Engine TOYOTA RAV4 1996 Service Repair Manual

PISTONS, PINS & RINGS
PISTONS, PINS & RINGS
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
1997
Standard.0047-.0055 (.120-.140)
Wear Limit.0063 (.160)
1998
Standard.0056-.0064 (.143-.163)
Wear Limit.0072 (.183)
Diameter (1)
1997
Size Mark "1"3.3807-3.3811 (85.870-85.880)
Size Mark "2"3.3811-3.3815 (85.880-85.890)
Size Mark "3"3.3815-3.3819 (85.890-85.900)
Over Sized .1969" (.50 mm)3.4004-3.4016 (86.370-86.400)
1998
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 Sized .1969" (.50 mm)3.3995-3.4007 (86.347-86.377)
Pins
1997
Diameter.8660-.8665 (21.997-22.009)
Piston Fit(2)
Rod Fit (Oil Clearance)
Standard.0002-.0004 (.005-.011)
Wear Limit.0020 (.050)
1998

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
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Sunday, November 22, 2009 10:23:31 AMPage 65 © 2005 Mitchell Repair Information Company, LLC.

Diameter.8660-.8665 (21.997-22.009)
Piston Fit(3)
Rod Fit (Oil Clearance)
Standard.0002-.0004 (.005-.011)
Wear Limit.0020 (.050)
Rings
1997
No. 1
End Gap (4)
Standard.0106-.0197 (.270-.500)
Wear Limit.0433 (1.100)
Side Clearance.0012-.0028 (.030-.070)
No. 2
End Gap (4)
Standard.0106-.0201 (.270-.510)
Wear Limit.0437 (1.110)
Side Clearance.0012-.0028 (.030-.070)
No. 3 (Oil)
End Gap (4)
Standard.0079-.0217 (.200-.550)
Wear Limit.0453 (1.150)
1998
No. 1
End Gap (4)
Standard.0106-.0185 (.270-.470)
Wear Limit.0421 (1.070)
Side Clearance.0012-.0028 (.030-.070)
No. 2
End Gap (4)
Standard.0177-.0256 (.450-.650)
Wear Limit.0492 (1.250)
Side Clearance.0012-.0028 (.030-.070)
No. 3 (Oil)
End Gap (4)
Standard.0039-.0177 (.100-.450)
Wear Limit.0413 (1.050)
(1)Piston diameter is determined by size mark stamped on top of piston. See Fig. 32 .
(2)With piston temperature at 140°F (60°C), piston pin should slide through piston with thumb pressure.

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
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Sunday, November 22, 2009 10:23:31 AMPage 66 © 2005 Mitchell Repair Information Company, LLC.

CYLINDER BLOCK
CYLINDER BLOCK
VALVES & VALVE SPRINGS
VALVES & VALVE SPRINGS
(3)On 1998 engine, piston pin has an interference fit and pin must be pressed into connecting rod and
piston.
(4)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)
(1)Cylinder bore diameter is determined by size mark on cylinder block deck surface. See Fig. 37 .
(2)Main bearing bore I.D. is determined by main bearing bore size mark on cylinder block. See Fig. 39 .
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)

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
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Sunday, November 22, 2009 10:23:31 AMPage 67 © 2005 Mitchell Repair Information Company, LLC.

CYLINDER HEAD
CYLINDER HEAD
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)
Pressure37-43 Lbs. @ 1.366 In. (16.7-
19.5 kg @ 34.70 mm)
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
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)

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:31 AMPage 68 © 2005 Mitchell Repair Information Company, LLC.

CAMSHAFT
CAMSHAFT
VALVE LIFTERS
VALVE LIFTERS
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 End Free Distance.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
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 Diameter1.2205-1.2212 (31.000-31.018)
Lifter Diameter1.2191-1.2195 (30.966-30.976)

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
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Sunday, November 22, 2009 10:23:31 AMPage 69 © 2005 Mitchell Repair Information Company, LLC.

Oil Clearance
Standard.0009-.0020 (.024-.052)
Wear Limit.0028 (.070)

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
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Sunday, November 22, 2009 10:23:32 AMPage 70 © 2005 Mitchell Repair Information Company, LLC.

1. Remove front wheel. Check wheel bearing backlash and deviation (rotational free play). See WHEEL
BEARING CHECKING under ADJUSTMENTS & INSPECTION.
2. Using punch and hammer, unstake drive shaft lock nut. Apply brakes and remove lock nut. Remove 2
bolts, brake caliper and disc. Support brake caliper out of way.
3. Remove bolt, and disconnect ABS speed sensor. Remove clip and nut. Using separator, separate steering
knuckle from lower suspension arm. Remove cotter pin and nut, and using tie rod separator, disconnect
tie rod end.
4. Remove 2 nuts, bolts and steering knuckle with axle hub from shock absorber.
Installation
To install, reverse removal procedure. Use NEW snap ring after pressing in NEW wheel bearing. Use NEW
cotter pins. Tighten bolts to specifications. See TORQUE SPECIFICATIONS
.
SHOCK ABSORBER
Removal & Installation
1. Remove front wheel. Disconnect brake hose and ABS speed sensor clamp from shock absorber. On
Sienna, remove outer front cowl top panel. See Fig. 6
.
2. Remove 2 lower shock absorber nuts and bolts and disconnect shock absorber from steering knuckle.
Remove 3 upper shock absorber mounting nuts from inside engine compartment and remove shock
absorber with coil spring.
3. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE
SPECIFICATIONS . NOTE: On Camry, note mounting position of curved mounting plate on shock
absorber tower. Ensure it is reinstalled in same position.

1999 Toyota RAV4
1999-2000 SUSPENSION Front - Avalon, Camry, Camry Solara, Celica, Corolla, Echo, RAV4 & Sienna
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Sunday, November 22, 2009 10:36:34 AMPage 8 © 2005 Mitchell Repair Information Company, LLC.

Removal & Installation (Avalon, Camry, Camry Solara & Sienna)
1. Remove front wheel. Remove 2 nuts and bolt, and disconnect lower control arm from lower ball joint.
Remove 2 bolts on front side of lower control arm and bolt and nut of rear side of lower control arm.
Remove lower control arm.
2. Remove lower control arm bushing stopper from control arm shaft. Bushing can be replaced with a press.
If a NEW bushing is installed, note position of installation and amount of protrusion. See Fig. 7
.
3. To install, reverse removal procedure. Tighten bolts and nuts to specifications. See TORQUE
SPECIFICATIONS
Fig. 7: Installed Position Of Lower Control Arm Bushing (Avalon, Camry Solara & Sienna)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (1999 Celica)
1. Remove front wheel. Remove both engine under covers. Remove cotter pin, lock cap and drive shaft lock
nut. Using separator tool, disconnect both tie rod ends from steering knuckles.
2. Disconnect both stabilizer bar links from both lower control arms. See Fig. 4
. See STABILIZER BAR .
Disconnect both lower suspensions arms from lower ball
joints. See BALL JOINTS .

1999 Toyota RAV4
1999-2000 SUSPENSION Front - Avalon, Camry, Camry Solara, Celica, Corolla, Echo, RAV4 & Sienna
Microsoft
Sunday, November 22, 2009 10:36:34 AMPage 10 © 2005 Mitchell Repair Information Company, LLC.

3. Remove 6 bolts (3 at each side) holding lower control arms to body. Support transaxle with a jack.
Remove 2 exhaust pipe support bracket set bolts in middle of suspension crossmember. Remove 2
grommets and center member set bolt and 2 nuts. Remove 2 power steering gear assembly mounting bolts
and nuts. Support suspension crossmember with a jack. Remove 2 upper inner bolts and lower suspension
crossmember from vehicle with lower control arms attached. See Fig. 4
.
4. Remove lower control arm collar. Remove control arm-to-suspension crossmember bolt and remove
lower control arm. See Fig. 4
.
5. To install, reverse removal procedure. Tighten all bolts and nut to specification. See TORQUE
SPECIFICATIONS .
Removal & Installation (2000 Celica)
1. Remove front wheel. Remove right side engine cover. Remove bolt and 2 nuts, and disconnect lower
suspension arm from lower ball joint. Remove 2 bolts, nut and lower suspension arm.
2. On models with A/T, remove left side engine covers. On all models, remove cotter pin and nut, and
disconnect tie rod ends from steering knuckle. Remove nut, and disconnect stabilizer bar link from shock
absorber. Remove bolt and 2 nuts, and disconnect lower suspension arm from lower ball joint. Loosen
lower suspension arm set bolts.
3. Remove hood. Disconnect 2 PVC hoses. Install No. 1 and No. 2 engine hangers in correct direction.
Attach engine chain hoist to engine hangers.
4. Remove 4 set bolts to disconnect power steering gear assembly from suspension member. Secure power
steering gear aside. Remove bolt "A" and 3 nuts. Disconnect engine rear mount. Remove 2 "B" bolts, and
disconnect engine front mount. See Fig. 8
.
5. Using a transmission jack, support suspension member. Remove 6 bolts ("C", "D", and "E"). Lower
suspension member. Remove 2 bolts, nut and lower suspension arm.
6. To install, reverse removal procedure. Tighten all bolts and nut to specification. See TORQUE
SPECIFICATIONS . CAUTION: DO NOT hook engine chain to any other part of vehicle.

1999 Toyota RAV4
1999-2000 SUSPENSION Front - Avalon, Camry, Camry Solara, Celica, Corolla, Echo, RAV4 & Sienna
Microsoft
Sunday, November 22, 2009 10:36:34 AMPage 11 © 2005 Mitchell Repair Information Company, LLC.

Fig. 9: Exploded View Of Lower Control Arm & Suspension Crossmember Components (Corolla)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 10: Location Of Suspension Crossmember Bolts & Nuts (Corolla)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (Echo)
1. Remove front wheel. Holding stabilizer bar link, remove 2 nuts, 5 retainers, 4 cushions and stabilizer bar
link. Remove clip and nut. Using ball joint puller, disconnect lower suspension arm from steering
knuckle.
2. On right side arm, remove bolt and 2 nuts, and disconnect engine rear mount. Using transmission jack and
wooden block, slightly raise engine. Remove 2 bolts, nut and lower suspension arm.
3. To install, reverse removal procedure. Tighten all bolts and nut to specification. See TORQUE
SPECIFICATIONS .

1999 Toyota RAV4
1999-2000 SUSPENSION Front - Avalon, Camry, Camry Solara, Celica, Corolla, Echo, RAV4 & Sienna
Microsoft
Sunday, November 22, 2009 10:36:34 AMPage 15 © 2005 Mitchell Repair Information Company, LLC.