fuel injector TOYOTA RAV4 1996 Service Repair Manual

Removal
1. Release fuel pressure. See FUEL PRESSURE RELEASE . Drain cooling system. Raise and support
vehicle. Remove right lower engine cover.
2. Disconnect control cables at throttle body. Remove air cleaner assembly and air cleaner case. Remove
accessory drive belt and generator.
3. Remove front exhaust pipe. Remove exhaust manifold and heat insulator assembly. Disconnect oxygen
sensor (except California) or Air/Fuel (A/F) ratio sensor (California), and remove exhaust manifold and
heat shield. Remove sensors from exhaust manifold and front catalytic converter, if equipped.
4. Remove heat insulator from front exhaust pipe. Remove throttle body and gasket. Remove ignition coils
with spark plug wires attached.
5. Disconnect necessary electrical connectors, coolant hoses and vacuum hoses from cylinder head and
intake manifold. Remove coolant outlet, coolant by-pass pipe and gaskets.
6. Disconnect hoses and ground strap. Remove union bolt, and disconnect fuel line at fuel filter. Remove
EGR valve and vacuum modulator. Disconnect power steering idle-up hoses from air tube.
7. Remove 2 bolts and accelerator cable bracket. Disconnect PCV hoses, cable brackets and control cables
for access to valve cover. Disconnect engine wiring harness protector at rear of timing belt cover for
access to valve cover. Remove nuts, grommets, valve cover and gasket. Note location of grommets for
reassembly reference, as grommets must be installed in original location.
8. Remove bolts, and disconnect engine wiring harness protector from left side of intake manifold.
Disconnect electrical connectors at injectors, A/C compressor and crankshaft position sensor. Remove
engine wiring harness clamps from timing belt cover and generator drive belt adjusting bar.
9. Remove scuff plate from passenger-side door opening and passenger-side kick panel. Remove right side
cowl side trim and floor carpet center cover. 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.
10. Disconnect engine wiring harness clamp located on engine wiring, near firewall. Pull engine wiring
harness out through firewall. Remove engine wiring harness from between cylinder head and intake
manifold.
11. Disconnect timing belt from camshaft timing pulley. Remove camshaft timing pulley. Remove No. 1 idler
pulley and tension spring. See TIMING BELT
. Remove 3 bolts and timing belt cover. See Fig. 14 .
After removing timing belt from camshaft sprocket, support timing belt so belt does not come off
crankshaft sprocket.

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
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Sunday, November 22, 2009 10:22:26 AMPage 18 © 2005 Mitchell Repair Information Company, LLC.

13. Loosen cylinder head bolts in proper sequence using several steps. See Fig. 15 . Remove cylinder head
bolts, washers, cylinder head with intake manifold. If cylinder head is difficult to remove, carefully pry
between cylinder head and block using a screwdriver. DO NOT damage contact surfaces between
cylinder head and block. Remove cylinder head gasket from cylinder block.
Fig. 15: Cylinder Head Bolt Removal & Installation Sequence

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
14. Remove air tube bolted onto side of intake manifold. Remove bolts/nuts, intake manifold and gasket from
cylinder head. Disconnect air hose from cylinder head port. Remove air hose.
15. Remove fuel delivery pipe-to-cylinder head bolts. Remove fuel delivery pipe from cylinder head.
Remove fuel injectors and spacers from cylinder head. Remove oil pressure switch from side of cylinder
head. CAUTION: Cylinder head bolts must be loosened in proper sequence to prevent
cylinder head warpage.

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
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Sunday, November 22, 2009 10:22:26 AMPage 20 © 2005 Mitchell Repair Information Company, LLC.

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

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:22:26 AMPage 21 © 2005 Mitchell Repair Information Company, LLC.

Removal
1. Release fuel pressure. See FUEL PRESSURE RELEASE . Drain cooling system. Raise and support
vehicle. Remove right lower engine cover.
2. Disconnect control cables at throttle body. Remove air cleaner assembly and air cleaner case. Remove
accessory drive belt and generator. On 1997 models, remove distributor with spark plug wires. On 1998
models, remove front exhaust pipe.
3. On 1997 models, disconnect electrical connectors for oxygen sensors and remove exhaust manifold and
front catalytic converter. On 1998 models, disconnect oxygen sensor (except California) or Air/Fuel ratio
(A/F) sensor (California) and remove exhaust manifold and heat shield. On all models, remove sensors
from exhaust manifold and front catalytic converter, if equipped. See Fig. 14
.
4. On 1997 models, separate exhaust manifold and front catalytic converter and disconnect oil pressure
switch. On 1998 models, remove heat insulator from front exhaust pipe. Remove ignition coils with spark
plug wires attached. Disconnect oil pressure switch. See Fig. 14
.
5. On all models, disconnect necessary electrical connectors, coolant hoses and vacuum hoses from throttle
body, cylinder head and intake manifold. Remove coolant outlet, coolant by-pass pipe and gaskets. See
Fig. 14
.
6. Remove throttle body and gasket. Remove union bolt and disconnect fuel line at fuel filter. Remove EGR
valve and vacuum modulator. Remove EGR Vacuum Switching Valve (VSV) from side of cylinder head.
See Fig. 14
.
7. Remove intake manifold brace located between cylinder block and intake manifold. On A/T models,
disconnect control cable bracket from side of intake manifold. On all models, disconnect power steering
fluid reservoir, PCV hoses, cable brackets and control cables for access to valve cover.
8. 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.
9. Remove nuts, grommets, valve cover and gasket. Note location of grommets for reassembly reference, as
grommets must be installed in original location.
10. Remove bolts and disconnect engine wiring harness protector from rear side of intake manifold.
Disconnect electrical connectors at injectors, A/C compressor and crankshaft position sensor. Remove
engine wiring harness clamps from timing belt cover and generator drive belt adjusting bar.
11. Disconnect engine wiring harness protector from brackets on front side of intake manifold. Remove scuff
plate from passenger-side door opening and passenger-side kick panel. Remove center console trim panel
from passenger-side of center console.
12. 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.
13. Disconnect engine wiring harness clamp located on engine wiring, near firewall. Pull engine wiring
harness out through firewall. Remove engine wiring harness from between cylinder head and intake
manifold. NOTE: On 4WD models, manufacturer recommends engine removal for servicing of
cylinder head and manifolds. See ENGINE. Proceed to appropriate step in
following procedure for servicing of cylinder head and manifolds.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
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Sunday, November 22, 2009 10:23:31 AMPage 17 © 2005 Mitchell Repair Information Company, LLC.

14. Remove timing belt from camshaft sprocket. Remove camshaft sprocket, No. 1 idler pulley and tension
spring. See TIMING BELT
. Remove No. 3 timing belt cover from cylinder head. See Fig. 14 . Remove
camshafts. See CAMSHAFTS
.
15. Loosen cylinder head bolts in proper sequence using several steps. See Fig. 15
. Remove cylinder head
bolts, washers, cylinder head with intake manifold. If cylinder head is difficult to remove, carefully pry
between cylinder head and block using a screwdriver. Use care not to damage contact surfaces between
cylinder head and block. Remove cylinder head gasket from cylinder block.
16. Remove air tube bolted onto side of intake manifold. Remove bolts/nuts, intake manifold and gasket from
cylinder head.
17. Remove fuel delivery pipe-to-cylinder head bolts. Remove fuel delivery pipe from cylinder head.
Remove fuel injectors and spacers from cylinder head. Remove oil pressure switch from side of cylinder
head.
18. Note location of adjusting shims and valve lifters for reassembly reference. Remove adjusting shims and
valve lifters from c
ylinder head (if necessary). NOTE: After removing timing belt from camshaft sprocket, manufacturer
recommends supporting timing belt so belt does not come off crankshaft
sprocket. If timing belt comes off crankshaft sprocket, timing belt must be
completely removed and reinstalled.
CAUTION: Cylinder head bolts must be loosened in proper sequence to prevent
cylinder head warpage.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:31 AMPage 18 © 2005 Mitchell Repair Information Company, LLC.

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
Microsoft
Sunday, November 22, 2009 10:23:31 AMPage 21 © 2005 Mitchell Repair Information Company, LLC.