TOYOTA RAV4 1996 Service Repair Manual

Fig. 2: Checking Valve Clearance
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 10:23:30 AMPage 3 © 2005 Mitchell Repair Information Company, LLC.

Fig. 3: Adjusting Valve Clearance
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
11. Using small screwdriver and magnet, remove adjusting shim. Measure and record thickness of adjusting
shim removed. Using measured valve clearance and adjusting shim thickness, select proper replacement
adjusting shim. See Fig. 6
and Fig. 7 .
12. Install replacement adjusting shim. Recheck valve clearance. Apply sealant at front and rear valve cover
areas on cylinder head. See Fig. 4
. Using NEW gasket, install valve cover.
13. Install grommets in original location with marking on grommet aligned in designated area. See Fig. 5
.
Install and ti
ghten valve cover nuts to specification. See TORQUE SPECIFICATIONS.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:30 AMPage 4 © 2005 Mitchell Repair Information Company, LLC.

Fig. 4: Applying Sealant On Cylinder Head
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 10:23:30 AMPage 5 © 2005 Mitchell Repair Information Company, LLC.

Fig. 5: Aligning Valve Cover Grommets
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 10:23:30 AMPage 6 © 2005 Mitchell Repair Information Company, LLC.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:30 AMPage 7 © 2005 Mitchell Repair Information Company, LLC.

Fig. 6: Intake Valve Adjusting Shim Selection Chart
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 10:23:30 AMPage 8 © 2005 Mitchell Repair Information Company, LLC.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:30 AMPage 9 © 2005 Mitchell Repair Information Company, LLC.

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.

removal. Remove A/C compressor with hoses attached, and secure aside.
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
.
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.
Fig. 8: Identifying Relay Box, Electrical Connector & Engine Wiring Harness

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 10:23:30 AMPage 11 © 2005 Mitchell Repair Information Company, LLC.

Fig. 9: Identifying ECM & Electrical Connectors
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
9. Raise and support vehicle. Remove lower engine covers. On M/T models, remove clutch release cylinder
with hose attached, and secure aside. Remove starter. On 4WD models with M/T, disconnect oil cooler
lines at transaxle.
10. On A/T models, disconnect oil cooler lines at transaxle. Disconnect shift cable bracket from engine
mount crossmember.
11. On all models, disconnect control cables, oil cooler hoses and electrical connectors at transaxle. Remove
front exhaust pipe from between front catalytic converter on exhaust manifold and rear exhaust pipe.
12. On 4WD models, place reference marks on drive shaft flanges for reassembly reference. Remove drive
shaft flange bolts/nuts at rear axle. Remove drive shaft center support bearing bolts. Pull drive shaft from
transaxle. Remove drive shaft.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:31 AMPage 12 © 2005 Mitchell Repair Information Company, LLC.