TOYOTA RAV4 1996 Service Repair Manual

Fig. 23: Exhaust Camshaft Bearing Cap Bolt Removal & Installation Sequence
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 33 © 2005 Mitchell Repair Information Company, LLC.

Fig. 24: Intake Camshaft Bearing Cap Bolt Removal & Installation Sequence
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
3. Alternatel
y loosen bolts on No. 2 camshaft bearing cap on intake camshaft. Ensure intake camshaft is

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:31 AMPage 34 © 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. 26: Applying Sealant On Front Camshaft Bearing Cap
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
6. Install front camshaft bearing cap for intake camshaft on cylinder head. Install remaining camshaft
bearing caps for intake camshaft on cylinder head in numerical sequence with arrow pointing toward
timing belt end of engine. See Fig. 22
.
7. 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. 24
. See TORQUE SPECIFICATIONS .
8. To install exhaust camshaft, rotate intake camshaft so knock pin is 10-45 degrees from vertical position.
See Fig. 20
. Install exhaust camshaft so timing mark aligns with timing mark on intake camshaft. DO
NOT use assembly reference marks. See Fig. 27
. Ensure exhaust camshaft is fully seated in cylinder
head.
NOTE: It may be necessary to slightly rotate intake camshaft so exhaust camshaft
fully seats in cylinder head.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:31 AMPage 37 © 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.

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
Microsoft
Sunday, November 22, 2009 10:23:31 AMPage 39 © 2005 Mitchell Repair Information Company, LLC.

Fig. 28: Exploded View Of Typical Water Pump & Components
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 40 © 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 10:23:31 AMPage 41 © 2005 Mitchell Repair Information Company, LLC.

Fig. 29: 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 on coolant by-pass pipe "O" ring before installing water pump.
2. Tighten water pump bolts to specification in sequence BEFORE tightening coolant by-pass pipe-to-water
pump nuts. See Fig. 29
. 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 that fits 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 on 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
under ENGINE
SPECIFICATIONS.
2. Install camshaft in cylinder head. 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 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

under ENGINE SPECIFICATIONS.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:31 AMPage 42 © 2005 Mitchell Repair Information Company, LLC.