1996 TOYOTA RAV4 timing belt

CO0BG−02
S01613
P15462
P15546
1
3
2
P15463
Disconnect
− COOLINGWATER PUMP
CO−5
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE RH ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. REMOVE TIMING BELT (See page EM−15)
4. DISCONNECT LOWER RADIATOR HOSE FROM
WATER INLET
5. REMOVE TIMING BELT TENSION SPRING AND NO.2
IDLER PULLEY
6. REMOVE GENERATOR DRIVE BELT ADJUSTING
BAR
(a) Disconnect the crankshaft position sensor connector
clamp.
(b) Remove the bolt and adjusting bar.
7. REMOVE WATER PUMP AND WATER PUMP COVER
ASSEMBLY
(a) Remove the 2 nuts holding the water pump to the water
bypass pipe.
(b) Remove the 3 bolts in the sequence shown.
(c) Disconnect the water pump cover from the water bypass
pipe, and remove the water pump and water pump cover
assembly.
(d) Remove the gasket and 2 O−ring from the water pump
and water bypass pipe.

CO0BH−02
CO0877
− COOLINGWATER PUMP
CO−7
1996 RAV4 (RM447U)
INSPECTION
INSPECT WATER PUMP
(a) Visually check the drain hole for coolant leakage.
If leakage is found, replace the water pump.
If engine coolant has leaked onto the timing belt, replace the
timing belt.
(b) Turn the pulley, and check that the water pump bearing
moves smoothly and quietly.
If necessary, replace the water pump.

CO0BI−03
P13480
New O−Ring
New Gasket
P15547
New O−Ring
P15464
Connect
Z16489
3
1
2 CO−8
− COOLINGWATER PUMP
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL WATER PUMP TO WATER PUMP COVER
Install a new gasket and the water pump with the 3 bolts.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
2. INSTALL WATER PUMP AND WATER PUMP COVER
ASSEMBLY
(a) Install new O−ring and gasket to water pump cover.
(b) Install a new O−ring to the water bypass pipe.
(c) Apply soapy water to the O−ring on the water bypass
pipe.
(d) Connect the water pump cover to the water bypass pipe.
Do not install the nuts yet.
(e) Install the water pump with the 3 bolts. Tighten the bolts
in the sequence shown.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
(f) Install the 2 nuts holding the water pump cover to the wa-
ter bypass pipe.
Torque: 9.3 N·m (95 kgf·cm, 82 in.·lbf)
3. INSTALL GENERATOR DRIVE BELT ADJUSTING BAR
(a) Install the adjusting bar with the bolt.
Torque: 27 N·m (275 kgf·cm, 20 ft·lbf)
(b) Connect the crankshaft position sensor connector clamp.
4. INSTALL NO.2 IDLER PULLEY AND TIMING BELT
TENSION SPRING
5. CONNECT LOWER RADIATOR HOSE
6. INSTALL TIMING BELT (See page EM−20)
7. FILL WITH ENGINE COOLANT
8. START ENGINE AND CHECK FOR COOLANT LEAKS
9. INSTALL RH ENGINE UNDER COVER

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.

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.

P03518
: Seal Packing
P01655
Marking
30°
Z17351
2 1 EM−10
− ENGINE MECHANICALVALVE CLEARANCE
1996 RAV4 (RM447U)
6. REINSTALL CYLINDER HEAD COVER
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head as shown in the
illustration.
Seal packing: Part No. 08826−00080 or equivalent
(c) Install the gasket to the cylinder head cover.
(d) Install the head cover with the 4 grommets and nuts. Uni-
formly tighten the nuts in several passes.
Torque: 23 N·m (230 kgf·cm, 17 ft·lbf)
HINT:
Install the grommets so that their markings are as shown in the
illustration.
(e) Install the engine wire protector to the 2 mounting bolts of
the No. 2 timing belt cover in the sequence shown.
(f) Connect the high−tension cords to the spark plugs.
(g) Install the accelerator cable bracket with the 2 bolts.
(h) Connect the accelerator cable to the throttle body.
(i) Connect the accelerator cable to the clamp on the intake
manifold.
(j) Connect the accelerator cable to the clamp on the gener-
ator bracket.
(k) Connect the A/T throttle control cable to the throttle body.
(l) Connect the PCV hose to the air cleaner hose.
(m) Connect the PCV hose to the intake manifold.
7. CONNECT PS RESERVOIR

EM0EL−02
− ENGINE MECHANICALTIMING BELT
EM−13
1996 RAV4 (RM447U)
TIMING BELT
COMPONENTS

EM−14
− ENGINE MECHANICALTIMING BELT
1996 RAV4 (RM447U)