1996 TOYOTA RAV4 cam belt

P25455
Turn
P03443
1
1
2
2
1
13
3
P03442
2 233 44
44
P13927
Upward
Cam Lobe
Spark Plug SideNotch EM−6
− ENGINE MECHANICALVALVE CLEARANCE
1996 RAV4 (RM447U)
3. 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) Check that the valve lifters on the No.1 cylinder are loose
and valve lifters on the No.4 are tight.
If not, turn the crankshaft 1 revolution (360°) and align the mark
as above.
4. INSPECT VALVE CLEARANCE
(a) Check only the valves indicated.
Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
Record the out−of−specification valve clearance
measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake0.19 − 0.29 mm (0.007 − 0.011 in.)
Exhaust0.28 − 0.38 mm (0.011 − 0.015 in.)
(b) Turn the crankshaft 1 revolution (360°) and align the mark
as above (See procedure in step 3).
(c) Check only the valves indicated as shown. Measure the
valve clearance (See procedure in step (a)).
5. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.
Turn the crankshaft so that the cam lobe of the cam-
shaft on the adjusting valve points upward.
Position the notch of the valve lifter facing the spark
plug side.

S01655
SST
S01284
SST
S01624
S01597
S01651
EM−16
− ENGINE MECHANICALTIMING BELT
1996 RAV4 (RM447U)
(b) Using SST, remove the pulley.
SST 09950−50010 (09951−05010, 09952−05010,
09953−05010, 09953−05020,
09954−05020 for type A,
09954−05010 for type B)
13. REMOVE RH ENGINE MOUNTING BRACKET
Using SST, remove the 3 bolts and mounting bracket.
SST 09249−63010
14. REMOVE NO. 2 TIMING BELT COVER
(a) Disconnect the engine wire from the timing belt cover.
(b) Remove the 4 bolts and timing belt cover.
15. 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.
16. 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) Check that the hole of the camshaft timing pulley is
aligned with the timing mark of the bearing cap.
If not, turn the crankshaft 1 revolution (360°).
17. REMOVE TIMING BELT FROM CAMSHAFT TIMING
PULLEY
HINT:
When re−using timing belt:
Place matchmarks on the timing belt and camshaft timing
pulley, and place matchmark on timing belt to match the end of
the No. 1 timing belt cover.

S01650
S01656
SST
SST
S01620
P25458
S01614
SST
− ENGINE MECHANICALTIMING BELT
EM−17
1996 RAV4 (RM447U)
(a) Loosen the mounting bolt of the No. 1 idler pulley and shift
the pulley toward the left as far as it will go, and temporari-
ly tighten it.
(b) Remove the timing belt from the camshaft timing pulley.
18. REMOVE CAMSHAFT TIMING PULLEY
Using SST, remove the pulley bolt and timing pulley.
SST 09249−63010, 09960−10010 (09962−01000,
09963−01000)
19. REMOVE CRANKSHAFT PULLEY
HINT:
When re−using timing belt:
Remove the pulley without turning it.
20. REMOVE NO. 1 TIMING BELT COVER
(a) Disconnect the engine wire from the timing belt cover.
(b) Remove the 4 bolts and timing belt cover.
21. REMOVE TIMING BELT GUIDE
22. REMOVE TIMING BELT
HINT:
(When re−using timing belt): Draw a direction arrow on the tim-
ing belt (in the direction of engine revolution), and place match-
marks on the timing belt and crankshaft timing pulley.
23. REMOVE NO. 1 IDLER PULLEY AND TENSION
SPRING
24. REMOVE NO. 2 IDLER PULLEY
25. REMOVE CRANKSHAFT TIMING PULLEY
If the pulley cannot be removed by hand, use SST to remove
the timing pulley.
SST 09950−50010 (09951−05010, 09952−05010,
09953−05010, 09953−05020, 09954−05010)
NOTICE:
Do not scratch the angle sensor of the timing pulley.

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.

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:

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.

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.)