engine TOYOTA RAV4 1996 Service Repair Manual

GENERAL SPECIFICATIONS
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
ApplicationSpecification
Displacement122 Cu. In. (2.0L)
Bore3.39" (86.0 mm)
Stroke3.39" (86.0 mm)
Compression Ratio9.5:1
Fuel SystemSFI
ApplicationIn. (mm)
Crankshaft
End Play
Standard.0008-.0087 (.020-.220)
Wear Limit.0118 (.300)
Maximum Runout.0024 (.060)
Main Bearings
Journal Diameter (1)
Size Mark "0"2.1653-2.1655 (54.998-55.003)
Size Mark "1"2.1651-2.1653 (54.993-54.998)
Size Mark "2"2.1649-2.1651 (54.988-54.993)
Journal Out-Of-Round.0008 (.020)
Journal Taper.0008 (.020)
Oil Clearance
Standard Crankshaft Journal
No. 3 Journal
Standard.0010-.0017 (.025-.044)
Wear Limit.0031 (.080)
All Other Journals
Standard.0006-.0013 (.015-.034)
Wear Limit.0031 (.080)
.010" (.25 mm) Undersize Crankshaft Journal
No. 3 Journal
Standard.0011-.0026 (.027-.067)
Wear Limit.0031 (.080)
All Other Journals
Standard.0007-.0023 (.019-.059)
Wear Limit.0031 (.080)
Connecting Rod Bearings
Journal Diameter
Standard2.0466-2.0472 (51.985-52.000)
Undersized .010" (.25 mm)2.0372-2.0376 (51.745-51.755)

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
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CONNECTING RODS
PISTONS, PINS & RINGS
Journal Out-Of-Round.0008 (.020)
Journal Taper.0008 (.020)
Oil Clearance
Standard Crankshaft Journal
Standard.0009-.0022 (.024-.055)
Wear Limit.0031 (.080)
.010" (.25 mm) Undersize Crankshaft Journal
Standard.0009-.0027 (.024-.069)
Wear Limit.0031 (.080)
(1)Main bearing journal diameter is determined by size mark stamped on crankshaft. See Fig. 37 .
ApplicationIn. (mm)
Piston Pin Bushing
Bore Diameter.8660-.8665 (21.997-22.009)
Piston Pin Oil Clearance (1)
Standard.0002-.0004 (.005-.010)
Wear Limit.0020 (.050)
Maximum Bend.002 Per 3.94 (.05 Per 100.0)
Maximum Twist.0059 Per 3.94 (.150 Per 100.0)
Side Play
Standard.0063-.0123 (.160-.312)
Wear Limit.0138 (.350)
(1)Piston pin oil clearance is the difference between the inside diameter of the connecting rod piston pin
bushing bore and the outside diameter of the piston pin.
ApplicationIn. (mm)
Pistons
Clearance
Standard.0056-.0064 (.143-.163)
Wear Limit.0072 (.183)
Diameter (1)
Size Mark "1"3.3798-3.3802 (85.847-
85.857)
Size Mark "2"3.3802-3.3806 (85.857-
85.867)
Size Mark "3"3.3806-3.3810 (85.867-
85.877)
Over Size .1969" (.50 mm)3.3995-3.4007 (86.347-

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
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CYLINDER BLOCK
86.377)
Pins
Diameter.8660-.8665 (21.997-22.009)
Piston Fit(2)
Rod Fit (Oil Clearance)
Standard.0002-.0004 (.005-.011)
Wear Limit.0020 (.050)
Rings
No. 1
End Gap (3)
Standard.0106-.0185 (.270-.470)
Wear Limit.0421 (1.070)
Side Clearance.0012-.0028 (.030-.070)
No. 2
End Gap (3)
Standard.0177-.0256 (.450-.650)
Wear Limit.0492 (1.250)
Side Clearance.0012-.0028 (.030-.070)
No. 3 (Oil)
End Gap (3)
Standard.0056-.0064 (.143-.163)
Wear Limit.0072 (.183)
(1)Piston diameter is determined by size mark stamped on top of piston. See Fig. 30 .
(2)Piston pin has an interference fit and pin must be pressed into connecting rod and piston.
(3)Using a piston with rings removed, push ring into cylinder bore 4.33" (110 mm) from the top.
ApplicationIn. (mm)
Cylinder Bore (1)
Size Mark "1"3.3858-3.3862 (86.000-86.010)
Size Mark "2"3.3862-3.3866 (86.010-86.020)
Size Mark "3"3.3866-3.3870 (86.020-86.030)
Maximum Standard Size3.3949 (86.230)
.020" (.50 mm) Oversize3.4146 (86.731)
Maximum Deck Warpage.0020 (.050)
Main Bearing Bore I.D. (2)
Size Mark "1"2.3236-2.3239 (59.020-59.026)
Size Mark "2"2.3239-2.3241 (59.026-59.032)
Size Mark "3"2.3241-2.3243 (59.032-59.038)

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
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VALVES & VALVE SPRINGS
CYLINDER HEAD
(1)Cylinder bore diameter is determined by size mark on cylinder block deck surface. See Fig. 33 .
(2)Main bearing bore I.D. is determined by main bearing bore size mark on cylinder block. See Fig. 37 .
ApplicationSpecification
Intake Valves
Face Angle44.5°
Minimum Margin.020" (.50 mm)
Minimum Refinish Length3.823" (97.10 mm)
Stem Diameter.2350-.2356" (5.970-5.985
mm)
Exhaust Valves
Face Angle44.5°
Minimum Margin.020" (.50 mm)
Minimum Refinish Length3.858" (98.00 mm)
Stem Diameter.2348-.2354" (5.965-5.980
mm)
Valve Springs
Free Length1.6520-1.6531" (41.96-41.99
mm)
Out-Of-Square Limit.079" (2.00 mm)
Lbs. @ In. (kg @ mm)
Pressure37-43 @ 1.366 (16.7-19.5 @
34.70)
ApplicationSpecification
Maximum Warpage
Cylinder Block Surface.0020" (.050 mm)
Intake & Exhaust Manifold Surface.0031" (.080 mm)
Valve Seats
Intake Valve
Seat Angle45°
Seat Width.039-.055" (1.00-1.40 mm)
Exhaust Valve
Seat Angle45°
Seat Width.039-.055" (1.00-1.40 mm)
Valve Guides
Intake Valve
Valve Guide Cylinder Head Bore I.D.
Standard Valve Guide.4325-.4335" (10.985-11.012

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
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CAMSHAFT
mm)
Oversize Valve Guide.4344-.4355" (11.035-11.062
mm)
Valve Guide I.D..2366-.2374" (6.010-6.030 mm)
Valve Guide Installed Height.315-.346" (8.00-8.80 mm)
Valve Stem-To-Guide Oil Clearance
Standard.0010-.0024" (.025-.060 mm)
Wear Limit.0031" (.080 mm)
Exhaust Valve
Valve Guide Cylinder Head Bore I.D.
Standard Valve Guide.4325-.4335" (10.985-11.012
mm)
Oversize Valve Guide.4344-.4355" (11.035-11.062
mm)
Valve Guide I.D..2366-.2374" (6.010-6.030 mm)
Valve Guide Installed Height.315-.346" (8.00-8.80)
Valve Stem-To-Guide Oil Clearance
Standard.0012-.0026" (.030-.065 mm)
Wear Limit.0039" (.100 mm)
ApplicationIn. (mm)
End Play
Intake Camshaft
Standard.0018-.0039 (.045-.100)
Wear Limit.0047 (.120)
Exhaust Camshaft
Standard.0012-.0033 (.030-.085)
Wear Limit.0039 (.100)
Gear Backlash
Standard.0008-.0079 (.020-.200)
Wear Limit.0118 (.300)
Gear Spring Free Length.886-.902 (22.50-22.91)
Journal Diameter1.0614-1.0620 (26.959-26.975)
Journal Runout.0016 (.040)
Lobe Height
Intake Camshaft
Standard1.6539-1.6579 (42.010-
42.110)
Wear Limit1.6496 (41.900)
Exhaust Camshaft

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
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Sunday, November 22, 2009 10:22:27 AMPage 64 © 2005 Mitchell Repair Information Company, LLC.

VALVE LIFTERS
Standard1.5772-1.5811 (40.060-
40.160)
Wear Limit1.5728 (39.950)
Oil Clearance
Standard.0010-.0024 (.025-.062)
Wear Limit.0039 (.100)
ApplicationIn. (mm)
Bore Diameter1.2205-1.2211 (31.000-31.016)
Lifter Diameter1.2191-1.2195 (30.966-30.976)
Oil Clearance
Standard.0009-.0020 (.024-.052)
Wear Limit.0028 (.070)

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
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Sunday, November 22, 2009 10:22:27 AMPage 65 © 2005 Mitchell Repair Information Company, LLC.

2.0L 4-CYL
1997-98 ENGINES Toyota 2.0L 4-Cylinder
ENGINE IDENTIFICATION
Engine serial number is stamped on rear of cylinder block. See Fig. 1 .
ENGINE IDENTIFICATION CODE
Fig. 1: Identifying Engine Serial Number

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: For engine repair procedures not covered in this article, see ENGINE
OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL
INFORMATION section.
EngineCode
2.0L 4-Cylinder3S-FE

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
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Sunday, November 22, 2009 10:23:30 AMPage 1 © 2005 Mitchell Repair Information Company, LLC.
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Sunday, November 22, 2009 10:23:35 AMPage 1 © 2005 Mitchell Repair Information Company, LLC.

ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT
1. Disconnect power steering fluid reservoir, PCV hoses, cable brackets and control cables for access to
valve cover. Disconnect spark plug wires from spark plugs.
2. Disconnect engine wiring harness protector at rear of timing belt cover for access to valve cover. When
disconnecting engine wiring harness protector, remove bolt on intake manifold side of engine first, and
then bolt on exhaust manifold side of engine.
3. Remove nuts, grommets, valve cover and gasket. Note location of grommets for reassembly reference, as
grommets must be installed in original location.
4. Rotate crankshaft clockwise, viewed from timing belt end of engine, so cylinder No. 1 is at TDC on
compression stroke and timing mark on crankshaft pulley aligns with "0" mark on timing belt cover.
Cylinder No. 1 is front cylinder at timing belt end of engine.
5. Ensure valve lifters are loose on cylinder No. 1 and tight on cylinder No. 4. If conditions are not as
described, rotate crankshaft clockwise one complete revolution (360 degrees).
6. With cylinder No. 1 at TDC on compression stroke, check valve clearance on specified valves. Perform
STEP 1. See Fig. 2
. Using feeler gauge, measure and record valve clearance between valve lifter and
camshaft.
7. To check remaining valves, rotate crankshaft clockwise, viewed from timing belt end of engine, one
complete revolution (360 degrees) until cylinder No. 4 cylinder is at TDC on compression stroke.
Measure and record valve clearance on specified valves. Perform STEP 2. See0Fig. 2
.
8. Ensure valve clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS
.
VALVE CLEARANCE SPECIFICATIONS
(1)
9. If valve clearance requires adjustment, rotate camshaft so lobe on valve to be adjusted is facing upward,
away from valve lifter. Rotate valve lifter so notch on valve lifter is toward spark plug.
10. Use Valve Clearance Adjuster (SST 09248-55040) to remove adjusting shim. Using SST "A" of valve
clearance adjuster, push downward on valve lifter. Place SST "B" between camshaft and valve lifter with
side marked with No. 9 at desi
gnated position. See Fig. 3. Remove SST "A". NOTE: Adjust valve clearance with engine cold.
ApplicationIn. (mm)
Intake Valve.007-.011 (.19-.29)
Exhaust Valve.011-.015 (.29-.38)
(1)Adjust valve clearance with engine cold.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
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Fig. 2: Checking Valve Clearance
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
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Sunday, November 22, 2009 10:23:30 AMPage 3 © 2005 Mitchell Repair Information Company, LLC.

Fig. 3: Adjusting Valve Clearance
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
11. Using small screwdriver and magnet, remove adjusting shim. Measure and record thickness of adjusting
shim removed. Using measured valve clearance and adjusting shim thickness, select proper replacement
adjusting shim. See Fig. 6
and Fig. 7 .
12. Install replacement adjusting shim. Recheck valve clearance. Apply sealant at front and rear valve cover
areas on cylinder head. See Fig. 4
. Using NEW gasket, install valve cover.
13. Install grommets in original location with marking on grommet aligned in designated area. See Fig. 5
.
Install and ti
ghten valve cover nuts to specification. See TORQUE SPECIFICATIONS.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
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Sunday, November 22, 2009 10:23:30 AMPage 4 © 2005 Mitchell Repair Information Company, LLC.