TOYOTA RAV4 1996 Service Repair Manual

Fig. 26: Aligning Camshaft Timing Marks
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
9. Install camshaft bearing caps for exhaust camshaft on cylinder head in numerical sequence with arrow
pointing toward timing belt end of engine. See Fig. 21
.
10. Coat threads and bolt head-to-camshaft bearing cap contact surfaces of camshaft bearing cap bolts with
engine oil. Install and tighten camshaft bearing cap bolts to specification in sequence using several steps.
See Fig. 22
. See TORQUE SPECIFICATIONS .
11. Remove service bolt "B" from camshaft gear. See Fig. 24
. Install No. 3 timing belt cover. Install and
tighten bolts to specification. See TORQUE SPECIFICATIONS
. Install timing belt using proper
procedure. See TIMING BELT
.
12. Check valve clearance. See VALVE CLEARANCE ADJUSTMENT
under ADJUSTMENTS. Apply
sealant in grooves on rear side of semi-circular plugs located on exhaust camshaft side of cylinder head.
Install semi-circular plugs in cylinder head.
13. Before installing gasket and valve cover, apply sealant at front and rear valve cover areas on cylinder
head. See Fig. 6
.
14. Using NEW gasket, install valve cover. Install grommets in original location with marking on grommet
aligned in designated area. See Fig. 7
. Install and tighten valve cover nuts to specification. See
TORQUE SPECIFICATIONS
.
15. If installing distributor, install NEW "O" ring on distributor. Coat "O" ring with engine oil.
16. Rotate crankshaft clockwise, as 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.
C
ylinder No. 1 is front cylinder at timing belt end of engine.

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1999-2000 ENGINES 2.0L 4-Cylinder
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17. Ensure slot area on intake camshaft is vertically positioned. Rotate coupling on distributor so cutout
aligns with alignment mark on distributor housing.
18. Install distributor so center of flange on distributor is aligned with bolt hole on cylinder head. Install
distributor hold-down bolt(s). Adjust ignition timing.
CRANKSHAFT REAR OIL SEAL
Removal
Remove transaxle, clutch assembly (if equipped) and flywheel/drive plate. Using a knife, cut seal lip from oil
seal. Pry oil seal from rear seal housing. DO NOT damage sealing surfaces.
Installation
1. Ensure all sealing surfaces are clean. Apply grease to seal lip of new oil seal. Using Oil Seal Installer
(SST 09223-15030), install oil seal into rear seal housing until oil seal is even with surface of rear seal
housing.
2. Apply Loctite to flywheel/drive plate bolts. Install flywheel/drive plate. Install bolts and tighten to
specification using a crisscross pattern. See TORQUE SPECIFICATIONS
. To install remaining
components, reverse removal procedure.
WATER PUMP
Removal
1. Disconnect negative battery cable. Drain cooling system. Remove timing belt and idler pulley(s) as
needed for access to water pump. See TIMING BELT
.
2. Disconnect lower radiator hose from thermostat housing. Remove generator adjusting bracket. Remove
coolant b
y-pass pipe-to-water pump nuts. See Fig. 27. NOTE: On 4WD models, manufacturer recommends removing engine with transaxle for
transaxle removal. On 2WD models, transaxle may be removed with engine in
vehicle.

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1999-2000 ENGINES 2.0L 4-Cylinder
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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,

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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.

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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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