TOYOTA RAV4 1996 Service Repair Manual

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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ROD BEARING SPECIFICATIONS
Fig. 35: Identifying Connecting Rod Cap & Rod Bearing Size Marks

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Crankshaft & Main Bearings
1. Main bearing caps are numbered on top of cap for location reference. No. 1 main bearing cap is at timing
belt end of engine and No. 5 is at flywheel/drive plate end of engine. Ensure arrow on top of main bearing
cap points toward timing belt end of engine.
2. Remove main bearing cap bolts in sequence. See Fig. 36
. Remove main bearing caps, crankshaft, thrust
bearings and main bearings.
3. Cylinder block main bearing bore inside diameter is identified by main bearing bore size mark ("1", "2"
or "3") stamped on cylinder block. See Fig. 37
. Front size mark indicates No. 1 main bearing bore and
rear size mark indicates No. 5 main bearing bore.
4. Crankshaft main bearing journal diameter is identified by main bearing journal size mark ("0", "1" or "2")
located on crankshaft counterweight. See Fig. 37
.
5. Ensure crankshaft runout, journal diameter, taper and out-of-round are within specification. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
table under ENGINE
Bearing Size MarkBearing Thickness - In. (mm)
"1".0584-.0586 (1.484-1.488)
"2".0586-.0587 (1.488-1.492)
"3".0587-.0589 (1.492-1.496)

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1999-2000 ENGINES 2.0L 4-Cylinder
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SPECIFICATIONS.
6. Main bearing size mark ("1", "2", "3", "4" or "5") is located on side of main bearing. See Fig. 37
. If
replacing main bearing, ensure size mark on replacement main bearing is same as size mark on original
main bearing.
7. If main bearing size mark cannot be obtained, add size marks on cylinder block and crankshaft to
determine size mark of main bearing to be used. For example, if size mark on cylinder block is "2" and
size mark on crankshaft is "1", use main bearing with size mark "3".
8. Main bearing thickness is determined by size mark. See MAIN BEARING SPECIFICATIONS
table.
Install main bearings, thrust bearings, crankshaft and main bearing caps.
9. Ensure main bearing caps are properly installed in numerical sequence with No. 1 at timing belt end, and
No. 5 at flywheel/drive plate end of engine. Ensure arrow on top of main bearing cap points toward
timing belt end of engine.
10. Coat threads and bolt-to-main bearing cap contact surfaces on main bearing cap bolts with engine oil.
Install and tighten main bearing cap bolts to specification in sequence. See Fig. 36
. See TORQUE
SPECIFICATIONS .
11. Ensure crankshaft main bearing oil clearance and crankshaft end play are within specification. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
table under ENGINE
SPECIFICATIONS. Replace thrust bearing if end play is not within specification.
MAIN BEARING SPECIFICATIONS NOTE: Different width main bearings are used. Install wide main bearing on No. 3
journal and narrow main bearings on all other journals.
Bearing Size MarkBearing Thickness - In. (mm)
No. 3 Main Bearing
"1".07842-.07854 (1.9920-1.9950)
"2".07854-.07866 (1.9950-1.9980)
"3".07866-.07877 (1.9980-2.0010)
"4".07877-.07889 (2.0010-2.0040)
"5".07889-.07901 (2.0040-2.0070)
All Others
"1".07862-.07874 (1.9970-2.0000)
"2".07874-.07885 (2.0000-2.0030)
"3".07885-.07897 (2.0030-2.0060)
"4".07897-.07909 (2.0060-2.0090)
"5".07909-.07921 (2.0090-2.0120)

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1999-2000 ENGINES 2.0L 4-Cylinder
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Fig. 36: Main Bearing Cap Bolt Removal & Installation Sequence
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 37: Identifying Cylinder Block, Crankshaft & Main Bearing Size Marks

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Thrust Bearing
Install thrust bearing on No. 3 main bearing with grooves facing toward crankshaft, and away from cylinder
block and main bearing cap. Replace thrust bearing if crankshaft end play is not within specification. See

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1999-2000 ENGINES 2.0L 4-Cylinder
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CRANKSHAFT, MAIN & CONNECTING ROD BEARINGStable under ENGINE SPECIFICATIONS.
Cylinder Block
1. Inspect cylinder block deck surface warpage. Replace cylinder block if deck warpage exceeds
specification. See CYLINDER BLOCK
table under ENGINE SPECIFICATIONS.
2. Different cylinder bore diameters are used. Cylinder bore diameter may be identified by size mark ("1",
"2" or "3") on cylinder block deck surface. See Fig. 37
.
3. Measure cylinder bore diameter at 2 different places, 90 degrees apart at .39" (10.0 mm) from top and
bottom of cylinder bore and at center of cylinder bore. Ensure cylinder bore diameter is within
specification. See CYLINDER BLOCK
table under ENGINE SPECIFICATIONS.
4. Bore cylinder block for oversize pistons if cylinder bore diameter is not within specification. Pistons are
available in .020" (.50 mm) oversize.
5. Install main bearing caps in numerical sequence with No. 1 at timing belt end, and No. 5 at flywheel/drive
plate end of engine. Ensure arrow on top of main bearing cap points toward timing belt end of engine.
6. Install and tighten main bearing cap bolts to specification in sequence. See Fig. 36
. See TORQUE
SPECIFICATIONS .
7. Ensure main bearing bore inside diameter is within specification. See CYLINDER BLOCK
table under
ENGINE SPECIFICATIONS.
ENGINE OILING
ENGINE LUBRICATION SYSTEM
Crankshaft driven oil pump provides pressurized engine lubrication. Oil cooler is installed between oil filter and
cylinder block.
Crankcase Capacity
Drain and refill capacity with oil filter is approximately 4.3 qts. (4.1L). Dry fill capacity is approximately 4.8
qts. (4.6L).
Oil Pressure
With engine at normal operating temperature, oil pressure should be at least 4.3 psi (0.3 kg/cm2 ) at idle and 36-
71 psi (2.5-5.0 kg/cm
2 ) at 3000 RPM.
OIL PUMP
Removal & Disassembly
1. Remove timing belt, No. 2 idler pulley, crankshaft sprocket and oil pump sprocket. See TIMING BELT
NOTE: Main bearing bore inside diameter is identified by main bearing bore size mark
("1", "2" or "3") stamped on cylinder block. See Fig. 37
.

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1999-2000 ENGINES 2.0L 4-Cylinder
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under REMOVAL & INSTALLATION. Remove oil pan. See OIL PANunder REMOVAL &
INSTALLATION.
2. Remove oil pump pick-up tube, gasket and oil baffle plate. Disconnect electrical connector for crankshaft
position sensor located on from of oil pump housing. Remove bolt and crankshaft position sensor from
front of oil pump housing.
3. Remove oil pump-to-cylinder block bolts. Using soft-face hammer, tap oil pump housing from cylinder
block. To disassemble oil pump, remove oil pump body cover bolts, oil pump body cover and "O" ring.
Disassemble oil pump components. See Fig. 38
. Remove oil pump oil seal and crankshaft front oil seal
(if necessary).
Fig. 38: Exploded View Of Oil Pump

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Inspection
1. Inspect components for damage. Coat relief valve with engine oil and ensure relief valve slides freely in
bore of oil pump housing. Replace relief valve and/or oil pump housing if relief fails to slide freely.
2. Install rotors in oil pump housing. Using feeler gauge, measure driven rotor-to-oil pump housing
clearance. Replace rotor assembly or oil pump housing if clearance exceeds specification. See OIL
PUMP SPECIFICATIONS table.
3. Using feeler gauge, measure rotor tip clearance between tip of drive rotor and tip of driven rotor. Tip of
drive rotor is on outside of rotor and tip of driven rotor is on inside of rotor. Replace rotor assembly if
clearance exceeds specification. See OIL PUMP SPECIFICATIONS
table.

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1999-2000 ENGINES 2.0L 4-Cylinder
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OIL PUMP SPECIFICATIONS
Reassembly & Installation
1. To reassemble, reverse disassembly procedure. Ensure reference marks (dot area) on rotors face toward
oil pump body cover, away from oil pump housing.
2. Using hammer and Oil Seal Installer (SST 09950-60010), install NEW crankshaft front oil seal (if
removed) until oil seal surface is even with oil pump housing. Coat lip of oil seal with grease.
3. Install NEW oil pump oil seal (if removed) until oil seal surface is even with oil pump body cover. Coat
lip of oil seal with grease.
4. Install oil pump body cover using NEW "O" ring. Install and tighten oil pump body cover bolts to
specification. See TORQUE SPECIFICATIONS
. Using NEW gasket, install oil pump on cylinder
block.
5. Ensure 2 longest oil pump-to-cylinder block bolts are located in lowest outside holes nearest to oil pan
flange on each side of oil pump. Tighten oil pump-to-cylinder block bolts to specification. See TORQUE
SPECIFICATIONS . To install remaining components, reverse removal procedure.
OIL COOLER
Removal
1. Oil cooler is mounted between oil filter and cylinder block. Disconnect negative battery cable. Drain
cooling system.
2. Remove passenger-side lower engine cover. Remove front exhaust pipe from between front catalytic
converter on exhaust manifold and rear exhaust pipe. Remove generator.
3. Remove exhaust manifold with catalytic converter and heat insulators for access to oil cooler. Remove oil
filter. Disconnect coolant hoses from oil cooler. Remove oil cooler relief valve and plate washer from
center of oil cooler housing. Remove oil cooler-to-cylinder block nut. Remove oil cooler, gasket and "O"
ring.
Inspection
1. Inspect oil cooler for damage. Apply air pressure to coolant hose pipe on oil cooler. Ensure air flows
through oil cooler, and oil cooler is not restricted. Replace oil cooler if damage or restricted.
2. Using wooden stick, push inward on check valve located in center of oil cooler relief valve. Push inward
from threaded end (opposite oil filter threads) on oil cooler relief valve. Replace oil cooler relief valve if
check valve fails to move.
ApplicationIn. (mm)
Driven Rotor-To-Oil Pump Housing Clearance
Standard.0039-.0063 (.100-.160)
Wear Limit.0079 (.200)
Rotor Tip Clearance
Standard.0016-.0063 (.040-.160)
Wear Limit.0079 (.200)

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1999-2000 ENGINES 2.0L 4-Cylinder
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Installation
1. To install, reverse removal procedure. Use a NEW "O" ring and gasket. Coat "O" ring with engine oil.
Coat threads and area below head of oil cooler relief valve with engine oil.
2. Install oil cooler with oil cooler-to-cylinder block nut and oil cooler relief valve loosely installed. Tighten
oil cooler relief valve, and then nut, to specification. See TORQUE SPECIFICATIONS
.
3. Use NEW gasket and NEW nuts when installing front exhaust pipe to catalytic converter. Ensure all
bolts/nuts are loosely installed before tightening to specification. See TORQUE SPECIFICATIONS
.
Add engine oil as needed. Fill cooling system.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ApplicationFt. Lbs. (N.m)
ABS Actuator Mounting Bracket-To-Body Bolt/Nut14 (19)
A/C Compressor Bolt/Nut
Bolt27 (37)
Nut20 (27)
Stud Bolt34 (46)
Axle Shaft Bearing Bracket Bolt
2WD A/T Models47 (64)
Axle Shaft Bearing Bracket-To-Cylinder Block Bolt
2WD A/T & M/T Models47 (64)
Axle Shaft Nut159 (216)
Axle Shaft Retaining Bolt
2WD M/T Models24 (33)
Ball Joint-To-Lower Control Arm Bolt/Nut94 (127)
Brake Line-To-ABS Actuator Nut11 (15)
Camshaft Bearing Cap Bolt (1) 14 (19)
Camshaft Sprocket Bolt40 (54)
Connecting Rod Nut
Step 118 (24)
Step 2Additional 90
Degrees
Coolant Outlet Nut11 (15)
Crankshaft Pulley Bolt80 (108)
Cylinder Head Bolt (2)
Step 136 (49)
Step 2Additional 90
Degrees
Distributor Hold-Down Bolt14 (19)
Drive Shaft Center Support Bearing Bolt

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1999-2000 ENGINES 2.0L 4-Cylinder
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