1996 TOYOTA RAV4 Service Repair Manual

S01638
Turn
Pull
S01600
Hold
Turn
S01604
Pull
Turn
S01601
TurnHold
S01652
− ENGINE MECHANICALTIMING BELT
EM−23
1996 RAV4 (RM447U)
When matchmark is misaligned clockwise:
Align the matchmark by pulling the timing belt up on the
water pump pulley side while turning the crankshaft pulley
counterclockwise.
When matchmark is misaligned clockwise:
After aligning the matchmark, hold the timing belt, turn the
crankshaft pulley clockwise, and align its groove with tim-
ing mark ”0” of the No. 1 timing belt cover.
When matchmark is misaligned counterclockwise:
Align the matchmark by pulling the timing belt up on the
No.1 idler pulley side while turning the crankshaft pulley
clockwise.
When matchmark is misaligned counterclockwise:
After aligning the matchmark, hold the timing belt, turn the
crankshaft pulley counterclockwise, and align its groove
with timing mark ”0” of the No. 1 timing belt cover.
(a) Remove any oil or water on the camshaft timing pulley,
and keep it clean.
(b) Align the matchmarks of the timing belt and camshaft tim-
ing pulley.
(c) Install the timing belt, and check the tension between the
crankshaft timing pulley and camshaft timing pulley.
12. CHECK VALVE TIMING
(a) Loosen the No. 1 idler pulley bolt 1/2 turn.

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

EM0EP−03
− ENGINE MECHANICALCYLINDER HEAD
EM−27
1996 RAV4 (RM447U)
CYLINDER HEAD
COMPONENTS

EM−28
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)

Z17352
ECM ConnectorConnector on Bracket
Engine Wire
Connector for Relay
Block No. 4
Cowl Side Trim Floor Carpet
Center Cover
Scuff Plate
− ENGINE MECHANICALCYLINDER HEAD
EM−29
1996 RAV4 (RM447U)

EM−30
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)