TOYOTA RAV4 1996 Service Repair Manual

S01560
(3)(1)
(2)
S01806
S01644
S01791
− ENGINE MECHANICALCYLINDER HEAD
EM−35
1996 RAV4 (RM447U)
17. DISCONNECT HOSES AND GROUND STRAP
(a) Disconnect the vacuum sensor hose from the gas filter on
intake manifold.
(b) Disconnect the brake booster vacuum hose from the in-
take manifold.
(c) Disconnect the ground strap from the intake manifold.
18. DISCONNECT FUEL INLET HOSE FROM FUEL FIL-
TER
Remove the union bolt and 2 gaskets, and disconnect the inlet
hose from the fuel filter.
19. REMOVE EGR VALVE AND VACUUM MODULATOR
(a) Disconnect the 2 vacuum hoses from the VSV for the
EGR.
(b) Disconnect the vacuum modulator from the clamp on the
intake manifold.
(c) Loosen the union nut of the EGR pipe, and remove the 2
nuts, the EGR valve, vacuum modulator, vacuum hoses
assembly and gasket.
20. REMOVE INTAKE MANIFOLD STAY
Remove the 2 bolts and intake manifold stay.
21. A/T only:
DISCONENCT A/T THROTTLE CONTROL CABEL
FROM INTAKE MANIFORD
Disconnect the control cable from the clamp on the rear side of
the intake manifold.
22. DISCONNECT PS IDLE−UP AIR HOSES FROM AIR
TUBE
23. DISCONNECT KNOCK SENSOR CONNECTOR
24. DISCONNECT GROUND CABLE
Remove the bolt, and disconnect the ground cable from the in-
take manifold.
25. REMOVE VSV FOR EGR (See page SF−42)
26. REMOVE CYLINDER HEAD COVER
(a) Remove the 2 bolts and accelerator cable bracket.
(b) Disconnect the PCV hose from the intake manifold.

S01653
1 2
S01646
S01647
S01645
S01432
EM−36
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
(c) Disconnect the engine wire protector from the 2 mounting
bolts of the No. 2 timing belt cover in the sequence shown.
(d) Remove the 4 nuts, grommets, head cover and gasket.
HINT:
Arrange the grommets in the correct order, so that they can be
reinstalled into their original positions. This minimizes any pos-
sibility of oil leakage due to reuse of the grommets in different
positions.
27. DISCONNECT ENGINE WIRE
(a) Remove the 2 bolts, and disconnect the engine wire pro-
tector from the LH side of the intake manifold.
(b) Disconnect the 4 injector connectors.
(c) w/ A/C:
Disconnect the A/C compressor connector.
(d) Disconnect the crankshaft position sensor connector.
(e) Disconnect the 3 clamps from the No. 2 timing bet cover
and generator drive belt adjusting bar.
(f) Disconnect the engine wire protector from the 2 brackets
on the front side of the intake manifold.
(g) Remove the RH scuff plate, RH cowl side trim and RH
floor carpet center cover.
(h) Disconnect the 2 ECM connectors.
(i) Disconnect the 2 connectors from the connectors on the
bracket.
(j) Disconnect the Connector from the J/B No. 4.
(k) Disconnect the wire clamp from the bracket.
(l) Pull out the engine wire from the cabin.
(m) Take out the engine wire between the cylinder head and
intake manifold.
28. DISCONNECT TIMING BELT FROM CAMSHAFT TIM-
ING PULLEY (See page EM−15)
29. REMOVE CAMSHAFT TIMING PULLEY (See page
EM−15)
30. REMOVE NO. 1 IDLER PULLEY AND TENSION
SPRING

S01649
S01789
S01794
10 − 45°
Knock
Pin
P03445
Service
BoltDrive Gear
Sub−Gear
− ENGINE MECHANICALCYLINDER HEAD
EM−37
1996 RAV4 (RM447U)
31. REMOVE NO. 3 TIMING BELT COVER
Remove the 3 bolts and timing belt cover.
NOTICE:
Support the timing belt, so the meshing of the crank-
shaft timing pulley and timing belt does not shift..
Be careful not to drop anything inside the timing belt
cover
Do not allow the belt to come into contact with oil, wa-
ter or dust.
32. REMOVE CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being removed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, the follow-
ing steps should be carried out.
(a) Remove the exhaust camshaft.
(1) Set the knock pin of the intake camshaft at 10 − 45°
BTDC of camshaft angle.
HINT:
The above angle allows No. 2 and No. 4 cylinder cam lobes of
the exhaust camshaft to push their valve lifters evenly.
(2) Secure the exhaust camshaft sub gear to drive gear
with a service bolt.
Recommended service bolt:
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 − 20 mm (0.63 − 0.79 in.)

S01787
S01792
1
23
4
5
6
S01788
EM−38
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
HINT:
When removing the camshaft, make sure that the torsional
spring force of the sub gear has been eliminated by the above
operation.
(3) Remove the 2 bolts and rear bearing cap.
(4) Uniformly loosen and remove the 6 bolts on the No.
1, No. 2 and No. 4 bearing caps, in several passes,
in the sequence shown.
NOTICE:
Do not remove the No. 3 bearing cap bolts at this stage.
(5) Remove the No. 1, No. 2 and No. 4 bearing caps.
(6) Alternately loosen and remove the 2 bolts on the
No. 3 bearing cap.
HINT:
As the 2 No. 3 bearing cap bolts are loosened, make sure
that the camshaft is lifted out straight and level.
If the camshaft is not being lifted out straight and level, re-
tighten the 2 No. 3 bearing cap bolts. Then do steps (f) to
(a) and reset the knock pin of the intake camshaft at 10
− 45° BTDC, and repeat steps (b) to (f) once again.
NOTICE:
Do not pry on or attempt to force the camshaft with a tool
or other object.
(7) Remove the No. 3 bearing cap and exhaust cam-
shaft.

S01777
80 − 11 5°
Knock
Pin
S01769
S01771
1 2
3 45 6
S01768
− ENGINE MECHANICALCYLINDER HEAD
EM−39
1996 RAV4 (RM447U)
(b) Remove the intake camshaft.
(1) Set the knock pin of the intake camshaft at 80 −
11 5° BTDC of camshaft angle.
HINT:
The above angle allows the No. 1 and No. 3 cylinder cam lobes
of intake camshaft to push their valve lifters evenly.
(2) Remove the 2 bolts, front bearing cap and oil seal.
(3) Uniformly loosen and remove the 6 bolts on the No.
1, No. 3 and No.4 bearing caps, in several passes,
in the sequence shown.
NOTICE:
Do not remove the No. 2 bearing cap bolts at this stage.
(4) Remove the No. 1, No. 3 and No. 4 bearing caps.
(5) Alternately loosen and remove the 2 bolts on the
No. 2 bearing cap.
HINT:
As the 2 No. 2 bearing cap bolts are loosened, make sure
that the camshaft is lifted out straight and level, after
breaking adhesion on the front bearing cap.
If the camshaft is not being lifted out straight and level, re-
tighten the 2 No. 2 bearing cap bolts. Do steps (e) to (a)
and reset the knock pin of the intake camshaft at 80 −
11 5° BTDC, and repeat steps (b) to (e) once again.
NOTICE:
Do not pry on or attempt to force the camshaft with a tool
or other object.
(6) Remove the No. 2 bearing cap and camshaft.

P05613
P05614
TurnB
A
P05615
P05616
(1)
(2)
(3) EM−40
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
33. DISASSEMBLE EXHAUST CAMSHAFT
(a) Mount the camshaft in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Insert service bolt A into the service hole of the camshaft
sub gear.
(c) Using a screwdriver, turn the sub gear clockwise, and re-
move service bolt B.
NOTICE:
Be careful not to damage the camshaft.
(d) Using snap ring pliers, remove the snap ring.
(e) Remove the wave washer (1), camshaft sub gear (2) and
camshaft gear spring (3).

S01798
2
108
5 3
4
96 7 1
S01767
S01763
S01764
− ENGINE MECHANICALCYLINDER HEAD
EM−41
1996 RAV4 (RM447U)
34. REMOVE CYLINDER HEAD AND INTAKE MANIFOLD
ASSEMBLY
(a) Uniformly loosen and remove the 10 cylinder head bolts,
in several passes, in the sequence shown.
NOTICE:
Cylinder head warpage or cracking could result from re-
moving bolts in incorrect order.
(b) Lift the cylinder head from the dowels on the cylinder
block, and place the cylinder head on wooden blocks on
a bench.
HINT:
If the cylinder head is difficult to the lift off, pry between the cylin-
der head and cylinder block with a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.
35. REMOVE AIR TUBE
(a) Disconnect the air hose from the intake manifold.
(b) Remove the 2 bolts, hose clamp and air tube.
36. REMOVE INTAKE MANIFOLD
Remove the 6 bolts, 2 nuts and intake manifold and gasket.
37. REMOVE AIR HOSE FOR AIR ASSIST SYSTEM
Disconnect the air hose from the cylinder head port, and re-
move the air hose.
38. REMOVE DELIVERY PIPE AND INJECTORS (See
page SF−19)

S01795
Oil Pressure
Switch EM−42
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
39. REMOVE OIL PRESSURE SWITCH

EM0ER−01
P03264
P03265
− ENGINE MECHANICALCYLINDER HEAD
EM−43
1996 RAV4 (RM447U)
DISASSEMBLY
1. REMOVE VALVE LIFTERS AND SHIMS
2. REMOVE VALVES
(a) Using SST, compress the valve spring and remove the 2
keepers.
SST 09202−70020 (09202−00010)
(b) Remove the spring retainer, valve spring, valve and
spring seat.
(c) Using needle−nose pliers, remove the oil seal.

EM1Q0−01
P15443
P15444
P03267
P03268
P03149
EM−44
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
INSPECTION
1. CLE AN TO P SURFACE S OF PIS TO NS AND CY L-
INDER BLOCK
(a) Turn the crankshaft, and bring each piston to top dead
center (TDC). Using a gasket scraper, remove all the car-
bon from the piston top surface.
(b) Using a gasket scraper, remove all the gasket material
from the cylinder block surface.
(c) Using compressed air, blow carbon and oil from the bolt
holes.
CAUTION:
Protect your eyes when using high−pressure compressed
air.
2. CLEAN CYLINDER HEAD
(a) Using a gasket scraper, remove all the gasket material
from the cylinder block contact surface.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
(b) Using a wire brush, remove all the carbon from the com-
bustion chamber.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
(c) Using a valve guide bushing brush and solvent, clean all
the guide bushings.