1996 TOYOTA RAV4 torque

EM0EO−03
S01634
SST
S01637
Inward
Sensor
S01625
35 mm
S01654
42 mm
S01657
Pry
Move EM−20
− ENGINE MECHANICALTIMING BELT
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL OIL PUMP PULLEY
(a) Align the cutouts of the pulley and shaft, and slide on the
pulley.
(b) Using SST, install the nut.
SST 09960−10010 (09962−01000, 09963−00600)
Torque: 24 N·m (245 kgf·cm, 18 ft·lbf)
2. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the timing pulley set key with the key groove of the
pulley.
(b) Install the timing pulley, facing the sensor side inward.
NOTICE:
Do not scratch the sensor part of the crankshaft timing
pulley.
3. INSTALL NO. 2 IDLER PULLEY
(a) Install the pulley with the bolt.
Torque: 42 N·m (425 kgf·cm, 31 ft·lbf)
HINT:
Use a bolt 35 mm (1.38 in.) in length.
(b) Check that the idler pulley moves smoothly.
4. TEMPORARILY INSTALL NO. 1 IDLER PULLEY AND
TENSION SPRING
(a) Align the bracket pin hole with the pivot pin.
(b) Install the pulley with the bolt. Do not tighten the bolt yet.
HINT:
Use a bolt 42 mm (1.65 in.) in length.
(c) Install the tension spring.
(d) Pry the pulley toward the left as far as it will go and tighten
the bolt.
(e) Check that the idler pulley moves smoothly.

S01627
SST
Fulcrum
Length SST
S01628
SST
S01598
EM−22
− ENGINE MECHANICALTIMING BELT
1996 RAV4 (RM447U)
8. TEMPORARILY INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley,
and slide on the pulley.
(b) Temporarily install the pulley bolt.
9. INSTALL CAMSHAFT TIMING PULLEY
(a) Align the camshaft knock pin with the knock pin groove of
the pulley, and slide on the timing pulley.
(b) Using SST, install the bolt.
SST 09249−63010, 09960−10010 (09962−01000,
09963−01000)
Torque:
54 N·m (550 kgf·cm, 40 ft·lbf)
37 N·m (380 kgf·cm, 27 ft·lbf) for SST
HINT:
Use a torque wrench with a fulcrum length of 340 cm (13.39 in.).
10. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with timing
mark ”0” of the No. 1 timing belt cover.
(b) Using SST, turn the camshaft, and align the hole of the
camshaft timing pulley with the timing mark of the bearing
cap.
SST 09960−10010 (09962−01000, 09963−01000)
11. INSTALL TIMING BELT
HINT:
When re−using timing belt:
Check that the matchmark on the timing belt matches the end
of the No. 1 timing belt cover. If the matchmark does not align,
align as follows:

S01602
Turn
S01597
S01603
Turn
S01238
P25229
Length = 735 mm (28.94 in.)
Length = 230 mm (9.06 in.) EM−24
− ENGINE MECHANICALTIMING BELT
1996 RAV4 (RM447U)
(b) Slowly turn the crankshaft pulley 2 revolutions from TDC
to TDC.
NOTICE:
Always turn the crankshaft clockwise.
(c) Check that each pulley aligns with the timing marks as
shown in the illustration.
If the timing marks do not align, remove the timing belt and rein-
stall it.
(d) Slowly turn the crankshaft pulley 1 and 7/8 revolutions,
and align its groove with the mark at 45 ° BTDC (for No.
1 cylinder) of the No.1 timing belt cover.
NOTICE:
Always turn the crankshaft clockwise.
(e) Torque the mounting bolt of the No.1 idler pulley.
Torque: 42 N·m (425 kgf·cm, 31 ft·lbf)
13. PLACE RH ENGINE MOUNTING BRACKET IN POSI-
TION
HINT:
Do not install the bolts.
14. INSTALL NO. 2 TIMING BELT COVER
(a) Check that the timing belt cover gaskets has no cracks or
peeling, etc.
If the gasket has cracks or peeling, etc., replace it using these
steps:
Using a screwdriver and gasket scraper, remove all
the old gasket material.
Thoroughly clean all components to remove all the
loose material.

S01626
Disconnect
P15391
S01284
SST
S01629
SSTSST
− ENGINE MECHANICALTIMING BELT
EM−25
1996 RAV4 (RM447U)
Remove the backing paper from a new gasket and
install the gasket evenly to the part of the timing belt
cover shaded black in the illustration.
After installing the gasket, press down on it so that
the adhesive firmly sticks to the timing belt cover.
(b) Disconnect the engine wire protector between the cylin-
der head cover and No. 3 timing belt cover.
(c) Install the No. 2 timing belt cover with the 4 bolts.
(d) Install the engine wire to the No. 2 timing belt cover.
(e) Install the engine wire protector to the 2 mounting bolts of
the No. 2 timing belt cover in the sequence shown.
15. REMOVE CRANKSHAFT PULLEY
16. INSTALL RH ENGINE MOUNTING BRACKET
Using SST, install the mounting bracket with the 3 bolts.
SST 09249−63010
Torque:
52 N·m (530 kgf·cm, 38 ft·lbf)
35 N·m (360 kgf·cm, 26 ft·lbf) for SST
HINT:
Use a torque wrench with a fulcrum length of 340 mm (13.39 in)
17. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley,
and slide on the pulley.
(b) Using SST (and bolt), install the pulley bolt.
SST 09213−54015 (91651−60855 for type A),
09330−00021
Bolt: Part No. 91121−40665 for type B
Torque: 108 N·m (1,100 kgf·cm, 80 ft·lbf)
18. INSTALL SPARK PLUGS

S01352
Ground Strap EM−26
− ENGINE MECHANICALTIMING BELT
1996 RAV4 (RM447U)
19. INSTALL RH ENGINE MOUNTING INSULATOR
(a) Attach the mounting insulator to the body and mounting
bracket with the 4 bolts and 2 nuts.
(b) Tighten the 3 bolts holding the mounting insulator to the
body.
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
(c) Tighten the 2 nuts and bolt holding the mounting insulator
to the mounting bracket.
Torque:
37 N·m (380 kgf·cm, 27 ft·lbf) for bolt
52 N·m (530 kgf·cm, 38 ft·lbf) for nut
20. INSTALL AND ADJUST PS PUMP DRIVE BELT
21. INSTALL RH ENGINE UNDER COVER
22. INSTALL RH FRONT WHEEL
23. w/ ABS:
INSTALL NO. 3 ABS ACTUATOR BRACKET (See page
BR−41)
24. INSTALL GENERATOR BRACKET
(a) Install the bracket with the 3 bolts.
Torque: 42 N·m (425 kgf·cm, 31 ft·lbf)
(b) Connect the ground strap connector.
25. INSTALL GENERATOR (See page CH−19)
26. INSTALL WIRE HARNESS BRACKET FOR DLC1
27. INSTALL PS RESERVOIR BRACKET AND RES-
ERVOIR

EM1B9−02
P13638
Adhesive
S01764
S01763
S01648
− ENGINE MECHANICALCYLINDER HEAD
EM−55
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL OIL PRESSURE SWITCH
(a) Apply adhesive to 2 or 3 threads.
Adhesive:
Part No. 08833−00080, THREE BOND 1344 or equiva-
lent
(b) Install the oil pressure switch.
2. INSTALL INJECTORS AND DELIVERY PIPE (See page
SF−23)
3. INSTALL AIR HOSE FOR AIR ASSIST SYSTEM
Connect the air hose to the cylinder head port.
4. INSTALL INTAKE MANIFOLD
Install a new gasket and the intake manifold with the 6 bolts and
2 nuts. Uniformly tighten the bolts and nuts in several passes.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
5. INSTALL AIR TUBE
(a) Install the air tube and hose clamp with the 2 bolts.
(b) Connect the air hose to the intake manifold.
6. INSTALL CYLINDER HEAD AND INTAKE MANIFOLD
ASSEMBLY
(a) Place the cylinder head on the cylinder block.
(1) Place a new cylinder head gasket in position on the
cylinder block.
NOTICE:
Be careful of the installation direction.
(2) Place the cylinder head in position on the cylinder
head gasket.

S01799
1086 1 3 9
4257
S01796
90°
90°Painted Mark
S01786
Z00058
(3)
(2)
(1) EM−56
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
(b) Install the cylinder head bolts.
HINT:
The cylinder head bolts are tightened in 2 progressive
steps (steps (b) and (d)).
If any cylinder head bolt is broken or deformed, replace
it.
(1) Apply a light coat of engine oil on the threads and
under the heads of the cylinder head bolts.
(2) Install and uniformly tighten the 10 cylinder head
bolts and plate washers, in several passes, in the
sequence shown.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
If any one of the cylinder head bolts does not meet the torque
specification, replace the cylinder head bolt.
(3) Mark the front of the cylinder head bolt head with
paint.
(4) Retighten the cylinder head bolts 90° in the se-
quence shown above.
(5) Check that the painted mark is now at a 90° angle
to front.
7. INSTALL SPARK PLUG TUBES
(a) Clean the cylinder head tube holes of any residual adhe-
sive, oil or foreign particles. Remove any oil with kerosene
or gasoline.
(b) Screw the threads of the spark plug tube coated with
adhesive into the cylinder head.
(c) Using the spark plug tube nut and a 30 mm socket
wrench, tighten the spark plug tubes.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
8. ASSEMBLE EXHAUST CAMSHAFT
(a) Mount the hexagon wrench head portion of the camshaft
in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Install the camshaft gear spring (1), camshaft sub gear (2)
and wave washer (3).
HINT:
Align the pins on the gears with the spring ends.

S01770
S01772
9
10 3
45
61
27
8
S01776
10 − 45°
Knock
Pin
S01773
Assembly
Timing Reference
Mark
Mark EM−58
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
(6) Install the bearing caps in their proper locations.
(7) Apply a light coat of engine oil on the threads and
under the heads of the bearing cap bolts.
(8) Install and uniformly tighten the 10 bearing cap
bolts, in several passes, in the sequence shown.
Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)
(b) Install the exhaust camshaft.
(1) Set the knock pin of the intake camshaft at 10 − 45°
BTDC of camshaft angle.
HINT:
The above angle allows the No. 2 and No. 4 cylinder cam lobes
of the exhaust camshaft to push their valve lifters evenly.
(2) Apply MP grease to the thrust portion of the cam-
shaft.
(3) Engage the exhaust camshaft gear to the intake
camshaft gear by matching the timing marks on
each gear.
(4) Roll down the exhaust camshaft onto the bearing
journals while engaging gears with each other.
NOTICE:
There are also assembly reference marks on each gear as
shown in the illustration. Do not use these marks.
(5) Turn the intake camshaft clockwise or counterclock-
wise a little until the exhaust camshaft sits in the
bearing journals evenly without rocking the cam-
shaft on the bearing journals.
NOTICE:
It is very important to replace the camshaft in the bearing
journals evenly while tightening bearing caps in the subse-
quent steps.