engine TOYOTA RAV4 1996 Service Repair Manual

Fig. 27: Exploded View Of Typical Water Pump & Components
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
3. Remove water pump bolts in sequence. See Fig. 28
. Remove water pump, water pump cover and "O"
rings. See Fig. 27
. Remove water pump-to-water pump cover bolts. Remove water pump and gasket
from water pump cover.

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1999-2000 ENGINES 2.0L 4-Cylinder
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1999-2000 ENGINES 2.0L 4-Cylinder
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Fig. 28: Water Pump Bolt Removal & Installation Sequence
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Installation
1. To install, reverse removal procedure. Use NEW gaskets and NEW "O" rings. Apply soapy water
solution to coolant by-pass pipe "O" ring before installing water pump.
2. Tighten water pump bolts to specification in sequence. Tightening coolant by-pass pipe-to-water pump
nuts. See Fig. 28
. See TORQUE SPECIFICATIONS . To install remaining components, reverse
removal procedure. Fill cooling system.
OIL PAN
Removal
1. Disconnect negative battery cable. Raise and support vehicle. Remove lower engine covers. Drain engine
oil. Remove oil dipstick. Remove front exhaust pipe from between front catalytic converter on exhaust
manifold and rear exhaust pipe for access to oil pan.
2. Remove stiffener plate at rear of oil pan for access to oil pan. Stiffener plate fits between sides of cylinder
block and front of transaxle. Remove bolts/nuts and oil pan.
Installation
1. Ensure sealing surfaces are clean. Apply bead of sealant at center of oil pan sealing surface, between
bolt/nut holes and on inside of bolt/nut holes.
2. Install oil pan. Install and tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS
.
3. To install remaining components, reverse removal procedure. Use NEW gasket and NEW nuts when
installing front exhaust pipe onto catalytic converter. Ensure all bolts/nuts are loosely installed before
tightening to specification. See TORQUE SPECIFICATIONS
.
OVERHAUL
CYLINDER HEAD
Cylinder Head
1. Inspect cylinder head warpage at cylinder block, exhaust manifold and intake manifold areas. Replace
cylinder head if warpage exceeds specification. See CYLINDER HEAD
table under ENGINE
SPECIFICATIONS.
2. Install camshaft into cylinder head. Using Plastigage, check camshaft oil clearance with camshaft bearing
cap bolts tightened to specification in sequence. See Fig. 22
and Fig. 23 . See TORQUE
SPECIFICATIONS .
3. Check camshaft end play with camshaft bearing cap bolts tightened to specification. Replace camshaft
and/or cylinder head if camshaft oil clearance or end play is not within specification. See CAMSHAFT

table under ENGINE SPECIFICATIONS.

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1999-2000 ENGINES 2.0L 4-Cylinder
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4. Ensure valve lifter bore diameter in cylinder head is within specification. See VALVE LIFTERS table
under ENGINE SPECIFICATIONS.
Valve Springs
Ensure valve spring free length, pressure and out-of-square are within specification. See VALVES & VALVE
SPRINGS table under ENGINE SPECIFICATIONS.
Valve Stem Oil Seals
Intake valve stem oil seal is Brown. Exhaust valve stem oil seal is Black. Ensure proper valve stem oil seal is
installed. Lubricate valve stem oil seal with engine oil. Install valve stem oil seal using Oil Seal Installer (SST
09201-41020).
Valve Guides
1. Ensure valve guide inside diameter is within specification. See CYLINDER HEAD table under ENGINE
SPECIFICATIONS. Replace valve guide if inside diameter exceeds specification.
2. To replace valve guide, heat cylinder head to 176-212°F (80-100°C). Using a hammer and Valve Guide
Remover/Installer (SST 09201-01060), drive valve guide from camshaft side of cylinder head.
3. Measure cylinder head valve guide bore inside diameter. If bore inside diameter is .4325-.4335" (10.985-
11.012 mm), use standard valve guide. If bore inside diameter is .4344-.4355" (11.035-11.062 mm), use
oversize valve guide.
4. If bore inside diameter exceeds .4335" (11.012 mm), machine valve guide bore to .4344-.4355" (11.035-
11.062 mm) for oversize valve guide. If bore inside diameter exceeds .4355" (11.062 mm), replace
cylinder head.
5. Intake valve guide is 1.516" (38.50 mm) long. Exhaust valve guide is 1.594" (40.50 mm) long. Ensure
proper valve guide is installed.
6. To install valve guide, heat cylinder head to 176-212°F (80-100°C). Using hammer and valve guide
remover/installer, drive valve guide in from camshaft side of cylinder head until valve guide installed
height is .315-.346" (8.00-8.80 mm). Valve guide installed height is measured from top of valve guide to
cylinder head surface. See Fig. 29
.
7. On all valve guide applications, use .236" (6.00 mm) reamer to ream valve guide to obtain correct valve
stem-to-guide oil clearance. See CYLINDER HEAD
table under ENGINE SPECIFICATIONS. CAUTION: Valve stems oil seals are painted a different color on top of oil seal for
specified valve application. Intake valve stem oil seal is Brown and
exhaust valve stem oil seal is Black. Ensure valve stem oil seal is installed
in proper location.

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1999-2000 ENGINES 2.0L 4-Cylinder
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Fig. 29: Measuring Valve Guide Installed Height
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Valve Seat
Ensure valve seat angle and seat width are within specification. See CYLINDER HEAD table under ENGINE
SPECIFICATIONS. Valve seat replacement information is not available from manufacturer.
Valves
Ensure minimum refinish length, stem diameter and valve margin are within specification. See VALVES &
VALVE SPRINGS table under ENGINE SPECIFICATIONS.
Valve Seat Correction Angles
Use 30-degree and 45-degree stones to lower valve seat contact area. Use 45-degree and 75-degree stones to
raise valve seat contact area.
VALVE TRAIN
Valve Lifters
Ensure valve lifter diameter, bore diameter and oil clearance are within specification. See VALVE LIFTERS
table under ENGINE SPECIFICATIONS.
CYLINDER BLOCK ASSEMBLY

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1999-2000 ENGINES 2.0L 4-Cylinder
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Piston & Rod Assembly
1. Ensure connecting rod and connecting rod cap are marked with matching cylinder number for reassembly
reference. Piston, connecting rod and connecting rod must be installed with front mark toward timing belt
end of engine. See Fig. 31
.
2. Before disassembling piston and connecting rod, try to move piston back and forth on piston pin. Replace
piston and piston pin as a set, if any movement is felt.
3. Remove 2 compression rings using a piston ring expander. Remove 2 oil rings and oil ring expander by
hand. Using Piston Pin Remover/Replacer (09221-25026), press piston pin from piston, and remove
connecting rod. See Fig. 32
.
4. Ensure piston pin diameter is within specification. See PISTONS, PINS & RINGS
table under ENGINE
SPECIFICATIONS. Ensure connecting rod bend, twist and piston pin bore diameter (connecting rod
small end) are within specification. See CONNECTING RODS
table under ENGINE
SPECIFICATIONS.
5. If piston pin bore diameter is not within specification, replace connecting rod assembly. See
CONNECTING RODS
table under ENGINE SPECIFICATIONS.
6. Using hand pressure, ensure nut rotates easily on connecting rod bolt. If nut fails to rotate easily, use
caliper to measure connecting rod bolt outside diameter .59" (15.0 mm) from end of bolt. Standard
connecting rod bolt outside diameter is .3094-.3150" (7.860-8.000 mm). Replace connecting rod bolt and
nut assembly if bolt outside diameter is less than .2992" (7.600 mm).
7. Pistons with different diameters are used. Piston diameter is identified by size mark ("1", "2" or "3")
stamped on top of piston. See Fig. 30
.
Fig. 30: Identifying Piston Size Marks

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
8. To determine piston diameter, measure piston skirt diameter .91-1.024" (23-26 mm) from top of piston, at
90-de
gree angle to piston pin. Ensure piston diameter is within size mark specification. See PISTONS,

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
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PINS & RINGS table under ENGINE SPECIFICATIONS.
9. To reassemble, position piston and connecting rod so front mark (cavity) on top of piston aligns with
front mark (protrusion) on connecting rod. See Fig. 31
. Coat piston bore and piston pin with engine oil.
Using Piston Pin Remover/Replacer (09221-25026), press piston pin into piston and connecting rod. See
Fig. 32
.
Fig. 31: Identifying Piston Front Marks

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
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Fig. 32: Removing & Installing Piston Pin
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fitting Pistons
1. Different diameter pistons are used. Piston diameter is identified by size mark ("1", "2" or "3") stamped
on top of piston. See Fig. 30
.
2. Different cylinder bore diameters are used. Cylinder bore diameter may be identified by size mark ("1",
"2" or "3") stamped on c
ylinder block deck surface. See Fig. 33.

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1999-2000 ENGINES 2.0L 4-Cylinder
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Fig. 33: Identifying Cylinder Bore Size Marks (Typical)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
3. To determine piston-to-cylinder clearance, measure piston diameter and cylinder bore diameter. Measure
piston skirt diameter .91-1.024" (23-26 mm) from top of piston.
4. Measure cylinder bore diameter at 3 different positions, 90 degrees apart, .39" (10.0 mm) from top and
bottom of cylinder bore, and at center of cylinder bore. Ensure piston diameter and cylinder bore diameter
are within specification. See PISTONS, PINS & RINGS
and CYLINDER BLOCK tables under
ENGINE SPECIFICATIONS.
5. Calculate piston-to-cylinder clearance. Replace piston, or bore cylinder block for oversize pistons, if
clearance is not within specification. See PISTONS, PINS & RINGS
table under ENGINE
SPECIFICATIONS. Pistons are available in .020" (.50 mm) oversize. If replacing piston, ensure
replacement piston contains same size mark as size mark on cylinder block.
Piston Rings
1. Ensure piston ring end gap and side clearance are within specification. See PISTONS, PINS & RINGS
table under ENGINE SPECIFICATIONS.
2. Install oil ring expander and 2 side rails by hand. Using a piston ring expander, install No. 2 compression
ring with 2N or 2T identification mark facing up. Using a piston ring expander, install No. 1 compression
ring with 1N or "T" identification mark facing up. Ensure compression rings and oil side rails are
positioned correctl
y. See Fig. 34 .

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1999-2000 ENGINES 2.0L 4-Cylinder
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Fig. 34: Positioning Piston Rings
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Rod Bearings
1. Ensure connecting rod and connecting rod cap are marked with matching cylinder number for reassembly
reference. Ensure connecting rod is installed so front mark (protrusion) at center of connecting rod is
toward timing belt end of engine. Front mark (protrusion) on connecting rod cap must also face timing
belt end of engine. See Fig. 31
.
2. Connecting rod cap and rod bearing are stamped with size mark ("1", "2" or "3"). See Fig. 35
. Ensure
size marks on connecting rod cap and rod bearing are same.
3. Rod bearing thickness is determined by size mark. See ROD BEARING SPECIFICATIONS
table.
4. Ensure nut rotates easily on connecting rod bolt. If nut fails to rotate easily, use caliper to measure
connecting rod bolt outside diameter at .59" (15.0 mm) from end of bolt. Replace connecting rod bolt and
nut as an assembly if bolt outside diameter is less than .2992" (7.600 mm).
5. Install connecting rod cap with front mark (protrusion) toward timing belt end of engine. See Fig. 31
.
Coat threads of connecting rod bolts and nut-to-connecting rod cap surface with engine oil before
tightening nuts to specification. See TORQUE SPECIFICATIONS
.
6. Ensure bearing oil clearance and connecting rod side play are within specification. See CRANKSHAFT,
MAIN & CONNECTING ROD BEARINGS and CONNECTING RODS tables under ENGINE
SPECIFICATIONS.
NOTE: If replacing rod bearing, ensure size mark on replacement rod bearing is
same as size mark on original rod bearing.

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1999-2000 ENGINES 2.0L 4-Cylinder
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