TOYOTA RAV4 1996 Service Repair Manual

P03363
Z02749
Cylinder Block Side
Intake Manifold Side
Exhaust Manifold Side
P03269
EM0580
− ENGINE MECHANICALCYLINDER HEAD
EM−45
1996 RAV4 (RM447U)
(d) Using a soft brush and solvent, thoroughly clean the cylin-
der head.
3. INSPECT CYLINDER HEAD
(a) Inspect for flatness.
Using a precision straight edge and feeler gauge, mea-
sure the surfaces contacting the cylinder block and the
manifolds for warpage.
Maximum warpage:
Cylinder block side0.05 mm (0.0020 in.)
Manifold side0.08 mm (0.0031 in.)
If warpage is greater than maximum, replace the cylinder head.
(b) Inspect for cracks.
Using a dye penetrant, check the combustion chamber,
intake ports, exhaust ports and cylinder block surface for
cracks.
If cracked, replace the cylinder head.
4. CLEAN VALVES
(a) Using a gasket scraper, chip off any carbon from the valve
head.
(b) Using a wire brush, thoroughly clean the valve.

Z00051
Z00052
Z00054
44.5°
EM0181
Margin Thickness EM−46
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
5. INSPECT VALVE STEMS AND GUIDE BUSHINGS
(a) Using a caliper gauge, measure the inside diameter of the
guide bushing.
Bushing inside diameter:
6.010 − 6.030 mm (0.2366 − 0.2374 in.)
(b) Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
Intake5.970 − 5.985 mm (0.2350 − 0.2356 in.)
Exhaust5.965 − 5.980 mm (0.2348 − 0.2354 in.)
(c) Subtract the valve stem diameter measurement from the
guide bushing inside diameter measurement.
Standard oil clearance:
Intake0.025 − 0.060 mm (0.0010 − 0.0024 in.)
Exhaust0.030 − 0.065 mm (0.0012 − 0.0026 in.)
Maximum oil clearance:
Intake0.08 mm (0.0031 in.)
Exhaust0.10 mm (0.0039 in.)
If the clearance is greater than maximum, replace the valve and
guide bushing (See page EM−52).
6. INSPECT AND GRIND VALVES
(a) Grind the valve enough to remove pits and carbon.
(b) Check that the valve is ground to the correct valve face
angle.
Valve face angle: 44.5°
(c) Check the valve head margin thickness.
Standard margin thickness:
0.8 − 1.2 mm (0.031 − 0.047 in.)
Minimum margin thickness: 0.5 mm (0.020 in.)
If the margin thickness is less than minimum, replace the valve.

EM2534
Overall Length
EM0255
EM3300
45° Carbide
Cutter
Z00055
Width
− ENGINE MECHANICALCYLINDER HEAD
EM−47
1996 RAV4 (RM447U)
(d) Check the valve overall length.
Standard overall length:
Intake97.60 mm (3.8425 in.)
Exhaust98.45 mm (3.8760 in.)
Minimum overall length:
Intake97.1 mm (3.823 in.)
Exhaust98.0 mm (3.858 in.)
If the overall length is less than minimum, replace the valve.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip with a grinder or
replace the valve.
NOTICE:
Do not grind off more than the minimum length.
7. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(b) Check the valve seating position.
Apply a light coat of prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate valve.
(c) Check the valve face and seat for the following:
If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.
If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
Check that the seat contact is in the middle of the
valve face with the following width:
1.0 − 1.4 mm (0.039 − 0.055 in.)

Z02852
45°
30°
1.0 − 1.4 mm
Z06188
75°
45°
1.0 − 1.4 mm
P03273
EM0988
Deviation
EM0801
EM−48
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
If not, correct the valve seats as follows:
(1) If the seating is too high on the valve face, use 30°
and 45° cutters to correct the seat.
(2) If the seating is too low on the valve face, use 75°
and 45° cutters to correct the seat.
(d) Hand−lap the valve and valve seat with an abrasive com-
pound.
(e) After hand−lapping, clean the valve and valve seat.
8. INSPECT VALVE SPRINGS
(a) Using a steel square, measure the deviation of the valve
spring.
Maximum deviation: 2.0 mm (0.079 in.)
If the deviation is greater than maximum, replace the valve
spring.
(b) Using a vernier caliper, measure the free length of the
valve spring.
Free length: 41.96 − 41.99 mm (1.6520 − 1.6531 in.)
If the free length is not as specified, replace the valve spring.

EM0281
EM1628
EM2011
EM2538
EM3322
Free Distance
− ENGINE MECHANICALCYLINDER HEAD
EM−49
1996 RAV4 (RM447U)
(c) Using a spring tester, measure the tension of the valve
spring at the specified installed length.
Installed tension:
164 − 189 N (16.7 − 19.3 kgf, 36.8 − 42.5 lbf)
at 34.7 mm (1.366 in.)
If the installed tension is not as specified, replace the valve
spring.
9. INSPECT CAMSHAFTS
(a) Inspect the circle runout.
(1) Place the camshaft on V−blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.04 mm (0.0016 in.)
If the circle runout is greater than maximum, replace the cam-
shaft.
(b) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake42.01 − 42.11 mm (1.6539 − 1.6579 in.)
Exhaust40.06 − 40.16 mm (1.5772 − 1.5811 in.)
Minimum cam lobe height:
Intake41.90 mm (1.6496 in.)
Exhaust39.95 mm (1.5728 in.)
If the cam lobe height is less than minimum, replace the cam-
shaft.
(c) Using a micrometer, measure the journal diameter.
Journal diameter:
26.959 − 26.975 mm (1.0614 − 1.0620 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
(d) Using vernier calipers, measure the free distance be-
tween the gear spring ends.
Free distance: 22.5 − 22.9 mm (0.886 − 0.902 in.)
If the free distance is not as specified, replace the gear spring.

EM3371
Plastigage
EM3310
P00263
EM−50
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
(e) Inspect the journal oil clearance.
(1) Clean the bearing caps and camshaft journals.
(2) Check that bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps and cyl-
inder head as a set.
(3) Place the camshafts on the cylinder head.
(4) Lay a strip of Plastigage across each of the cam-
shaft journals.
(5) Install the bearing caps (See page EM−55).
NOTICE:
Do not turn the camshaft.
(6) Remove the bearing caps.
(7) Measure the Plastigage at its widest point.
Standard oil clearance:
0.025 − 0.062 mm (0.0010 − 0.0024 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the cam-
shaft. If necessary, replace the bearing caps and cylinder head
as a set.
(8) Completely remove the Plastigage.
(f) Inspect the camshaft thrust clearance.
(1) Install the camshaft (See page EM−55).
(2) Using a dial indicator, measure the thrust clearance
while moving the camshaft back and forth.
Standard thrust clearance:
Intake0.045 − 0.100 mm (0.0018 − 0.0039 in.)
Exhaust0.030 − 0.085 mm (0.0012 − 0.0033 in.)
Maximum thrust clearance:
Intake0.12 mm (0.0047 in.)
Exhaust0.10 mm (0.0039 in.)
If the thrust clearance is greater than maximum, replace the
camshaft. If necessary, replace the bearing caps and cylinder
head as a set.

EM3308
EM3372
EM2196
Z03030
Z03031
Exhaust
− ENGINE MECHANICALCYLINDER HEAD
EM−51
1996 RAV4 (RM447U)
(g) Inspect the camshaft gear backlash.
(1) Install the camshafts without installing the exhaust
cam sub−gear (See page EM−55).
(2) Using a dial indicator, measure the backlash.
Standard backlash:
0.020 − 0.200 mm (0.0008 − 0.0079 in.)
Maximum backlash: 0.30 mm (0.0188 in.)
If the backlash is greater then maximum, replace the cam-
shafts.
10. INSPECT VALVE LIFTERS AND LIFTER BORES
(a) Using a caliper gauge, measure the lifter bore diameter
of the cylinder head.
Lifter bore diameter:
31.000 − 31.018 mm (1.2205 − 1.2212 in.)
(b) Using a micrometer, measure the lifter diameter.
Lifter diameter:
30.966 − 30.976 mm (1.2191 − 1.2195 in.)
(c) Subtract the lifter diameter measurement from the lifter
bore diameter measurement.
Standard oil clearance:
0.024 − 0.052 mm (0.0009 − 0.0020 in.)
Maximum oil clearance: 0.07 mm (0.0028 in.)
If the oil clearance is greater than maximum, replace the lifter.
If necessary, replace the cylinder head.
11. INSPECT INTAKE MANIFOLD
Using a precision straight edge and feeler gauge, measure the
surface contacting the cylinder head for warpage.
Maximum warpage: 0.30 mm (0.0118 in.)
If warpage is greater than maximum, replace the manifold.
12. INSPECT EXHAUST MANIFOLD
Using a precision straight edge and feeler gauge, measure the
surface contacting the cylinder head for warpage.
Maximum warpage: 0.30 mm (0.0118 in.)
If warpage is greater than maximum, replace the manifold.

EM1Q1−01
P13987
SST
SST
P03365
Both intake and exhaust
Bushing bore diameter
mm (in.)Bushing size
10.985 − 11.012
(0.4325 − 0.4335)Use STD
11.035 − 11.062
(0.4344 − 0.4355)Use O/S 0.05
P03156
Intake Exhaust
38.5 mm
(1.516 in.)40.5 mm
(1.594 in.)
S02337
SST
SST8.0 − 8.8
mm
8.0 − 8.8
mm Intake
Exhaust
EM−52
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
REPLACEMENT
REPLACE VALVE GUIDE BUSHINGS
(a) Gradually heat the cylinder head to 80 − 100°C (176 −
212°F).
(b) Using SST and a hammer, tap out the guide bushing.
SST 09201−10000 (09201−01060), 09950−70010
(09951−07100)
(c) Using a caliper gauge, measure the bushing bore diame-
ter of the cylinder head.
(d) Select a new guide bushing (STD or O/S 0.05).
If the bushing bore diameter of the cylinder head is greater than
11.012 mm (0.4335 in.), machine the bushing bore to the follow-
ing dimension:
11.035 − 11.062 mm (0.4344 − 0.4355 in.)
If the bushing bore diameter of the cylinder head is greater than
11.062 mm (0.4355 in.), replace the cylinder head.
HINT:
Different the bushings are used for the intake and exhaust.
(e) Gradually heat the cylinder head to 80 − 100°C (176 −
212°F).
(f) Using SST and a hammer, tap in a new guide bushing un-
til there is 8.0 − 8.8 mm (0.315 − 0.346 in.) protruding from
the cylinder head.
SST 09201−10000 (09201−01060), 09950−70010
(09951−07100)

P03367
Sharp 6 mm
Reamer
− ENGINE MECHANICALCYLINDER HEAD
EM−53
1996 RAV4 (RM447U)
(g) Using a sharp 6 mm reamer, ream the guide bushing to
obtain the standard specified clearance (See page
EM−44) between the guide bushing and valve stem.

EM0ET−02
P03274
SST
Z00573
SSTIntake
Painted
BlackExhaust
Painted
Brown
P03265
SST
P03276
EM−54
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
REASSEMBLY
HINT:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all slid-
ing and rotating surfaces.
Replace all gaskets and oil seals with new ones.
1. INSTALL VALVES
(a) Using SST, push in a new oil seal.
SST 09201−41020
HINT:
The intake valve oil seal is brown and the exhaust valve oil seal
is black.
(b) Install the valve, spring seat, valve spring and spring re-
tainer.
(c) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202−70020 (09202−00010)
(d) Using a plastic−faced hammer, lightly tap the valve stem
tip to assure proper fit.
2. INSTALL VALVE LIFTERS AND SHIMS
(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.