service TOYOTA RAV4 1996 Service Workshop Manual

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.

1. Install NEW insulator at bottom of fuel injector and NEW grommet on top of fuel injector. Coat NEW
"O" rings with gasoline and install on fuel injector.
2. Install 2 spacers on cylinder head. Install fuel injectors on cylinder head. Install fuel delivery pipe on fuel
injectors. Using twisting motion, push fuel injectors into fuel delivery pipe.
3. Install and slightly tighten fuel delivery pipe-to-cylinder head bolts. Ensure all fuel injectors rotate
smoothly. If fuel injector fails to rotate smoothly, check for improperly installed or damaged "O" rings.
4. Position electrical connector on fuel injector facing toward top of engine. Tighten fuel delivery pipe-to-
cylinder head bolts to specification. See TORQUE SPECIFICATIONS
.
5. Using NEW gasket, install intake manifold. Install and tighten bolts/nuts to specification. See TORQUE
SPECIFICATIONS . Install air tube on side of intake manifold.
6. Install adjusting shims and valve lifters in original location on cylinder head (if removed). Ensure valve
lifters rotate smoothly in cylinder head.
7. Install NEW gasket for cylinder head on cylinder block. Ensure all holes in gasket align with holes in
cylinder block.
8. Install cylinder head. Coat threads and bolt-to-cylinder contact surfaces on cylinder head bolts with
engine oil. Install and tighten cylinder head bolts to specification in sequence. See Fig. 15
. See
TORQUE SPECIFICATIONS
.
9. Install camshafts using proper procedure. See CAMSHAFTS. Install No. 3 timing belt cover. Install and
tighten bolts to specification. See TORQUE SPECIFICATIONS
.
10. To install remaining components, reverse removal procedure. If camshaft or cylinder head components
are serviced, adjust valve clearance. See VALVE CLEARANCE ADJUSTMENT
under
ADJUSTMENTS.
11. Before installing gasket and valve cover, apply sealant at front and rear valve cover areas on cylinder
head. See Fig. 4
. Using NEW gasket, install valve cover.
12. Install grommets in original location with marking on grommet aligned in designated area. See Fig. 5
.
Install and tighten valve cover nuts to specification. See TORQUE SPECIFICATIONS
.
13. Install NEW throttle body gasket with protruding area on gasket facing toward bottom of throttle body.
On throttle bodies using 4 mounting bolts, ensure longer bolts are installed in 2 lower bolt holes.
14. 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 on "O" ring before installing coolant by-pass pipe. Use
NEW gasket when installing catalytic converter on exhaust manifold.
15. Use NEW gasket and NEW nuts when installing front exhaust pipe on front catalytic converter. Ensure
all bolts/nuts are loosely installed on front exhaust pipe before tightening to specification. See TORQUE
SPECIFICATIONS .
16. Install NEW "O" ring on distributor. Coat "O" ring with engine oil. Rotate crankshaft clockwise, as
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.
17. Ensure slot area on intake camshaft is positioned vertically. Rotate drive 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 hol
d-down bolt. Adjust control cables and ignition timing. Fill cooling system.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:31 AMPage 21 © 2005 Mitchell Repair Information Company, LLC.

Removal
Remove camshaft. See CAMSHAFTS . Note location of adjusting shims and valve lifters for reassembly
reference. Remove adjusting shims and valve lifters from cylinder head.
Inspection
Inspect components for damage. Measure valve lifter diameter and bore diameter. Ensure oil clearance is within
specification. Replace components if not within specification. See VALVE LIFTERS
under ENGINE
SPECIFICATIONS.
Installation
To install, reverse removal procedure. Ensure components are installed in original location and valve lifters
rotate smoothly in cylinder head. If camshaft, adjusting shims or valve lifters are replaced, check valve
clearance. See VALVE CLEARANCE ADJUSTMENT
under ADJUSTMENTS.
CAMSHAFTS
Removal (Exhaust Side)
1. Remove timing belt and camshaft sprocket. See TIMING BELT . Remove No. 3 timing belt cover.See
Fig. 14
.
2. Disconnect power steering fluid reservoir, PCV hoses, cable brackets and control cables for access valve
cover. Disconnect spark plug wires from spark plugs. Remove nuts, grommets, valve cover and gasket.
Note location of grommets for reassembly reference, as grommets must be installed in original location.
3. For servicing of exhaust camshaft, rotate intake camshaft so knock pin is 10-45 degrees from vertical
position. See Fig. 20
. This aids in exhaust camshaft removal by using camshaft lobes on cylinders No. 2
and 4 to push on valve lifters.
4. Secure sub-gear to main gear on exhaust camshaft with a 6 x 1.0 x 18 mm service bolt "B". See Fig. 21
.
Before removing camshaft bearing cap bolts, ensure torsional spring force of sub-gear is secured by
service bolt "B". CAUTION: Camshafts must be properly positioned to lift camshaft straight from
cylinder head to prevent damage to cylinder head and camshaft. DO
NOT pry or force camshafts from cylinder head or component
damage will result.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:31 AMPage 29 © 2005 Mitchell Repair Information Company, LLC.

lifted upward as No. 2 camshaft bearing cap bolts are loosened.
4. If intake camshaft is not lifted upward, reinstall all camshaft bearing caps. Reposition intake camshaft so
knock pin is 80-115 degrees from vertical position. See Fig. 20
. Repeat steps 9) and 10). Remove No. 2
camshaft bearing cap and intake camshaft.
5. If removing sub-gear from exhaust camshaft, mount camshaft in soft-jaw vise on hexagonal area of
camshaft. Install service bolt "A" in camshaft. See Fig. 25
.
6. Using screwdriver, rotate sub-gear clockwise and remove service bolt "B". Remove snap ring, wave
washer, sub-gear and camshaft gear spring from exhaust camshaft. See Fig. 14
.
7. Note location of adjusting shims and valve lifters for reassembly reference. Remove adjusting shims and
valve lifters from cylinder head (if necessary).
Fig. 25: Removing & Installing Sub
-Gear On Main Gear
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Inspection
1. Inspect components for damage. Check camshaft journal diameter, lobe height and journal runout.
Replace camshaft if not within specification. See CAMSHAFT
under ENGINE SPECIFICATIONS.
Install camshaft in cylinder head.
2. Using Plastigage, check camshaft oil clearance with camshaft bearing cap bolts tightened to specification
in sequence.See Fig. 23
and Fig. 24 . See TORQUE SPECIFICATIONS .
3. Check camshaft end pla
y with camshaft bearing cap bolts tightened to specification. Replace camshaft

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:31 AMPage 35 © 2005 Mitchell Repair Information Company, LLC.

and/or cylinder head if camshaft end play is not within specification. See CAMSHAFT under ENGINE
SPECIFICATIONS.
4. Install both camshafts in cylinder head without sub-gear installed on exhaust camshaft. Install and tighten
camshaft bearing cap bolts to specification in sequence. See Fig. 23
and Fig. 24 . See TORQUE
SPECIFICATIONS .
5. Using dial indicator, check gear backlash between gears on camshafts. Replace camshafts if gear backlash
exceeds specification. See CAMSHAFT
under ENGINE SPECIFICATIONS.
6. Measure distance between ends of camshaft gear spring. Replace camshaft gear spring if distance is
not .886-.902" (22.50-22.90 mm). Measure valve lifter diameter and bore diameter. Ensure oil clearance
is within specification. Replace components if not within specification. See VALVE LIFTERS
under
ENGINE SPECIFICATIONS.
Installation
1. If installing sub-gear on exhaust camshaft, install camshaft gear spring, sub-gear, wave washer and snap
ring on exhaust camshaft. Ensure pins on main gear and sub-gear engage with ends of camshaft gear
spring.
2. Install service bolt "A" on sub-gear. See Fig. 25
. Using screwdriver, rotate sub-gear clockwise and align
holes in sub-gear with hole on main gear. Install service bolt "B". Remove service bolt "A".
3. Install adjusting shims and valve lifters in original location on cylinder head (if removed). Ensure valve
lifters rotate smoothly in cylinder head.
4. Coat thrust surfaces of camshafts with multipurpose grease. To install intake camshaft, rotate intake
camshaft so knock pin is at 80-115 degrees from vertical position and install in cylinder head. See Fig.
20 .
5. Coat seal lip of NEW oil seal for intake camshaft with grease. Install oil seal on front of intake camshaft
until oil seal is fully seated in cylinder head. Apply sealant on front camshaft bearing cap for intake
camshaft. See Fig. 26
.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:31 AMPage 36 © 2005 Mitchell Repair Information Company, LLC.

Fig. 27: Aligning Camshaft Timing Marks
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
9. Install camshaft bearing caps for exhaust camshaft on cylinder head in numerical sequence with arrow
pointing toward timing belt end of engine. See Fig. 22
.
10. Coat threads and bolt head-to-camshaft bearing cap contact surfaces of camshaft bearing cap bolts with
engine oil. Install and tighten camshaft bearing cap bolts to specification in sequence using several steps.
See Fig. 23
. See TORQUE SPECIFICATIONS .
11. Remove service bolt "B" from camshaft gear. See Fig. 25
. Install No. 3 timing belt cover. Install and
tighten bolts to specification. See TORQUE SPECIFICATIONS
. Install timing belt using proper
procedure. See TIMING BELT
.
12. Check valve clearance. See VALVE CLEARANCE ADJUSTMENT
under ADJUSTMENTS. Apply
sealant in grooves on rear side of semi-circular plugs located on exhaust camshaft side of cylinder head.
Install semi-circular plugs in cylinder head.
13. Before installing gasket and valve cover, apply sealant at front and rear valve cover areas on cylinder
head. See Fig. 4
.
14. Using NEW gasket, install valve cover. Install grommets in original location with marking on grommet
aligned in designated area.See Fig. 5
. Install and tighten valve cover nuts to specification. See TORQUE
SPECIFICATIONS .
15. If installing distributor, install NEW "O" ring on distributor. Coat "O" ring with engine oil.
16. 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.
C
ylinder No. 1 is front cylinder at timing belt end of engine.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:31 AMPage 38 © 2005 Mitchell Repair Information Company, LLC.

1999 HEATER SYSTEMS
RAV4, Tacoma & 4Runner
DESCRIPTION
Major components of the heater system are a heater core, control panel, blower motor, water valve, hoses,
control cables and air ducts. 4Runner may be equipped with a dual heater system with separate controls for
front and rear. Rear temperature and blower controls are located in the console between front seats.
OPERATION
BLOWER SWITCH
Switch controls blower motor speed through blower resistor. Blower speed is adjusted by control lever, knob or
push button.
CONTROL PANEL
Temperature and mode knobs or levers are connected by cable to heater coolant valve and air doors. All models
have a fresh/recirculation lever to provide choice of outside air or recirculated inside air.
HEATER RELAY
A heater (or main) relay controls current through system. For location of heater (main) relay, see WIRING
DIAGRAMS .
ADJUSTMENTS
AIR INLET DAMPER CABLE
Set air inlet damper and control lever to fresh (recirculated on RAV4) air position. Remove cable retaining clip,
and ensure damper and cable are in full fresh (recirculated on RAV4) air position. Install control cable clip.
Check operation of air intake damper.
AIRFLOW MODE DAMPER CABLE WARNING:To avoid injury from accidental air bag deployment, read and carefully
follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR
BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY article in
GENERAL SERVICING.
CAUTION: When battery is disconnected, radio will go into anti-theft protection mode.
Obtain radio anti-theft protection code from owner prior to servicing
vehicle.

1999 Toyota RAV4
1999 HEATER SYSTEMS RAV4, Tacoma & 4Runner

1999 Toyota RAV4
1999 HEATER SYSTEMS RAV4, Tacoma & 4Runner
Microsoft
Sunday, November 22, 2009 10:30:50 AMPage 1 © 2005 Mitchell Repair Information Company, LLC.
Microsoft
Sunday, November 22, 2009 10:30:55 AMPage 1 © 2005 Mitchell Repair Information Company, LLC.

Set control lever to correct position. See AIRFLOW MODE DAMPER CABLE ADJUSTMENTtable.
Remove cable retaining clip. Ensure airflow mode damper and cable are in their respective positions. Install
cable retaining clip.
AIRFLOW MODE DAMPER CABLE ADJUSTMENT
AIR MIX DAMPER CABLE
Set air door lever to cool position. Remove cable retaining clip. Ensure cable and damper are in full cool
position. Install cable retaining clip. Check air mix damper operation.
REAR HEAT DAMPER CABLE
4Runner
Set control lever to warm position. Remove cable retaining clip. Ensure cable and damper are in full warm
position. Install cable retaining clip.
WATER VALVE CONTROL CABLE
Set control lever to cool position. Remove cable retaining clip. Ensure water valve control cable is in full cool
position. Install cable retaining clip.
TROUBLE SHOOTING
BLOWER DOES NOT WORK
Inspect for blown heater fuse or faulty heater relay. Inspect heater blower switch, heater blower resistor, heater
blower motor, or wiring fault. See WIRING DIAGRAMS
.
INCORRECT TEMPERATURE OUTPUT
Inspect for broken or out of adjustment control cables, heater hoses leaking or clogged, or faulty water pump.
Inspect for broken air dampers, clogged air ducts, leaking or clogged heater core, or faulty heater control unit.
TESTING
ApplicationLever Position
Tacoma & 4RunnerFace
RAV4(1)
(1)Information is not available from manufacturer.
WARNING:To avoid injury from accidental air bag deployment, read and carefully
follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR
BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY article in
GENERAL SERVICING.

1999 Toyota RAV4
1999 HEATER SYSTEMS RAV4, Tacoma & 4Runner
Microsoft
Sunday, November 22, 2009 10:30:50 AMPage 2 © 2005 Mitchell Repair Information Company, LLC.

Fig. 6: Identifying 5-Pin Heater Main Relay Connector Terminals (4Runner - Rear)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
REMOVAL & INSTALLATION
BLOWER MOTOR
Removal & Installation (Except 4Runner Rear)
Disconnect negative battery cable. Remove glove box, if necessary. Unplug blower motor and resistor
connectors. Remove blower motor. To install, reverse removal procedure. See Fig. 7
, Fig. 8 or Fig. 9 .
Removal & Installation (4Runner Rear)
Remove rear heater assembly. See HEATER ASSEMBLY. Remove wire harness and clamps. Separate heater
WARNING:To avoid injury from accidental air bag deployment, read and carefully
follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR
BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY article in
GENERAL SERVICING.

1999 Toyota RAV4
1999 HEATER SYSTEMS RAV4, Tacoma & 4Runner
Microsoft
Sunday, November 22, 2009 10:30:50 AMPage 9 © 2005 Mitchell Repair Information Company, LLC.

1999 MANUAL A/C-HEATER SYSTEMS
RAV4
SPECIFICATIONS
SPECIFICATIONS
DESCRIPTION
RAV4 manual A/C-heater system uses a Nippondenso 10-cylinder compressor. The compressor only operates
in normal operating temperatures and pressures set for this model. An electric condenser fan is used and
operates at 2 speeds, depending on system pressure, engine coolant temperature and A/C switch position.
System components used are: fan switch, A/C amplifier, evaporator, thermistor, dual-pressure switch, engine
coolant temperature switch, compressor, condenser, receive
r-drier, and all the necessary pipes and hoses. Air
ApplicationSpecification
Compressor TypeNippondenso 10PA15 10-Cyl.
Compressor Clutch Clearance.014-.026" (.35-.65 mm)
Compressor Belt Tension (1)
New Belt (2) 135-185 lbs. (61-84 kg)
Used Belt80-120 lbs. (36-54 kg)
Compressor Oil Capacity (3) 4.1 ozs.
Refrigerant (R-134a) Capacity22.9-26.5 ozs.
System Operating Pressures (4)
Low Side22-37 psi (1.5-2.5 kg/cm2 )
High Side206-235 psi (14-16 kg/cm2 )
(1)Using a belt tension gauge, measure at longest run of belt.
(2)A new belt is one that has been used less than 5 minutes.
(3)Use ND-Oil 8 (Part No. 08885-09109).
(4)When ambient temperature is 86-95°F (30-35°C).
WARNING:To avoid injury from accidental air bag deployment, read and carefully
follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR
BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY article in
GENERAL SERVICING.
CAUTION: When battery is disconnected, radio will go into anti-theft protection mode.
Obtain radio anti-theft protection code from owner prior to servicing
vehicle.

1999 Toyota RAV4
1999 MANUAL A/C-HEATER SYSTEMS RAV4

1999 Toyota RAV4
1999 MANUAL A/C-HEATER SYSTEMS RAV4
Microsoft
Sunday, November 22, 2009 10:29:27 AMPage 1 © 2005 Mitchell Repair Information Company, LLC.
Microsoft
Sunday, November 22, 2009 10:29:33 AMPage 1 © 2005 Mitchell Repair Information Company, LLC.