wheel bolts TOYOTA RAV4 1996 Service Owner's Guide

TORQUE SPECIFICATIONS (4RUNNER)
TORQUE SPECIFICATIONS (SIENNA)
Wheel Lug Nuts83 (113)
INCH Lbs. (N.m)
Brake Bleeder Screw97 (11)
Master Cylinder Mounting Nuts115 (13)
Master Cylinder Piston Stopper Bolt89 (10)
Master Cylinder Reservoir16 (1.8)
Parking Brake Bellcrank Bracket115 (13)
Rear Wheel Cylinder Mounting Bolts89 (10)
(1)Tighten to 115 INCH lbs. (13 N.m).
ApplicationFt. Lbs. (N.m)
Brake Line Fittings11 (15)
Caliper Mounting Bolts/Slide Pins90 (122)
LSPV Mounting Bolts22 (30)
Power Brake Unit Rod Nut19 (25)
Rear Axle Retainer & Backing Plate Nuts48 (66)
Wheel Lug Nuts83 (112)
INCH Lbs. (N.m)
Brake Bleeder Screws97 (11)
LSPV Adjusting Nuts115 (13)
Master Cylinder Mounting Nuts115 (13)
Master Cylinder Piston Stopper Bolt89 (10)
Power Brake Unit Mounting Nuts124 (14)
Rear Wheel Backing Plate Bolts115 (13)
Rear Wheel Cylinder Mounting Nuts89 (10)
ApplicationFt. Lbs. (N.m)
Brakeline Fittings11 (15)
Brake Pedal Bracket Bolts14 (19)
Brake Pedal Swivel Bolt/Nut26 (35)
Caliper Mounting Bolts25 (34)
Caliper-To-Knuckle Bolts79 (107)
Parking Brake Assembly Mounting Bolt/Nuts45 (61)
Power Brake Unit Push Rod Nut19 (25)
Rear Wheel Hub Nuts59 (80)
Wheel Cylinder Mounting Nuts11 (150
Wheel Lug Nuts77 (104)
INCH Lbs. (N.m)

1999 Toyota RAV4
1999-2000 BRAKES Disc & Drum - Trucks & Vans
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Sunday, November 22, 2009 10:07:29 AMPage 41 © 2005 Mitchell Repair Information Company, LLC.

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.
9. Raise and support vehicle. Remove lower engine covers. On M/T models, remove clutch release cylinder
with hose attached, and secure aside. Disconnect transaxle control cables from transaxle. Remove starter
and transaxle ground cable. On A/T, and 4WD vehicles with M/T, disconnect transaxle oil cooler hoses.
10. On A/T models, disconnect transaxle control cable from front suspension crossmember and engine mount
center member. Disconnect connectors, plug wires, strap and hoses from top of engine. On 4WD M/T,
disconnect ground strap from engine cowl. Disconnect differential lock control solenoid connector.
11. Using 14-mm deep socket wrench, remove 2 bolts holding front exhaust pipe to front TWC. Remove 2
bolts and 2 nuts holding front exhaust pipe to TWC. Remove front exhaust pipe and 2 gaskets.
12. Disconnect A/C compressor connector. Remove 2 bolts, nut and stud bolt. Disconnect A/C compressor
from engine, and secure aside. On 4WD vehicles, remove rear drive shaft. On all models, remove front
drive shaft.
13. Remove front wheel and engine undercover. On M/T vehicles drain gear oil. On A/T models, drain
transmission fluid. On vehicles with ABS, remove bolt and ABS speed sensor. Remove cotter pin, lock
cap and lock nut.
14. Disconnect tie rod from steering knuckle. Disconnect stabilizer bar link from lower control arm.
Disconnect lower ball joint from lower control arm.
15. Using soft-face hammer, tap axle shaft from hub assembly. Pull steering knuckle outward and separate
axle shaft from hub assembly.
16. On 2WD A/T models, remove axle shaft bearing bracket bolts for right (passenger-side) axle shaft. See
Fig. 10
. Remove right axle shaft assembly from transaxle and axle shaft bearing bracket.

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:22:26 AMPage 12 © 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
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Sunday, November 22, 2009 10:22:26 AMPage 23 © 2005 Mitchell Repair Information Company, LLC.

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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Sunday, November 22, 2009 10:22:26 AMPage 39 © 2005 Mitchell Repair Information Company, LLC.

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)

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:22:27 AMPage 50 © 2005 Mitchell Repair Information Company, LLC.

SPECIFICATIONS.
6. Main bearing size mark ("1", "2", "3", "4" or "5") is located on side of main bearing. See Fig. 37
. If
replacing main bearing, ensure size mark on replacement main bearing is same as size mark on original
main bearing.
7. If main bearing size mark cannot be obtained, add size marks on cylinder block and crankshaft to
determine size mark of main bearing to be used. For example, if size mark on cylinder block is "2" and
size mark on crankshaft is "1", use main bearing with size mark "3".
8. Main bearing thickness is determined by size mark. See MAIN BEARING SPECIFICATIONS
table.
Install main bearings, thrust bearings, crankshaft and main bearing caps.
9. Ensure main bearing caps are properly installed in numerical sequence with No. 1 at timing belt end, and
No. 5 at flywheel/drive plate end of engine. Ensure arrow on top of main bearing cap points toward
timing belt end of engine.
10. Coat threads and bolt-to-main bearing cap contact surfaces on main bearing cap bolts with engine oil.
Install and tighten main bearing cap bolts to specification in sequence. See Fig. 36
. See TORQUE
SPECIFICATIONS .
11. Ensure crankshaft main bearing oil clearance and crankshaft end play are within specification. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
table under ENGINE
SPECIFICATIONS. Replace thrust bearing if end play is not within specification.
MAIN BEARING SPECIFICATIONS NOTE: Different width main bearings are used. Install wide main bearing on No. 3
journal and narrow main bearings on all other journals.
Bearing Size MarkBearing Thickness - In. (mm)
No. 3 Main Bearing
"1".07842-.07854 (1.9920-1.9950)
"2".07854-.07866 (1.9950-1.9980)
"3".07866-.07877 (1.9980-2.0010)
"4".07877-.07889 (2.0010-2.0040)
"5".07889-.07901 (2.0040-2.0070)
All Others
"1".07862-.07874 (1.9970-2.0000)
"2".07874-.07885 (2.0000-2.0030)
"3".07885-.07897 (2.0030-2.0060)
"4".07897-.07909 (2.0060-2.0090)
"5".07909-.07921 (2.0090-2.0120)

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:22:27 AMPage 51 © 2005 Mitchell Repair Information Company, LLC.

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGStable under ENGINE SPECIFICATIONS.
Cylinder Block
1. Inspect cylinder block deck surface warpage. Replace cylinder block if deck warpage exceeds
specification. See CYLINDER BLOCK
table under ENGINE SPECIFICATIONS.
2. Different cylinder bore diameters are used. Cylinder bore diameter may be identified by size mark ("1",
"2" or "3") on cylinder block deck surface. See Fig. 37
.
3. Measure cylinder bore diameter at 2 different places, 90 degrees apart at .39" (10.0 mm) from top and
bottom of cylinder bore and at center of cylinder bore. Ensure cylinder bore diameter is within
specification. See CYLINDER BLOCK
table under ENGINE SPECIFICATIONS.
4. Bore cylinder block for oversize pistons if cylinder bore diameter is not within specification. Pistons are
available in .020" (.50 mm) oversize.
5. Install main bearing caps in numerical sequence with No. 1 at timing belt end, and No. 5 at flywheel/drive
plate end of engine. Ensure arrow on top of main bearing cap points toward timing belt end of engine.
6. Install and tighten main bearing cap bolts to specification in sequence. See Fig. 36
. See TORQUE
SPECIFICATIONS .
7. Ensure main bearing bore inside diameter is within specification. See CYLINDER BLOCK
table under
ENGINE SPECIFICATIONS.
ENGINE OILING
ENGINE LUBRICATION SYSTEM
Crankshaft driven oil pump provides pressurized engine lubrication. Oil cooler is installed between oil filter and
cylinder block.
Crankcase Capacity
Drain and refill capacity with oil filter is approximately 4.3 qts. (4.1L). Dry fill capacity is approximately 4.8
qts. (4.6L).
Oil Pressure
With engine at normal operating temperature, oil pressure should be at least 4.3 psi (0.3 kg/cm2 ) at idle and 36-
71 psi (2.5-5.0 kg/cm
2 ) at 3000 RPM.
OIL PUMP
Removal & Disassembly
1. Remove timing belt, No. 2 idler pulley, crankshaft sprocket and oil pump sprocket. See TIMING BELT
NOTE: Main bearing bore inside diameter is identified by main bearing bore size mark
("1", "2" or "3") stamped on cylinder block. See Fig. 37
.

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:22:27 AMPage 54 © 2005 Mitchell Repair Information Company, LLC.

ENGINE SPECIFICATIONS
Power Steering Pump Mounting Bracket-To-Cylinder Block Bolt32 (43)
Spark Plug13 (18)
Spark Plug Tube39 (53)
Stabilizer Bar Link-To-Lower Control Arm Nut
2-Door Vehicles33 (45)
4-Door Vehicles54 (73)
Stabilizer Bar-To-Frame Mount Bolt22 (30)
Starter Bolt29 (39)
Steering Gear Assembly-To-Front Suspension Crossmember Bolt/Nut 83 (113)
Stiffener Plate Bolt27 (37)
Throttle Body Bolt/Nut14 (19)
Tie Rod Nut41 (56)
Valve Cover Nut33 (45)
Wheel Lug Nut76 (103)
INCH Lbs. (N.m)
ABS Speed Sensor Bolt71 (8.0)
Clutch Release Cylinder Bolt106 (12.0)
Coolant By-Pass Pipe-To-Water Pump Nut82 (9.3)
Crankshaft Position Sensor Bolt71 (8.0)
Fuel Delivery Pipe-To-Cylinder Head Bolt115 (13.0)
No. 3 Timing Belt Cover Bolt69 (7.8)
Oil Baffle Plate-To-Cylinder Block Bolt/Nut48 (5.4)
Oil Cooler-To-Cylinder Block Nut78 (8.8)
Oil Pan Bolt/Nut48 (5.4)
Oil Pump Body Cover Bolt78 (8.8)
Oil Pump Pick-Up Tube Bolt/Nut48 (5.4)
Oil Pump-To-Cylinder Block Bolt78 (8.8)
Rear Plate-To-Cylinder Block Bolt82 (9.3)
Rear Seal Housing Bolt115 (13.0)
Thermostat Housing Nut78 (8.8)
Water Pump-To-Cylinder Block Bolt (5) 78 (8.8)
Water Pump-To-Water Pump Cover Bolt78 (8.8)
(1)Tighten bolts to specification in sequence. See Fig. 22 and Fig. 23 .
(2)Tighten bolts to specification in sequence. See Fig. 15 .
(3)Tighten nut to 115 INCH lbs. (13.0 N.m).
(4)Tighten bolts to specification in sequence. See Fig. 36 .
(5)Tighten bolts to specification in sequence. See Fig. 28 .

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:22:27 AMPage 59 © 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.

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. On all models, 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. 17
. Install crankshaft pulley on crankshaft. Temporarily install
crankshaft pulley bolt.
8. Rotate crankshaft clockwise, 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.
Cylinder No. 1 is front cylinder at timing belt end of engine.
9. Ensure hole in camshaft sprocket aligns with alignment mark on camshaft bearing cap. See Fig. 18
. If
hole in camshaft sprocket is not aligned with alignment mark, rotate crankshaft clockwise one full
revolution.

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