fuel cap TOYOTA RAV4 1996 Service Repair Manual

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.

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:22:26 AMPage 22 © 2005 Mitchell Repair Information Company, LLC.

4WD Models27 (37)
Drive Shaft Flange Bolt/Nut
4WD Models54 (73)
EGR Valve
Nut(3)
Union Nut43 (58)
Engine Mounts & Brackets
Front (Exhaust Manifold Side) Engine Mount-To-Engine Mount
Crossmember Bolt59 (80)
Left (Transaxle Side) Engine Mounting Bracket-To-Engine Mount Bolt/Nut47 (64)
Right (Timing Belt Side) Engine Mounting Bracket-To-Cylinder Block Bolt38 (52)
Right (Timing Belt Side) Engine Mount-To-Body Bolt47 (64)
Right (Timing Belt Side) Engine Mounting Bracket-To-Engine Mount Bolt/Nut
Bolt27 (37)
Nut38 (52)
Engine Mount Crossmember-To-Body Bolt26 (35)
Exhaust Manifold Nut36 (49)
Flywheel/Drive Plate Bolt
A/T61 (83)
M/T65 (88)
Front Catalytic Converter Brace Bolt/Nut31 (42)
Front Catalytic Converter-To-Exhaust Manifold Bolt/Nut45 (61)
Front Exhaust Pipe-To-Front Catalytic Converter Nut46 (62)
Front Exhaust Pipe-To-Rear Exhaust Pipe Bolt/Nut35 (47)
Front Suspension Crossmember Bolt
Bolt At Body152 (206)
Bolt At Lower Control Arm101 (137)
Fuel Line-To-Fuel Filter Union Bolt21 (28)
Fuel Pipe-To-Delivery Pipe Union Bolt25 (34)
Generator Adjusting Bracket Bolt20 (27)
Generator Mounting Bracket Bolt31 (42)
Intake Manifold Bolt/Nut14 (19)
Intake Manifold Brace Bolt31 (42)
Main Bearing Cap Bolt (4) 43 (58)
No. 1 & No. 2 Idler Pulley Bolt31 (42)
Oil Cooler Relief Valve58 (79)
Oil Pump Sprocket Nut18 (24)
Oxygen Sensor-To-Exhaust Manifold Nut15 (20)
Oxygen Sensor-To-Front Catalytic Converter33 (45)
Power Steering Pump Bolt32 (43)

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:22:27 AMPage 58 © 2005 Mitchell Repair Information Company, LLC.

Distributor Hold-Down Bolt14 (19)
Drive Shaft Center Support Bearing Bolt
4WD Models27 (37)
Drive Shaft Flange Bolt/Nut
4WD Models54 (73)
EGR Valve
Nut(3)
Union Nut43 (58)
Engine Mounts & Brackets
Front (Exhaust Manifold Side) Engine Mount-To-Engine Mount
Crossmember Bolt59 (80)
Left (Transaxle Side) Engine Mounting Bracket-To-Engine Mount
Bolt/Nut47 (64)
Right (Timing Belt Side) Engine Mounting Bracket-To-Cylinder Block
Bolt38 (52)
Right (Timing Belt Side) Engine Mount-To-Body Bolt47 (64)
Right (Timing Belt Side) Engine Mounting Bracket-To-Engine Mount Bolt/Nut
Bolt27 (37)
Nut38 (52)
Engine Mount Crossmember-To-Body Bolt26 (35)
Engine Mount Crossmember-To-Front Suspension Crossmember Nut82 (111)
Exhaust Manifold Nut36 (49)
Flywheel/Drive Plate Bolt
A/T61 (83)
M/T65 (88)
Front Catalytic Converter Brace Bolt/Nut31 (42)
Front Catalytic Converter-To-Exhaust Manifold Bolt/Nut21 (29)
Front Exhaust Pipe-To-Front Catalytic Converter Nut46 (62)
Front Exhaust Pipe-To-Rear Exhaust Pipe Bolt/Nut35 (47)
Front Suspension Crossmember Bolt
Bolt At Body152 (206)
Bolt At Lower Control Arm101 (137)
Fuel Line-To-Fuel Filter Union Bolt21 (29)
Fuel Pipe-To-Delivery Pipe Union Bolt25 (34)
Generator Adjusting Bracket Bolt20 (27)
Generator Mounting Bracket Bolt31 (42)
Intake Manifold Bolt/Nut14 (19)
Intake Manifold Brace Bolt31 (42)
Main Bearing Cap Bolt (4) 43 (58)
No. 1 Idler Pulley Bolt31 (42)
No. 2 Idler Pulley Bolt31 (42)

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:31 AMPage 61 © 2005 Mitchell Repair Information Company, LLC.

LUBRICATION SPECIFICATIONS
LUBRICATION SPECIFICATIONS
FLUID CAPACITIES
FLUID CAPACITIES
BATTERY SPECIFICATIONS
MaterialConditionSpecification
Engine OilAmbient Temperature Less Than
50°F (10°C) to -20°F (-29°C)SAE 5W-30 API SH
Engine OilAmbient Temperature Above 0°F
(-18°C) to Over 100°F (38°C)SAE 10W-30 API SH
Automatic Transaxle Fluid2WD: AllATF DEXRON II
Automatic Transaxle Fluid4WD: AllATF Type T or Equiv.
Manual Transaxle FluidAllAPI GL-4 or GL-5 SAE 75W-90
Clutch FluidAllDOT 3
Transfer Case FluidAllMultipurpose Gear Oil API GL-5,
SAE 75W-90
Rear Differential FluidAllHypoid Gear Oil API GL-5, SAE
90
Engine CoolantAllEthylene-Glycol Based
Power Steering FluidAllATF DEXRON II
Brake FluidAllDOT 3
ItemConditionSpecification (1)
Engine OilDrained, With Filter4.3 Qts. (4.1L)
Engine OilDrained, Without Filter4.1 Qts. (3.9L)
Engine CoolantM/T: Drained8.5 Qts. (8.0L)
Engine CoolantA/T: Drained8.1 Qts. (7.7L)
Transfer Case Oil (2) Drained0.7 Qts. (0.7L)
Automatic Transaxle Fluid2WD: Drained3.5 Qts. (3.3L)
Automatic Transaxle Fluid4WD: Drained7.4 Qts. (7.0L)
Manual Transaxle Oil2WD: Drained4.1 Qts. (3.9L)
Manual Transaxle Oil4WD: Drained5.3 Qts. (5.0L)
Rear Differential Oil (3) Drained1.0 Qts. (0.9L)
Fuel TankCapacity15.3 Gals. (58.0L)
(1)Capacities are recommended or calculated levels. Always use dipstick (if available) to measure level.
(2)4WD models with an automatic transaxle.
(3)4WD models, includes LSD.

1999 Toyota RAV4
MAINTENANCE INFORMATION 1997-99 MAINTENANCE Toyota Maintenance Information
Microsoft
Sunday, November 22, 2009 10:32:42 AMPage 6 © 2005 Mitchell Repair Information Company, LLC.

On models equipped with anti-lock brake systems, ALWAYS observe the following cautions:
DO NOT attempt to bleed hydraulic system without first referring to the appropriate ANTI-LOCK
BRAKE SYSTEM article in the BRAKES Section.
DO NOT mix tire sizes. As long as tires remain close to the original diameter, increasing the width is
acceptable. Rolling diameter must be identical for all 4 tires. Some manufacturers recommend tires of the
same brand, style and type. Failure to follow this precaution may cause inaccurate wheel speed readings.
Use ONLY recommended brake fluids. DO NOT use silicone brake fluids in an ABS-equipped vehicle.
BATTERY WARNING
REPLACING BLOWN FUSES
BRAKE PAD WEAR INDICATOR
Indicator will cause a squealing or scraping noise, warning that brake pads need replacement.
CATALYTIC CONVERTER CAUTION: The anti-lock brake system contains electronic equipment that can be
susceptible to interference caused by improperly installed or high output
radio transmitting equipment. Since this interference could cause the
possible loss of the anti-lock braking capability, such equipment should
be installed by qualified professionals.
WARNING:When battery is disconnected, vehicles equipped with computers may
lose memory data. When battery power is restored, driveability problems
may exist on some vehicles. These vehicles may require a relearn
procedure. See COMPUTER RELEARN PROCEDURES article in GENERAL
INFORMATION section.
CAUTION: Before replacing a blown fuse, remove ignition key, turn off all lights and
accessories to avoid damaging the electrical system. Be sure to use fuse
with the correct indicated amperage rating. The use of an incorrect
amperage rating fuse may result in a dangerous electrical system
overload.
CAUTION: Continued operation of vehicle with a severe malfunction could cause
converter to overheat, resulting in possible damage to converter and
vehicle.
CAUTION: Any modification to the exhaust system on turbo models, which reduces
exhaust backpressure, will lead to lean fuel mixtures and excessive spark
advance. This could cause serious engine damage.

1999 Toyota RAV4
MAINTENANCE INFORMATION 1997-99 MAINTENANCE Toyota Maintenance Information
Microsoft
Sunday, November 22, 2009 10:32:42 AMPage 8 © 2005 Mitchell Repair Information Company, LLC.

ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS
ENGINE OIL
FUEL SYSTEM SERVICE
HALOGEN BULBS
RADIATOR CAP
RADIATOR FAN
WARRANTY INFORMATION
NEW VEHICLE LIMITED WARRANTY WARNING:Many solid state electrical components can be damaged by static
electricity (ESD). Some will display a warning label, but many will not.
Discharge personal static electricity by touching a metal ground point on
the vehicle prior to servicing any ESD sensitive component.
CAUTION: Never use non-detergent or straight mineral oil.
WARNING:Relieve fuel system pressure prior to servicing any fuel system
component (fuel injection models).
WARNING:Halogen bulbs contain pressurized gas which may explode if overheated.
DO NOT touch glass portion of bulb with bare hands. Eye protection
should be worn when handling or working around halogen bulbs.
CAUTION: Always disconnect the fan motor when working near the radiator fan. The
fan is temperature controlled and could start at any time even when the
ignition key is in the OFF position. DO NOT loosen or remove radiator cap
when cooling system is hot.
WARNING:Keep hands away from radiator fan. Fan is controlled by a thermostatic
switch which may come on or run for up to 15 minutes even after engine
is turned off.
CAUTION: Due to the different warranties offered in various regions and the variety of
after-market extended warranties available, please refer to the warranty
package that came with the vehicle to verify all warranty options.

1999 Toyota RAV4
MAINTENANCE INFORMATION 1997-99 MAINTENANCE Toyota Maintenance Information
Microsoft
Sunday, November 22, 2009 10:32:42 AMPage 9 © 2005 Mitchell Repair Information Company, LLC.