seats TOYOTA RAV4 1996 Service Repair Manual

Fig. 6: Identifying Transaxle-To-Cylinder Block Bolt Tightening Specifications (Corolla 1.8L 7A-FE)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Land Cruiser 1997)
1. Disconnect negative battery cable. Remove battery and battery tray. Remove fan shroud bolts from top of
radiator to prevent damage to cooling fan.
2. Remove throttle valve cable from mounting bracket and throttle linkage. Remove upper starter bolt.
Disconnect transfer case shift linkage at transfer case. Disconnect transmission shift linkage at control rod
on transmission. Remove knob from transfer case shift lever.
3. Remove screws from each side of center console located around transmission and transfer case shift
levers. Remove center console. Remove shift boot from transfer case shift lever.
4. Remove bolts and center console box located between the seats. Disconnect electrical connectors at

1998 Toyota Avalon XLS
TRANSMISSION SERVICING - A/T 1997-98 TRANSMISSION SERVICING Toyota - Transmission Removal &
Installation

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November-03-08 10:30:28 AMPage 14 © 2005 Mitchell Repair Information Company, LLC.

exceeds .0079" (.200 mm).
2. Install torque converter on transmission. To ensure torque converter is fully seated, torque converter
depth should be checked. Using straightedge and caliper, measure torque converter depth from torque
converter bolt lug on torque converter to the surface on transmission. See Fig. 1
.
3. Torque converter depth should be more than .707" (17.95 mm). If torque converter depth is less than
specified, check for improperly seated torque converter.
4. To install, reverse removal procedure. Tighten all bolts/nuts to specification. See TORQUE
SPECIFICATIONS When installing torque converter bolts, apply Loctite to torque converter bolt
threads before installing. Ensure the Green torque converter bolt is installed first before installing the
remaining torque converter bolts.
5. Once engine and transmission are installed, adjust all cables and fill with ATF. See appropriate
TRANSMISSION SERVICING article.
Removal (Tacoma 4WD)
1. Disconnect negative battery cable. Remove transmission oil dipstick. Disconnect throttle valve cable from
throttle body.
2. Raise and support vehicle. Remove lower engine cover. Remove fan shroud from radiator. Remove rear
console box, located between the seats. Remove screws from front console, located near transfer case and
transmission shift levers.
3. Remove front console with transfer case shift lever knob. Disconnect electrical connectors for removal of
transmission shift lever assembly. Disconnect shift linkage at transmission shift lever assembly. Remove
transmission shift lever assembly.
4. Remove snap ring and transfer case shift lever from transfer case. Remove transmission oil dipstick tube
and "O" ring. Place reference marks on drive shaft flanges for reassembly reference. Remove drive shafts.
5. Remove exhaust pipes as necessary for access to transmission and transfer case. Disconnect speedometer
cable and necessary electrical connectors for transmission and transfer case removal. Remove
transmission oil cooler pipes and brackets as necessary.
6. Remove starter and stabilizer bar. Remove torque converter cover from front of transmission. Remove
torque converter bolts. Front differential assembly rear mount must be removed for transmission removal.
Rear mount is located on front differential assembly, just behind the drive shaft flange.
7. Support front differential assembly with jack. Remove front differential assembly rear mount-to-
crossmember nut. Slightly raise front differential assembly. Remove the 2 front differential assembly rear
mount bolts.
8. Support transmission with transmission jack. Remove transmission mount-to-transmission crossmember
bolts. Remove transmission crossmember, located below transmission and transfer case. Remove
transmission-to-cylinder block bolts. Lower transmission with transfer case from vehicle.
Installation
1. Before installing transmission, use dial indicator to check drive plate runout. Drive plate runout should be
checked right next to the starter ring gear on the drive plate. Replace drive plate if runout
exceeds .0079" (.200 mm).
2. Install torque converter on transmission. To ensure torque converter is full
y seated, torque converter

1998 Toyota Avalon XLS
TRANSMISSION SERVICING - A/T 1997-98 TRANSMISSION SERVICING Toyota - Transmission Removal &
Installation

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Fig. 25: Applying Sealant To Front Camshaft Bearing Cap
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
6. Install front camshaft bearing cap for intake camshaft onto cylinder head. Install remaining camshaft
bearing caps for intake camshaft onto cylinder head in numerical sequence with arrow pointing toward
timing belt end of engine. See Fig. 21
.
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. 23
. See TORQUE SPECIFICATIONS .
8. To install exhaust camshaft, rotate intake camshaft so knock pin is 10-45 degrees from vertical position.
See Fig. 19
. Install exhaust camshaft so timing mark aligns with timing mark on intake camshaft. DO
NOT use assembly reference marks. See Fig. 26
. 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.

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
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VALVES & VALVE SPRINGS
CYLINDER HEAD
(1)Cylinder bore diameter is determined by size mark on cylinder block deck surface. See Fig. 33 .
(2)Main bearing bore I.D. is determined by main bearing bore size mark on cylinder block. See Fig. 37 .
ApplicationSpecification
Intake Valves
Face Angle44.5°
Minimum Margin.020" (.50 mm)
Minimum Refinish Length3.823" (97.10 mm)
Stem Diameter.2350-.2356" (5.970-5.985
mm)
Exhaust Valves
Face Angle44.5°
Minimum Margin.020" (.50 mm)
Minimum Refinish Length3.858" (98.00 mm)
Stem Diameter.2348-.2354" (5.965-5.980
mm)
Valve Springs
Free Length1.6520-1.6531" (41.96-41.99
mm)
Out-Of-Square Limit.079" (2.00 mm)
Lbs. @ In. (kg @ mm)
Pressure37-43 @ 1.366 (16.7-19.5 @
34.70)
ApplicationSpecification
Maximum Warpage
Cylinder Block Surface.0020" (.050 mm)
Intake & Exhaust Manifold Surface.0031" (.080 mm)
Valve Seats
Intake Valve
Seat Angle45°
Seat Width.039-.055" (1.00-1.40 mm)
Exhaust Valve
Seat Angle45°
Seat Width.039-.055" (1.00-1.40 mm)
Valve Guides
Intake Valve
Valve Guide Cylinder Head Bore I.D.
Standard Valve Guide.4325-.4335" (10.985-11.012

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
Microsoft
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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
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CYLINDER HEAD
CYLINDER HEAD
Minimum Refinish Length3.858" (98.00 mm)
Stem Diameter.2348-.2354" (5.965-5.980
mm)
Valve Springs
Free Length1.6520-1.6531" (41.96-41.99
mm)
Out-Of-Square Limit.079" (2.00 mm)
Pressure37-43 Lbs. @ 1.366 In. (16.7-
19.5 kg @ 34.70 mm)
ApplicationSpecification
Maximum Warpage
Cylinder Block Surface.0020" (.050 mm)
Intake & Exhaust Manifold Surface.0031" (.080 mm)
Valve Seats
Intake Valve
Seat Angle45°
Seat Width.039-.055" (1.00-1.40 mm)
Exhaust Valve
Seat Angle45°
Seat Width.039-.055" (1.00-1.40 mm)
Valve Guides
Intake Valve
Valve Guide Cylinder Head Bore I.D.
Standard Valve Guide.4325-.4335" (10.985-11.012
mm)
Oversize Valve Guide.4344-.4355" (11.035-11.062
mm)
Valve Guide I.D..2366-.2374" (6.010-6.030 mm)
Valve Guide Installed Height.315-.346" (8.00-8.80 mm)
Valve Stem-To-Guide Oil Clearance
Standard.0010-.0024" (.025-.060 mm)
Wear Limit.0031" (.080 mm)
Exhaust Valve
Valve Guide Cylinder Head Bore I.D.
Standard Valve Guide.4325-.4335" (10.985-11.012
mm)
Oversize Valve Guide.4344-.4355" (11.035-11.062
mm)

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
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1999 HEATER SYSTEMS
RAV4, Tacoma & 4Runner
DESCRIPTION
Major components of the heater system are a heater core, control panel, blower motor, water valve, hoses,
control cables and air ducts. 4Runner may be equipped with a dual heater system with separate controls for
front and rear. Rear temperature and blower controls are located in the console between front seats.
OPERATION
BLOWER SWITCH
Switch controls blower motor speed through blower resistor. Blower speed is adjusted by control lever, knob or
push button.
CONTROL PANEL
Temperature and mode knobs or levers are connected by cable to heater coolant valve and air doors. All models
have a fresh/recirculation lever to provide choice of outside air or recirculated inside air.
HEATER RELAY
A heater (or main) relay controls current through system. For location of heater (main) relay, see WIRING
DIAGRAMS .
ADJUSTMENTS
AIR INLET DAMPER CABLE
Set air inlet damper and control lever to fresh (recirculated on RAV4) air position. Remove cable retaining clip,
and ensure damper and cable are in full fresh (recirculated on RAV4) air position. Install control cable clip.
Check operation of air intake damper.
AIRFLOW MODE DAMPER CABLE WARNING:To avoid injury from accidental air bag deployment, read and carefully
follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR
BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY article in
GENERAL SERVICING.
CAUTION: When battery is disconnected, radio will go into anti-theft protection mode.
Obtain radio anti-theft protection code from owner prior to servicing
vehicle.

1999 Toyota RAV4
1999 HEATER SYSTEMS RAV4, Tacoma & 4Runner

1999 Toyota RAV4
1999 HEATER SYSTEMS RAV4, Tacoma & 4Runner
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case and remove blower motor. To install, reverse removal procedure. See Fig. 10 .
HEATER ASSEMBLY
Removal & Installation (All Except 4Runner Rear)
1. Remove A/C cooling unit (if equipped). See appropriate MANUAL A/C-HEATER SYSTEMS article.
Drain cooling system. Disconnect hoses from heater core. Remove grommets from hoses. Remove
instrument panel (if required).
2. Disconnect control cables from heater assembly. Remove defroster nozzle and heater duct. Remove
heater unit. See Fig. 7
, Fig. 8 or Fig. 9 . Remove screws, clamps and heater core. To reassemble and
install, reverse removal procedure.
Removal & Installation (4Runner Rear)
1. Drain cooling system. Remove front seats and center console box. Roll floor carpet back and disconnect
water hoses. Remove heater duct.
2. Disconnect control cable and remove heater control assembly. Remove heater unit. See Fig. 10
. Remove
wire harness and clamps. Separate heater case and heater core. To reassemble and install, reverse removal
procedure. NOTE: Tacoma and 4Runner may require removal of instrument panel and/or glove box
components. See INSTRUMENT PANEL
.

1999 Toyota RAV4
1999 HEATER SYSTEMS RAV4, Tacoma & 4Runner
Microsoft
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REMOVAL & INSTALLATION
See appropriate MANUAL TRANSMISSION REMOVAL article in TRANSMISSION SERVICING.
TRANSAXLE DISASSEMBLY
1. Unbolt transfer case from transaxle housing. Using a plastic hammer, remove transfer case from
transaxle. Screw appropriate bolt and washer into differential side gear intermediate shaft. Using slide
hammer type puller, remove shaft. Remove snap ring from shaft.
2. Remove clutch release fork and bearing. Remove back-up light switch. Remove speedometer adapter.
Remove speedometer driven gear or speed sensor, if equipped. Remove gear selecting bellcrank. Remove
shift and select lever lock bolt. Remove control shaft cover. Remove shift and select lever shaft assembly.
See Fig. 1
.
3. Remove case cover. Unstake output shaft lock nut. Lock transmission in 2 gears. Remove output shaft
lock nut. Unlock transmission. See Fig. 2
.
4. Remove No. 3 shift fork set bolt. Remove No. 3 hub sleeve and No. 3 shift fork. Using puller, remove 5th
driven gear. See Fig. 2
. Measure 5th gear clearances. Record for reassembly reference. Using dial
indicator, measure 5th gear thrust clearance. See Fig. 3
and Fig. 4 . Standard clearance should be .004-
.022" (.10-.57 mm). Service limit is .026" (.65 mm). Remount dial indicator to measure lateral movement
(oil clearance) of 5th gear. Standard clearance should be .0004-.002" (.009-.05 mm). Service limit
is .0028" (.070 mm).
5. Remove input shaft snap ring. Using puller, remove No. 3 clutch hub with synchronizer ring and 5th gear.
Remove needle bearing and spacer. Remove 7 Torx (T45) screws and rear bearing retainer. Remove
adjusting shim.
6. Remove input shaft rear bearing snap ring. Remove shift fork shaft snap rings. Remove plug. Remove
seat, spring and detent ball with a magnet. Remove reverse idler gear shaft retaining bolt.
7. Remove transmission housing. Remove output shaft rear bearing outer race. Remove No. 2 oil pipe.
Remove reverse shift arm bracket. Remove reverse idler gear, thrust washer and shaft. Remove all
remaining plugs, seats, springs and detent balls with magnet.
8. To remove No. 1 shift fork shaft, pull up No. 3 shift fork shaft. Using magnetic finger, remove interlock
roller. Remove No. 2 shift fork shaft, shift head and No. 1 shift fork. Pull out No. 3 shift fork shaft along
with the reverse shift fork. Remove No. 2 shift fork. Remove snap rings from shift fork shafts.
9. Remove output and input shaft assemblies. Remove oil pump drive gear. Remove differential case
assembly. Remove oil pipe and oil pump. See Fig. 1
.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
Microsoft
Sunday, November 22, 2009 10:48:07 AMPage 2 © 2005 Mitchell Repair Information Company, LLC.

REASSEMBLY
1. Assembly is reverse order of disassembly. Remove output shaft. Install oil pump drive gear. Install input
and output shaft assemblies, and shift fork assemblies as single unit. Install shift fork shaft locking balls,
springs, seats and plugs. Install reverse idler gear and shaft. Align referencing marks on idler gear and
clutch housing. Place reverse shift fork pivot into reverse shift arm, and install reverse shift arm bracket to
clutch housing. Install No. 2 oil pipe. Install NEW gasket to oil pipe. See Fig. 1
.
2. Apply Three Bond (1281) sealant to transmission housing. Install transmission housing to clutch housing.
Install reverse idler gear shaft retaining bolt. Install shift shaft locking ball, spring, seat and plug. Install
snap rings onto shift fork shafts.
3. Install output shaft rear bearing outer race. Install correct adjusting shim. Install snap ring onto input shaft
rear bearing. Install rear bearing retainer. Install spacer, needle bearing and 5th gear. Install synchro ring
and key spring to No. 3 clutch hub. Using Installer (09310-17010), install No. 3 clutch hub with
synchronizer ring and key spring. See Fig. 2
.
4. Select a snap ring that will allow minimum axial play and install snap ring onto shaft. Snap rings are
available in thicknesses of .068" (1.75 mm) to .084" (2.15 mm) in .002" (.05 mm) increments. Shims are
stamped "A"-"J". See Fig. 2
.
5. Recheck 5th gear thrust clearance. Standard clearance is .004-.022" (.10-.57 mm). Install 5th driven gear.
Install No. 3 hub sleeve and No. 3 shift fork. Lock transmission in 2 gears. Install and tighten NEW lock
nut to 90 ft. lbs. (123 N.m). Stake lock nut. Unlock transmission.
6. Apply Three Bond (1281) sealant to transmission case cover. Install cover. Install shift and select lever
shaft. Install control shaft cover. Install lock bolt. Install boot onto control shaft oil seal. Ensure boot is
installed in correct direction. Position air bleed of boot downward. Install selecting bellcrank. Install
back-up light switch and speedometer driven gear. Install side gear intermediate shaft. Distance from end
of shaft to clutch housing should be 10.06" (255.5 mm).
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS NOTE: This transmission does not use gaskets between major housings, use
Three Bond (1281) sealant. Assemble housing within 20 minutes after
applying liquid gasket. Allow 30 minutes curing time before filling with oil.
ApplicationFt. Lbs. (N.m)
Back-Up Light Switch30 (40)
Bellcrank Bolt14 (20)
Clutch Release Fork Bolt35 (47)
Differential Case Bolt46 (63)
Differential Ring Gear Bolt91 (123)
Drain & Filler Plug36 (49)
Elbow-To-Transaxle Bolt20 (27)
Oil Cooler Tube-To-Elbow Bolt25 (34)
Oil Pipe Clamp13 (17)

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
Microsoft
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