1996 TOYOTA RAV4 oil

EM0EI−02
S01653
21
S01367
− ENGINE MECHANICALVALVE CLEARANCE
EM−5
1996 RAV4 (RM447U)
VALVE CLEARANCE
INSPECTION
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1. DISCONNECT PS RESERVOIR
2. REMOVE CYLINDER HEAD COVER
(a) Disconnect the accelerator cable from the throttle body.
(b) Disconnect the accelerator cable from the clamp on the
intake manifold.
(c) Disconnect the accelerator cable from the clamp on the
generator bracket.
(d) Disconnect the A/T throttle control cable from the throttle
body.
(e) Disconnect the PCV hose from the air cleaner hose.
(f) Disconnect the PCV hose from the intake manifold.
(g) Disconnect the high−tension cords from the spark plugs.
(h) Remove the 2 bolts, and disconnect the accelerator cable
bracket from the intake manifold.
(i) Disconnect the engine wire protector from the 2 mounting
bolts of the No. 2 timing belt cover in the sequence shown.
(j) Remove the 4 nuts, grommets, cylinder 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.

EM0EM−03
S01283
B
SST
A
S01358
Oil Pump
S01630
SST
SST
− ENGINE MECHANICALTIMING BELT
EM−15
1996 RAV4 (RM447U)
REMOVAL
1. DISCONNECT PS RESERVOIR AND REMOVE RES-
ERVOIR BRACKET
2. DISCONNECT WIRE HARNESS BRACKET FOR DLC1
3. REMOVE GENERATOR (See page CH−7)
4. REMOVE GENERATOR BRACKET
5. w/ ABS:
REMOVE NO. 3 ABS ACTUATOR BRACKET (See page
BR−40)
6. REMOVE RH FRONT WHEEL
7. REMOVE RH ENGINE UNDER COVER
8. REMOVE PS PUMP DRIVE BELT
(a) Loosen the bolt A.
(b) Using SST and a deep socket wrench, loosen the bolt B.
SST SST09249−63010
(c) Remove the drive belt.
9. SLIGHTLY JACK UP ENGINE
Attach the jack to the oil pan, and raise the engine enough to
remove the weight from the engine mounting on the right side.
10. REMOVE RH ENGINE MOUNTING INSULATOR
11. REMOVE SPARK PLUGS
12. REMOVE CRANKSHAFT PULLEY
(a) Using SST (and bolt), remove the pulley bolt.
SST 09213−54015 (91651−60855 for type A),
09330−00021
Bolt: Part No. 91121−40665 for type B
HINT:
Either of 2 types of pulley may be used, each with its own
bolt size, type A and type B.
When using bolt type B, a plate washer must be inserted
between the bolt and SST.

S01636
SST EM−18
− ENGINE MECHANICALTIMING BELT
1996 RAV4 (RM447U)
26. REMOVE OIL PUMP PULLEY
Using SST, remove the nut and pulley.
SST 09960−10010 (09962−01000, 09963−00600)

EM0EN−02
EM3336
No!
EM3295
P15243Free Length
− ENGINE MECHANICALTIMING BELT
EM−19
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT TIMING BELT
NOTICE:
Do not bend, twist or turn the timing belt inside out.
Do not allow the timing belt to come into contact with
oil, water or steam.
Do not utilize timing belt tension when installing or re-
moving the mounting bolt of the camshaft timing
pulley.
If there are any defects as shown in the illustration, check these
points:
(a) Premature parting
Check for proper installation.
Check the timing cover gasket for damage and
proper installation.
(b) If the belt teeth are cracked or damaged, check to see if
either camshaft or water pump is locked.
(c) If there is noticeable wear or cracks on the belt face,
check to see if there are nicks on the side of the idler
pulley lock.
(d) If there is wear or damage on only one side of the belt,
check the belt guide and the alignment of each pulley.
(e) If there is noticeable wear on the belt teeth, check the tim-
ing cover for damage, correct gasket installation, and for
foreign material on the pulley teeth.
If necessary, replace the timing belt.
2. INSPECT IDLER PULLEYS
Check that the idler pulley turns smoothly.
If necessary, replace the idler pulley.
3. INSPECT TENSION SPRING
(a) Measure the free length of tension spring.
Free length: 46.0 mm (1.811 in.)
If the free length is not as specified, replace the tension spring.
(b) Measure the tension of the tension spring at the specified
installed length.
Installed tension (at 50.5 mm (1.988 in.)):
22 − 27 N (2.25 − 2.75 kgf, 5.0 − 6.1 lbf)
If the installed tension is not as specified, replace the tension
spring.

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.

S01621
S01623
S01622
S07327Length = 660 mm (25.98 in.)
− ENGINE MECHANICALTIMING BELT
EM−21
1996 RAV4 (RM447U)
5. TEMPORARILY INSTALL TIMING BELT
NOTICE:
The engine should be cold.
(a) Using the crankshaft pulley bolt, turn the crankshaft and
position the key groove of the crankshaft timing pulley up-
ward.
(b) Remove any oil or water on the crankshaft pulley, oil
pump pulley, water pump pulley, No. 1 idler pulley and No.
2 idler pulley, and keep them clean.
(c) Install the timing belt on the crankshaft timing pulley, oil
pump pulley, No. 1 idler pulley, water pump pulley and No.
2 idler pulley.
HINT:
When re−using timing belt:
Align the points marked during removal, and install the belt with
the arrow pointing in the direction of engine revolution.
6. INSTALL TIMING BELT GUIDE
Install the guide, facing the cup side outward.
7. INSTALL NO. 1 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.
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) Install the timing belt cover with the 4 bolts.
(c) Install the engine wire to the timing belt cover.

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.

S01823
Oxygen Sensor
(Bank 1 Sensor 1)
Oxygen Sensor (Bank 1 Sensor 2)
P03152
S01368
S01365
S01594
EM−34
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
10. REMOVE OXYGEN SENSOR (BANK 1 SENSOR 1)
FROM EXHAUST MANIFOLD
11. REMOVE OXYGEN SENSOR (BANK 1 SENSOR 2)
FROM FRONT TWC
12. SEPARATE EXHAUST MANIFORD AND FRON TWC
(a) Remove the 5 bolts and lower manifold heat insulator.
(b) Remove the 8 bolts and 2 TWC heat insulators.
(c) Remove the 3 bolts, 2 nuts, TWC, gasket retainer and
cushion.
13. DISCONNECT OIL PRESSURE SWITCH CONNECTOR
14. REMOVE WATER OUTLET
(a) Disconnect the ECT sensor connector.
(b) Disconnect the ECT sender gauge connector.
(c) Disconnect the radiator hose from the water outlet.
(d) Disconnect the water bypass pipe hose from the water
outlet.
(e) Disconnect the heater water hose from the water outlet.
(f) Remove the 2 nuts, water outlet and gasket.
15. REMOVE WATER BYPASS PIPE
(a) Remove the bolt, 2 nuts and oil cooler heat protector.
(b) Disconnect the IAC valve water bypass hose from the wa-
ter bypass pipe.
(c) Disconnect the heater water hose from the water bypass
pipe.
(d) Disconnect the 2 oil cooler water bypass hoses from the
oil cooler.
(e) Remove the nut and disconnect the wire protector.
(f) Remove the 2 bolts and 2 nuts.
(g) Disconnect the water bypass pipe from the water pump
cover, and remove the water bypass pipe.
(h) Remove the gasket and O−ring.
16. REMOVE THROTTLE BODY (See page SF−30)