check engine TOYOTA RAV4 1996 Service Manual PDF

Fig. 2: Checking Valve Clearance
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
7. To check remaining valves, rotate crankshaft clockwise, viewed from timing belt end of engine, one
complete revolution (360 degrees) until cylinder No. 4 cylinder is at TDC on compression stroke.
Measure and record valve clearance on specified valves. Perform STEP 2 in illustration. See Fig. 2
.
8. Ensure valve clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS
table.
VALVE CLEARANCE SPECIFICATIONS
(1)
ApplicationIn. (mm)
Intake Valve.007-.011 (.19-.29)
Exhaust Valve.011-.015 (.29-.38)
(1)Adjust valve clearance with engine cold.

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1999-2000 ENGINES 2.0L 4-Cylinder
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Fig. 5: Exhaust Valve Adjusting Shim Selection Chart
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
12. Install replacement adjusting shim. Recheck valve clearance. Apply sealant at front and rear valve cover
areas on cylinder head. See Fig. 6
. Using NEW gasket, install valve cover.
Fig. 6: Applying Sealant On Cylinder Head

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
13. Install grommets in original location with marking on grommet aligned in designated area. See Fig. 7
.
Install and ti
ghten valve cover nuts to specification. See TORQUE SPECIFICATIONS.

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Inspection
1. Inspect cylinder head warpage at cylinder block, exhaust manifold and intake manifold surfaces. Replace
cylinder head if warpage exceeds specification. See CYLINDER HEAD
table under ENGINE
SPECIFICATIONS.
2. Inspect cylinder block deck surface for warpage. Replace cylinder block if deck surface warpage exceeds
specification. See CYLINDER BLOCK
table under ENGINE SPECIFICATIONS.
3. Inspect intake and exhaust manifold machined surfaces for warpage. Replace component if warpage
exceeds .0118" (.300 mm). Inspect camshaft and components. See CAMSHAFT
.
4. Measure valve lifter diameter and bore diameter. Ensure oil clearance is within specification. Replace
components if not within specification. See VALVE LIFTERS
table under ENGINE
SPECIFICATIONS.
Installation
1. Apply adhesive to 2 or 3 threads of oil pressure switch, and install switch. 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 in several steps, to specification in sequence. See Fig.
15 . See TORQUE SPECIFICATIONS .
9. If removed, install spark plug tubes. Install camshafts using proper procedure. See CAMSHAFT
. 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. 6
. Using NEW gasket, install valve cover.
12. Install grommets in original location with marking on grommet aligned in designated area. See Fig. 7
.
Install and tighten valve cover nuts to specification. See TORQUE SPECIFICATIONS
.
13. Install VSV for EGR. Connect ground cable to intake manifold with bolt. Connect knock sensor
connector. Connect power steerin
g idle-up air hoses to air tube. On A/T models, connect A/T throttle

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1999-2000 ENGINES 2.0L 4-Cylinder
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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.

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VALVE LIFTER
Removal
Remove camshaft. See CAMSHAFT . 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
table 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.
CAMSHAFT
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 to
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. 19
. This aids in exhaust camshaft removal by using camshaft lobes on cylinders No. 2
and 4 to push on valve lifters. 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.

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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. 19
. 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. 24
.
Fig. 24: Removing & Installing Sub
-Gear On Main Gear
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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).
Inspection
1. Inspect components for damage. Check camshaft journal diameter, lobe height and journal runout.
Replace camshaft if not within specification. See CAMSHAFT
table 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. 22
and Fig. 23 . See TORQUE SPECIFICATIONS.

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3. Check camshaft end play with camshaft bearing cap bolts tightened to specification. Replace camshaft
and/or cylinder head if camshaft end play is not within specification. See CAMSHAFT
table 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. 22
and Fig. 23 . See TORQUE
SPECIFICATIONS .
5. Using dial indicator, check gear backlash between gears on camshafts. Replace camshafts if gear backlash
exceeds specification. See CAMSHAFT
table under ENGINE SPECIFICATIONS.
6. Measure length of camshaft gear spring. Replace camshaft gear spring if distance is not within
specification. See CAMSHAFT
table under ENGINE SPECIFICATIONS. Measure valve lifter diameter
and bore diameter. Ensure oil clearance is within specification. Replace components if not within
specification. See VALVE LIFTERS
table 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. 24
. Using screwdriver, rotate sub-gear clockwise and align
hole 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 into cylinder head. See Fig.
19 .
5. Coat seal lip of NEW oil seal for intake camshaft with grease. Install oil seal onto front of intake camshaft
until oil seal is fully seated in cylinder head. Apply sealant to front camshaft bearing cap for intake
camshaft. See Fig. 25
.

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1999-2000 ENGINES 2.0L 4-Cylinder
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Fig. 26: 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. 21
.
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. 22
. See TORQUE SPECIFICATIONS .
11. Remove service bolt "B" from camshaft gear. See Fig. 24
. 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. 6
.
14. Using NEW gasket, install valve cover. Install grommets in original location with marking on grommet
aligned in designated area. See Fig. 7
. 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, 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.
C
ylinder No. 1 is front cylinder at timing belt end of engine.

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Fig. 28: Water Pump Bolt Removal & Installation Sequence
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Installation
1. To install, reverse removal procedure. Use NEW gaskets and NEW "O" rings. Apply soapy water
solution to coolant by-pass pipe "O" ring before installing water pump.
2. Tighten water pump bolts to specification in sequence. Tightening coolant by-pass pipe-to-water pump
nuts. See Fig. 28
. See TORQUE SPECIFICATIONS . To install remaining components, reverse
removal procedure. Fill cooling system.
OIL PAN
Removal
1. Disconnect negative battery cable. Raise and support vehicle. Remove lower engine covers. Drain engine
oil. Remove oil dipstick. Remove front exhaust pipe from between front catalytic converter on exhaust
manifold and rear exhaust pipe for access to oil pan.
2. Remove stiffener plate at rear of oil pan for access to oil pan. Stiffener plate fits between sides of cylinder
block and front of transaxle. Remove bolts/nuts and oil pan.
Installation
1. Ensure sealing surfaces are clean. Apply bead of sealant at center of oil pan sealing surface, between
bolt/nut holes and on inside of bolt/nut holes.
2. Install oil pan. Install and tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS
.
3. To install remaining components, reverse removal procedure. Use NEW gasket and NEW nuts when
installing front exhaust pipe onto catalytic converter. Ensure all bolts/nuts are loosely installed before
tightening to specification. See TORQUE SPECIFICATIONS
.
OVERHAUL
CYLINDER HEAD
Cylinder Head
1. Inspect cylinder head warpage at cylinder block, exhaust manifold and intake manifold areas. Replace
cylinder head if warpage exceeds specification. See CYLINDER HEAD
table under ENGINE
SPECIFICATIONS.
2. Install camshaft into cylinder head. Using Plastigage, check camshaft oil clearance with camshaft bearing
cap bolts tightened to specification in sequence. See Fig. 22
and Fig. 23 . See TORQUE
SPECIFICATIONS .
3. Check camshaft end play with camshaft bearing cap bolts tightened to specification. Replace camshaft
and/or cylinder head if camshaft oil clearance or end play is not within specification. See CAMSHAFT

table under ENGINE SPECIFICATIONS.

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OIL PUMP SPECIFICATIONS
Reassembly & Installation
1. To reassemble, reverse disassembly procedure. Ensure reference marks (dot area) on rotors face toward
oil pump body cover, away from oil pump housing.
2. Using hammer and Oil Seal Installer (SST 09950-60010), install NEW crankshaft front oil seal (if
removed) until oil seal surface is even with oil pump housing. Coat lip of oil seal with grease.
3. Install NEW oil pump oil seal (if removed) until oil seal surface is even with oil pump body cover. Coat
lip of oil seal with grease.
4. Install oil pump body cover using NEW "O" ring. Install and tighten oil pump body cover bolts to
specification. See TORQUE SPECIFICATIONS
. Using NEW gasket, install oil pump on cylinder
block.
5. Ensure 2 longest oil pump-to-cylinder block bolts are located in lowest outside holes nearest to oil pan
flange on each side of oil pump. Tighten oil pump-to-cylinder block bolts to specification. See TORQUE
SPECIFICATIONS . To install remaining components, reverse removal procedure.
OIL COOLER
Removal
1. Oil cooler is mounted between oil filter and cylinder block. Disconnect negative battery cable. Drain
cooling system.
2. Remove passenger-side lower engine cover. Remove front exhaust pipe from between front catalytic
converter on exhaust manifold and rear exhaust pipe. Remove generator.
3. Remove exhaust manifold with catalytic converter and heat insulators for access to oil cooler. Remove oil
filter. Disconnect coolant hoses from oil cooler. Remove oil cooler relief valve and plate washer from
center of oil cooler housing. Remove oil cooler-to-cylinder block nut. Remove oil cooler, gasket and "O"
ring.
Inspection
1. Inspect oil cooler for damage. Apply air pressure to coolant hose pipe on oil cooler. Ensure air flows
through oil cooler, and oil cooler is not restricted. Replace oil cooler if damage or restricted.
2. Using wooden stick, push inward on check valve located in center of oil cooler relief valve. Push inward
from threaded end (opposite oil filter threads) on oil cooler relief valve. Replace oil cooler relief valve if
check valve fails to move.
ApplicationIn. (mm)
Driven Rotor-To-Oil Pump Housing Clearance
Standard.0039-.0063 (.100-.160)
Wear Limit.0079 (.200)
Rotor Tip Clearance
Standard.0016-.0063 (.040-.160)
Wear Limit.0079 (.200)

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1999-2000 ENGINES 2.0L 4-Cylinder
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