft
Sunday, November 22, 2009 10:13:08 AMPage 35 © 2005 Mitchell Repair Information Company, LLC.

Fig. 17: Charging System Wiring Diagram (4Runner)

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Generators & Regulators
Microsoft
Sunday, November 22, 2009 10:13:08 AMPage 36 © 2005 Mitchell Repair Information Company, LLC.

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
Microsoft
Sunday, November 22, 2009 10:22:26 AMPage 11 © 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.

control cable to intake manifold. On all models, install NEW gasket and EGR valve with union nut and 2
nuts. Install vacuum modulator to clamp on intake manifold. Connect vacuum hoses to EGR VSV.
Connect fuel inlet hose to fuel filter
14. Connect vacuum sensor hose to gas filter, and brake booster vacuum hose to intake manifold. Install
throttle body. Install NEW "O" ring on coolant by-pass pipe, and NEW gasket on water pump cover
before installing coolant by-pass pipe. Apply soapy water solution to "O" ring before installing coolant
by-pass pipe. Install by-pass pipe.
15. Install NEW gasket and water outlet. Connect radiator, water by-pass and heater water hoses. Connect
ECT sensor and sender gauge connectors. Connect oil pressure switch.
16. Install ignition coils, manifold stay and spark plug wires. Connect wire clamp to manifold stay. Connect
spark plug wires to spark plugs and clamps on cylinder head cover. Connect ignition coil connectors.
17. Install 2 heat insulators. Install lower heat insulator. On California models, install A/F sensor to exhaust
manifold. All others, install oxygen sensor (bank 1 sensor 1) to exhaust manifold.
18. Using a new gasket, install exhaust manifold and heat insulator assembly. Install right-side exhaust
manifolds stay (California). Install left-side exhaust manifold stay. Install upper manifold heat insulator.
Connect A/F sensor connectors (California), or Oxygen sensor (bank 1 sensor 1).
19. Use NEW gasket and NEW nuts when installing front exhaust pipe. Ensure all bolts/nuts are loosely
installed on front exhaust pipe before tightening to specification. See TORQUE SPECIFICATIONS

20. Install generator and air cleaner and cap. Connect accelerator cable to throttle body and cable bracket. On
A/T models, connect throttle cable to throttle body and cable bracket. On all models, start engine and
check for leaks. Recheck engine coolant and oil level. Install right-side engine undercover.
CRANKSHAFT FRONT SEAL
Removal & Installation (Oil Pump Installed)
1. Remove timing belt and crankshaft sprocket. See TIMING BELT . Using a knife, cut lip from seal. Pry
seal from oil pump housing. DO NOT damage sealing surfaces.
2. To install, apply grease to lip of new seal. Using hammer and Seal Installer (SST 09226-10010), install
seal until seal surface is even with oil pump housing. To install remaining components, reverse removal
procedure.
Removal & Installation (Oil Pump Removed)
Using hammer and drift, remove seal from oil pump housing. To install, use hammer and Seal Installer (SST
09226-10010). Install seal until seal surface is even with oil pump housing. Apply grease to lip of new seal.
TIMING BELT
CAUTION: If reusing timing belt, mark direction of timing belt rotation, and place
reference mark on timing belt at camshaft sprocket for reassembly
reference. Also, place reference mark on timing belt at upper edge of No. 1
timing belt cover. DO NOT bend, twist or turn timing belt inside-out. DO
NOT expose timing to oil, water or steam.

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

Removal
1. Disconnect negative battery cable. Remove power steering fluid reservoir with mounting bracket.
Remove accessory drive belts. Remove generator and generator mounting bracket. Remove wiring
brackets for access to timing belt covers.
2. On models with Anti-Lock Brake System (ABS), disconnect electrical connectors and brake lines from
ABS actuator. ABS actuator is located in front of passenger-side strut tower. Remove ABS actuator
mounting bracket-to-body bolts/nuts. Remove ABS actuator with mounting bracket.
3. Raise and support vehicle. Remove passenger-side lower engine cover. Remove passenger-side front
wheel.
4. Using floor jack, slightly raise engine to remove weight from right (timing belt side) engine mount at
timing belt cover. Remove right (timing belt side) engine mount from body and mounting bracket on
cylinder block for access to timing belt covers.
5. Remove spark plugs. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. Remove
right (timing belt side) engine mounting bracket from front of cylinder block.
6. Disconnect engine wiring harness protector from rear of No. 2 timing belt cover. When disconnecting
engine wiring harness protector, remove bolt on intake manifold side of engine first and then bolt on
exhaust manifold side of engine.
7. Remove No. 2 timing belt cover. See Fig. 16
. Install crankshaft pulley on crankshaft. Temporarily install
crankshaft pulley bolt.

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:22:26 AMPage 23 © 2005 Mitchell Repair Information Company, LLC.