check engine TOYOTA RAV4 1996 Service Manual PDF

ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT
1. Disconnect power steering fluid reservoir, PCV hoses, cable brackets and control cables for access to
valve cover. Disconnect spark plug wires from spark plugs.
2. Disconnect engine wiring harness protector at rear of timing belt cover for access to valve cover. When
disconnecting engine wiring harness protector, remove bolt on intake manifold side of engine first, and
then bolt on exhaust manifold side of engine.
3. Remove nuts, grommets, valve cover and gasket. Note location of grommets for reassembly reference, as
grommets must be installed in original location.
4. 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.
Cylinder No. 1 is front cylinder at timing belt end of engine.
5. Ensure valve lifters are loose on cylinder No. 1 and tight on cylinder No. 4. If conditions are not as
described, rotate crankshaft clockwise one complete revolution (360 degrees).
6. With cylinder No. 1 at TDC on compression stroke, check valve clearance on specified valves. Perform
STEP 1. See Fig. 2
. Using feeler gauge, measure and record valve clearance between valve lifter and
camshaft.
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. See0Fig. 2
.
8. Ensure valve clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS
.
VALVE CLEARANCE SPECIFICATIONS
(1)
9. If valve clearance requires adjustment, rotate camshaft so lobe on valve to be adjusted is facing upward,
away from valve lifter. Rotate valve lifter so notch on valve lifter is toward spark plug.
10. Use Valve Clearance Adjuster (SST 09248-55040) to remove adjusting shim. Using SST "A" of valve
clearance adjuster, push downward on valve lifter. Place SST "B" between camshaft and valve lifter with
side marked with No. 9 at desi
gnated position. See Fig. 3. Remove SST "A". NOTE: Adjust valve clearance with engine cold.
ApplicationIn. (mm)
Intake Valve.007-.011 (.19-.29)
Exhaust Valve.011-.015 (.29-.38)
(1)Adjust valve clearance with engine cold.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
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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
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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.

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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
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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.

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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. 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
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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
.

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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.

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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
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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.
Installation
1. To install, reverse removal procedure. Use a NEW "O" ring and gasket. Coat "O" ring with engine oil.
Coat threads and area below head of oil cooler relief valve with engine oil.
2. Install oil cooler with oil cooler-to-cylinder block nut and oil cooler relief valve loosely installed. Tighten
oil cooler relief valve and then nut to specification. See TORQUE SPECIFICATIONS
.
3. 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
.
Add engine oil as needed. Fill cooling system.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ApplicationFt. Lbs. (N.m)
ABS Actuator Mounting Bracket-To-Body Bolt/Nut14 (19)
A/C Compressor Bolt/Nut
Bolt27 (37)
Nut20 (27)
Stud Bolt34 (46)
Axle Shaft Bearing Bracket Bolt
2WD A/T Models47 (64)
Axle Shaft Bearing Bracket-To-Cylinder Block Bolt
2WD A/T & M/T Models47 (64)
Axle Shaft Nut159 (216)
Axle Shaft Retaining Bolt
2WD M/T Models24 (33)
Ball Joint-To-Lower Control Arm Bolt/Nut94 (127)
Brake Line-To-ABS Actuator Nut11 (15)
Camshaft Bearing Cap Bolt (1) 14 (19)
Camshaft Sprocket Bolt40 (54)
Connecting Rod Nut
Step 118 (24)
Step 2Additional 90 Degrees
Coolant Outlet Nut11 (15)
Crankshaft Pulley Bolt80 (109)
Cylinder Head Bolt (2)
Step 136 (49)
Step 2Additional 90 Degrees

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
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