wheel bolts TOYOTA RAV4 1996 Service Service Manual

17. Ensure slot area on intake camshaft is vertically positioned. Rotate coupling on distributor so cutout
aligns with alignment mark on distributor housing. See Fig. 16
.
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 in 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 by-pass pipe-to-water pump nuts. See Fig. 28
.
3. Remove water pump bolts in sequence. See Fig. 29
. Remove water pump, water pump cover and "O"
rings. See Fig. 28
. Remove water pump-to-water pump cover bolts. Remove water pump and gasket
from water pump cover. NOTE: On 4WD models, manufacturer recommends removing engine with transaxle for
transaxle removal. On 2WD models, transaxle may be removed with engine in
vehicle.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
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Sunday, November 22, 2009 10:23:31 AMPage 39 © 2005 Mitchell Repair Information Company, LLC.

ROD BEARING SPECIFICATIONS
Fig. 37: 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. Arrow on top of main bearing cap
must point toward timing belt end of engine.
2. Remove main bearing cap bolts in sequence. See Fig. 38
. 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. 39
. 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. 39
.
5. Ensure crankshaft runout, journal diameter, taper and out-of-round are within specification. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
under ENGINE SPECIFICATIONS.
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)

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
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6. Main bearing size mark ("1", "2", "3", "4" or "5") is located on side of main bearing. See Fig. 39 . 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
. 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. 38
. See TORQUE
SPECIFICATIONS .
11. Ensure crankshaft main bearing oil clearance and crankshaft end play are within specification. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
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)

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
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Sunday, November 22, 2009 10:23:31 AMPage 53 © 2005 Mitchell Repair Information Company, LLC.

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGSunder ENGINE SPECIFICATIONS.
Cylinder Block
1. Inspect cylinder block deck surface warpage. Replace cylinder block if deck warpage exceeds
specification. See CYLINDER BLOCK
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. 39
.
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
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. 38
. See TORQUE
SPECIFICATIONS .
7. Ensure main bearing bore inside diameter is within specification. See CYLINDER BLOCK
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
On 1997 models, drain and refill capacity with oil filter is approximately 4.1 qts. (3.9L). Dry fill capacity is
approximately 4.7 qts. (4.4L). On 1998 models, 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
NOTE: Main bearing bore inside diameter is identified by main bearing bore size mark
("1", "2" or "3") stamped on cylinder block. See Fig. 39
.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
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Oil Cooler Relief Valve58 (79)
Oil Pump Sprocket Nut18 (24)
Oxygen Sensor-To-Exhaust Manifold Nut15 (20)
Oxygen Sensor-To-Front Catalytic Converter33 (45)
Power Steering Pump Bolt32 (43)
Power Steering Pump Mounting Bracket-To-Cylinder Block Bolt32 (43)
Spark Plug13 (18)
Spark Plug Tube39 (49)
Stabilizer Bar Link-To-Lower Control Arm Nut
3-Door Vehicles47 (64)
5-Door Vehicles83 (113)
Stabilizer Bar-To-Frame Mount Bolt22 (29)
Starter Bolt29 (39)
Steering Gear Assembly-To-Front Suspension Crossmember Bolt/Nut83 (113)
Stiffener Plate Bolt27 (37)
Throttle Body Bolt/Nut14 (19)
Tie Rod Nut36 (49)
Valve Cover Nut33 (44)
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. 23 and Fig. 24 .
(2)Tighten bolts to specification in sequence. See Fig. 15 .

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
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Sunday, November 22, 2009 10:23:31 AMPage 62 © 2005 Mitchell Repair Information Company, LLC.

Fig. 2: Identifying Hub Components (Corolla Shown; Celica & RAV4 Similar)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
REMOVAL & INSTALLATION
FRONT AXLE HUB & WHEEL BEARING
Removal (Avalon, Camry, Camry Solara & Sienna)
1. Remove front wheel. Check wheel bearing backlash and deviation (rotational free play). See WHEEL
BEARING CHECKING under ADJUSTMENTS & INSPECTION.
2. Remove cotter pin and lock nut cap. Hold drive shaft from turning by applying brakes and remove drive
shaft lock nut. Remove brake caliper and disc and support calliper out of way.
3. Remove ABS speed sensor and wire harness clamp. Loosen 2 nuts on lower end of shock absorber (DO
NOT remove nuts).
4. Remove cotter pin and nut from tie rod end. Use tie rod separator to disconnect tie rod end from steering
knuckle. Remove 2 nuts and 1 bolt and disconnect lower ball joint from lower control arm. See Fig. 1
and
Fig. 3
.
5. Remove 2 nuts and bolts from lower end of shock absorber. Remove steering knuckle and axle hub from
vehicle.
6. Carefully pry off dust deflector. Mount assembly in vise and use separator tool to remove lower ball joint
from hub assembly. Use a slide hammer and attaching plate to remove axle hub.
7. Place axle hub on press and use appropriate support plates to press inner bearin
g race from axle hub.

1999 Toyota RAV4
1999-2000 SUSPENSION Front - Avalon, Camry, Camry Solara, Celica, Corolla, Echo, RAV4 & Sienna
Microsoft
Sunday, November 22, 2009 10:36:34 AMPage 3 © 2005 Mitchell Repair Information Company, LLC.

Remove 4 Torx bolts and remove dust cover.
8. Remove wheel bearing snap ring. Place inner race against outside of bearing and press wheel bearing
from axle hub. See Fig. 1
.
Installation
To install, reverse removal procedure. Use NEW snap ring after pressing in NEW wheel bearing. Use NEW
cotter pins. Tighten bolts to specifications. See TORQUE SPECIFICATIONS
.
Fig. 3: Exploded View Of Front Suspension Components (Avalon, Camry, Camry Solara & Sienna)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999-2000 SUSPENSION Front - Avalon, Camry, Camry Solara, Celica, Corolla, Echo, RAV4 & Sienna
Microsoft
Sunday, November 22, 2009 10:36:34 AMPage 4 © 2005 Mitchell Repair Information Company, LLC.

Removal (Celica, Corolla & RAV4)
1. Remove front wheel. On Celica, remove ABS speed sensor. Check wheel bearing backlash and deviation
(rotational free play). See WHEEL BEARING CHECKING
under ADJUSTMENTS & INSPECTION.
2. Remove cotter pin and lock nut cap. Hold drive shaft from turning by applying brakes and remove drive
shaft lock nut. Remove brake caliper and disc and support caliper out of way.
3. On Corolla and RAV4 with ABS, remove ABS speed sensor and wire harness clamp. On Corolla, remove
brake hose from shock absorber clamp. Loosen 2 nuts on lower end of shock absorber (DO NOT
remove).
4. On all models, remove cotter pin and nut from tie rod end. Use separator tool to disconnect tie rod end
from steering knuckle. On Celica, disconnect stabilizer bar link from lower control arm.
5. On all models, remove 2 nuts and 1 bolt and disconnect lower ball joint from lower control arm. Remove
2 nuts and bolts from lower end of shock absorber. Remove steering knuckle and axle hub from vehicle.
See Fig. 2
.
6. Mount assembly in vise. Carefully pry dust deflector from hub. Remove cotter pin and nut, and use
separator tool to remove lower ball joint from hub assembly. On Celica and Corolla, remove inner oil seal
from hub. On Corolla, remove inner snap ring.
7. On all models, use slide hammer and attaching plate to remove axle hub. Place axle hub on press and use
appropriate support plates to press inner bearing race from axle hub. Remove Torx bolts and remove dust
cover.
8. On Celica and Corolla, use a suitable extractor to remove outer oil seal from hub. On RAV4, use a
suitable extractor to remove inner and outer oil seals from hub. On all models, remove wheel bearing
snap ring, if equipped. Place inner race against outside of bearing and press wheel bearing from axle hub.
See Fig. 2
.
Installation
To install, reverse removal procedure. Use NEW snap ring after pressing in NEW wheel bearing. Use NEW
cotter pins. Ti
ghten bolts to specifications. See TORQUE SPECIFICATIONS.

1999 Toyota RAV4
1999-2000 SUSPENSION Front - Avalon, Camry, Camry Solara, Celica, Corolla, Echo, RAV4 & Sienna
Microsoft
Sunday, November 22, 2009 10:36:34 AMPage 5 © 2005 Mitchell Repair Information Company, LLC.

1. Remove front wheel. Check wheel bearing backlash and deviation (rotational free play). See WHEEL
BEARING CHECKING under ADJUSTMENTS & INSPECTION.
2. Using punch and hammer, unstake drive shaft lock nut. Apply brakes and remove lock nut. Remove 2
bolts, brake caliper and disc. Support brake caliper out of way.
3. Remove bolt, and disconnect ABS speed sensor. Remove clip and nut. Using separator, separate steering
knuckle from lower suspension arm. Remove cotter pin and nut, and using tie rod separator, disconnect
tie rod end.
4. Remove 2 nuts, bolts and steering knuckle with axle hub from shock absorber.
Installation
To install, reverse removal procedure. Use NEW snap ring after pressing in NEW wheel bearing. Use NEW
cotter pins. Tighten bolts to specifications. See TORQUE SPECIFICATIONS
.
SHOCK ABSORBER
Removal & Installation
1. Remove front wheel. Disconnect brake hose and ABS speed sensor clamp from shock absorber. On
Sienna, remove outer front cowl top panel. See Fig. 6
.
2. Remove 2 lower shock absorber nuts and bolts and disconnect shock absorber from steering knuckle.
Remove 3 upper shock absorber mounting nuts from inside engine compartment and remove shock
absorber with coil spring.
3. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE
SPECIFICATIONS . NOTE: On Camry, note mounting position of curved mounting plate on shock
absorber tower. Ensure it is reinstalled in same position.

1999 Toyota RAV4
1999-2000 SUSPENSION Front - Avalon, Camry, Camry Solara, Celica, Corolla, Echo, RAV4 & Sienna
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Sunday, November 22, 2009 10:36:34 AMPage 8 © 2005 Mitchell Repair Information Company, LLC.

Removal & Installation (Avalon, Camry, Camry Solara & Sienna)
1. Remove front wheel. Remove 2 nuts and bolt, and disconnect lower control arm from lower ball joint.
Remove 2 bolts on front side of lower control arm and bolt and nut of rear side of lower control arm.
Remove lower control arm.
2. Remove lower control arm bushing stopper from control arm shaft. Bushing can be replaced with a press.
If a NEW bushing is installed, note position of installation and amount of protrusion. See Fig. 7
.
3. To install, reverse removal procedure. Tighten bolts and nuts to specifications. See TORQUE
SPECIFICATIONS
Fig. 7: Installed Position Of Lower Control Arm Bushing (Avalon, Camry Solara & Sienna)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (1999 Celica)
1. Remove front wheel. Remove both engine under covers. Remove cotter pin, lock cap and drive shaft lock
nut. Using separator tool, disconnect both tie rod ends from steering knuckles.
2. Disconnect both stabilizer bar links from both lower control arms. See Fig. 4
. See STABILIZER BAR .
Disconnect both lower suspensions arms from lower ball
joints. See BALL JOINTS .

1999 Toyota RAV4
1999-2000 SUSPENSION Front - Avalon, Camry, Camry Solara, Celica, Corolla, Echo, RAV4 & Sienna
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Sunday, November 22, 2009 10:36:34 AMPage 10 © 2005 Mitchell Repair Information Company, LLC.