TOYOTA RAV4 1996 Service Repair Manual

P13414
EM3553
− ENGINE MECHANICALCYLINDER BLOCK
EM−95
1996 RAV4 (RM447U)
5. INSPECT CRANKSHAFT
(a) Inspect for circle runout.
(1) Place the crankshaft on V−blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
(b) Inspect the main journals and crank pins.
(1) Using a micrometer, measure the diameter of each
main journal and crank pin.
Main journal diameter:
STD54.988 − 55.003 mm (2.1653 − 2.1655 in.)
U/S 0.2554.745 − 54.755 mm (2.1553 − 2.1557 in.)
Crank pin diameter:
STD51.985 − 52.000 mm (2.0466 − 2.0472 in.)
U/S 0.2551.745 − 51.755 mm (2.0372 − 2.0376 in.)
If the diameter is not as specified, check the oil clearance (See
page EM−81). If necessary, grind or replace the crankshaft.
(2) Check each main journal and crank pin for taper
and out−of−round as shown.
Maximum taper and out−of−round:
0.02 mm (0.0008 in.)
If the taper and out−of−round is greater than maximum, replace
the crankshaft.
6. IF NECESSARY, GRIND AND HONE MAIN JOURNALS
AND/OR CRANK PINS
Grind and hone the main journals and/or crank pins to the fin-
ished undersized diameter (See procedure in step 5). Install
new main journal and/or crankshaft pin undersized bearings.

EM1Q2−01
EM1321
SST
EM7329
Oil Hole
P01038
EM1322
EM−96
− ENGINE MECHANICALCYLINDER BLOCK
1996 RAV4 (RM447U)
REPLACEMENT
1. REPLACE CONNECTING ROD BUSHINGS
(a) Using SST and a press, press out the bushing.
SST 09222−30010
(b) Align the oil holes of a new bushing and the connecting
rod.
(c) Using SST and a press, press in the bushing.
SST 09222−30010
(d) Using a pin hole grinder, hone the bushing to obtain the
standard specified clearance (See page EM−89) be-
tween the bushing and piston pin.
(e) Check the piston pin fit at normal room temperature. Coat
the piston pin with engine oil, and push it into the connect-
ing rod with your thumb.
2. REPLACE OVERSIZED (O/S) PISTONS FOR CYLIN-
DER BORING
HINT:
Bore all the 4 cylinders for the O/S piston outside diame-
ter.
Replace all the piston rings with ones to match the O/S
pistons.
(a) Keep 4 new O/S pistons.
O/S 0.50 piston diameter:
86.370 − 86.400 mm (3.4004 − 3.4016 in.)

Z11709
26 mm
(1.02 in.)
P05299
P05301
SST
Z00072
Cut Position
− ENGINE MECHANICALCYLINDER BLOCK
EM−97
1996 RAV4 (RM447U)
(b) Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 26 mm (1.02 in.) from
the piston head.
(c) Calculate the amount of each cylinder is to be rebored as
follows:
Size to be rebored = P + C − H
P = Piston diameter
C = Piston oil clearance
0.120 − 0.140 mm (0.0047 − 0.0055 in.)
H = Allowance for honing
0.02 mm (0.0008 in.) or less
(d) Bore and hone the cylinders to calculated dimensions.
Maximum honing: 0.02 mm (0.0008 in.)
NOTICE:
Excess honing will destroy the finished roundness.
3. REPLACE CRANKSHAFT FRONT OIL SEAL
HINT:
There are 2 methods ((a) and (b)) to replace the oil seal.
(a) If the oil pump is removed from the cylinder block:
(1) Using a screwdriver and hammer, tap out the oil
seal.
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the oil pump body edge.
SST 09226−10010
(3) Apply MP grease to the oil seal lip.
(b) If the oil pump is installed to the cylinder block:
(1) Using a knife, cut off the oil seal lip.
(2) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Tape the screw-
driver tip.

EM7361
SST
EM7362
P19502
SST
P04023
Cut Position
P19503
SST EM−98
− ENGINE MECHANICALCYLINDER BLOCK
1996 RAV4 (RM447U)
(3) Apply MP grease to a new oil seal lip.
(4) Using SST and a hammer, tap in the oil seal until its
surface is flush with the oil pump body edge.
SST 09226−10010
4. REPLACE CRANKSHAFT REAR OIL SEAL
HINT:
there are 2 methods ((a) and (b)) to replace the oil seal.
(a) If the rear oil seal retainer is removed from the cylinder
block:
(1) Using a screwdriver and hammer, tap out the oil
seal.
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the rear oil seal retainer
edge.
SST 09223−15030, 09608−30022 (09608−05010)
(3) Apply MP grease to the oil seal lip.
(b) If rear oil seal retainer is installed to cylinder block:
(1) Using a knife, cut off the oil seal lip.
(2) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Tape the screw-
driver tip.
(3) Apply MP grease to a new oil seal lip.
(4) Using SST and a hammer, tap in the oil seal until its
surface is flush with the rear oil seal retainer edge.
SST 09223−15030, 09608−30022 (09608−05010)

EM1BD−02
S01247
Front Mark
(Cavity)
Front Mark
(Protrusion)
Z17148
Code Mark
No. 1
No. 2Code Mark
S01227
Upper Side Rail
Expander
No. 2
Compression
RingLower Side
Rail No. 1 Compression
Ring
Front Mark
(Cavity)
P00797
− ENGINE MECHANICALCYLINDER BLOCK
EM−99
1996 RAV4 (RM447U)
REASSEMBLY
HINT:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply new engine oil to all slid-
ing and rotating surfaces.
Replace all gaskets, O−rings and oil seals with new parts.
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Install a small screwdriver, install a new snap ring on one
side of the piston pin hole.
(b) Gradually heat the piston to 80 − 90°C (176 − 194°F).
(c) Coat the piston pin with engine oil.
(d) Align the front marks of the piston and connecting rod,
and push in the piston pin with your thumb.
(e) Install a small screwdriver, install a new snap ring on the
other side of the piston pin hole.
2. INSTALL PISTON RINGS
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings with the code mark facing upward.
Code mark:
No. 11N or T
No. 22N or 2T
(c) Position the piston rings so that the ring ends are as
shown.
NOTICE:
Do not align the ring ends.
3. INSTALL BEARINGS
(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.

P05533
No.3 Others
22.9 mm19.2 mm
P05353
P03177
Mark
1, 2, 3, 4 or 5
P05354
P03173
EM−100
− ENGINE MECHANICALCYLINDER BLOCK
1996 RAV4 (RM447U)
4. INSTALL MAIN BEARINGS
HINT:
Main bearings come in widths of 19.2 mm (0.756 in.) and
22.9 mm (0.902 in.). Install the 22.9 mm (0.902 in.) bear-
ings in the No. 3 cylinder block journal position with the
main bearing cap. Install the 19.2 mm (0.756 in.) bearings
in the other positions.
Upper bearings have an oil groove and oil holes; lower
bearings do not.
(a) Align the bearing claw with the claw groove of the cylinder
block, and push in the 5 upper bearings.
(b) Align the bearing claw with the claw groove of the main
bearing cap, and push in the 5 lower bearings.
HINT:
A number is marked on each main bearing cap to indicate the
installation position.
5. INSTALL UPPER THRUST WASHERS
Install the 2 thrust washers under the No. 3 journal position of
the cylinder block with the oil grooves facing outward.
6. PLACE CRANKSHAFT ON CYLINDER BLOCK
7. INSTALL MAIN BEARING CAPS AND LOWER
THRUST WASHERS
(a) Install the 2 thrust washers on the No. 3 bearing cap with
the grooves facing outward.

P13450
P13448
Z17147
Front Mark
(Cavity)
FrontPush
P13451
Front Mark
(Protrusion)
P13441
− ENGINE MECHANICALCYLINDER BLOCK
EM−101
1996 RAV4 (RM447U)
(b) Install the 5 main bearing caps in their proper locations.
HINT:
Each bearing cap has a number and front mark.
(c) Apply a light coat of engine oil on the threads and under
the heads of the main bearing cap bolts.
(d) Install and uniformly tighten the 10 bolts of the main bear-
ing caps, in several passes, in the sequence shown.
Torque: 59 N·m (600 kgf·cm, 43 ft·lbf)
(e) Check that the crankshaft turns smoothly.
(f) Check the crankshaft thrust clearance (See page
EM−81).
8. INSTALL PISTON AND CONNECTING ROD AS-
SEMBLES
(a) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(b) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
9. INSTALL CONNECTING ROD CAPS
(a) Place the connecting rod cap on the connecting rod.
(1) Match the numbered connecting rod cap with the
connecting rod.
(2) Install the connecting rod cap with the front mark
facing forward.
(b) Install the connecting rod cap nuts.
HINT:
The cap nuts are tightened in 2 progressive steps (steps
(b) and (d)).
If any one of the connecting rod bolts is broken or de-
formed, replace it.
(1) Apply a light coat of engine oil on the threads and
under the nuts of the connecting rod cap.
(2) Install and alternately tighten the 2 cap nuts in sev-
eral passes.

P13453
Painted Mark
90°90°
P05527
S01632
SST
P15371
New O−Ring EM−102
− ENGINE MECHANICALCYLINDER BLOCK
1996 RAV4 (RM447U)
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
If any one of the cap nuts does not meet the torque specifica-
tion, replace the connecting rod bolt and cap nut as a set.
(3) Mark the front of the cap nut with the paint.
(4) Retighten the cap nuts 90° as shown.
(5) Check that the painted mark is now at a 90° angle
to the front.
(c) Check that the crankshaft turns smoothly.
(d) Check the connecting rod thrust clearance (See page
EM−81).
10. INSTALL REAR OIL SEAL RETAINER
Install a new gasket and the retainer with the 6 bolts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
11. INSTALL KNOCK SENSOR
Using SST, install the knock sensor.
SST 09816−30010
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
12. INSTALL OIL COOLER AND OIL FILTER (See page
LU−20)
13. INSTALL WATER PUMP, WATER PUMP COVER AS-
SEMBLY AND GENERATOR DRIVE BELT ADJUSTING
BAR
(a) Install a new O−ring to the water pump cover.

Z17349
3
1
2
P15304
RH Engine
Mounting
Bracket
PS Pump
Bracket
P13432
EM7333
P15298
3
1
2 M/T
5
8 7
6
4
− ENGINE MECHANICALCYLINDER BLOCK
EM−103
1996 RAV4 (RM447U)
(b) 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)
(c) Install the adjusting bar with the bolt.
Torque: 22 N·m (220 kgf·cm, 16 ft·lbf)
14. INSTALL OIL PUMP AND OIL PAN (See page LU−14)
15. INSTALL CYLINDER HEAD (See page EM−55)
16. INSTALL TIMING BELT AND PULLEYS (See page
EM−20)
17. INSTALL RH ENGINE MOUNTING BRACKET
Install the mounting bracket with the 3 bolts.
Torque: 52 N·m (530 kgf·cm, 38 ft·lbf)
18. INSTALL PS PUMP BRACKET
Install the PS pump bracket with the 3 bolts.
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
19. DISCONNECT ENGINE FROM ENGINE STAND
20. INSTALL REAR END PLATE
Install the rear end plate with the bolt.
Torque: 9.3 N·m (95 kgf·cm, 82 in.·lbf)
21. M/T:
INSTALL FLYWHEEL
(a) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive:
Part No. 08833−00070, THREE BOND 1324 or equiva-
lent
(b) Install the flywheel on the crankshaft.
(c) Install and uniformly tighten the 8 bolts, in several passes,
in the sequence shown.
Torque: 88 N·m (900 kgf·cm, 65 ft·lbf)

P15300
3
1
2 A/T
5
8 7
6
4 EM−104
− ENGINE MECHANICALCYLINDER BLOCK
1996 RAV4 (RM447U)
22. A/T:
INSTALL DRIVE PLATE
Torque: 83 N·m (850 kgf·cm, 61 ft·lbf)