TOYOTA RAV4 1996 Service Repair Manual

4WD Models27 (37)
Drive Shaft Flange Bolt/Nut
4WD Models54 (73)
EGR Valve
Nut(3)
Union Nut43 (58)
Engine Mounts & Brackets
Front (Exhaust Manifold Side) Engine Mount-To-Engine Mount
Crossmember Bolt59 (80)
Left (Transaxle Side) Engine Mounting Bracket-To-Engine Mount Bolt/Nut47 (64)
Right (Timing Belt Side) Engine Mounting Bracket-To-Cylinder Block Bolt38 (52)
Right (Timing Belt Side) Engine Mount-To-Body Bolt47 (64)
Right (Timing Belt Side) Engine Mounting Bracket-To-Engine Mount Bolt/Nut
Bolt27 (37)
Nut38 (52)
Engine Mount Crossmember-To-Body Bolt26 (35)
Exhaust Manifold Nut36 (49)
Flywheel/Drive Plate Bolt
A/T61 (83)
M/T65 (88)
Front Catalytic Converter Brace Bolt/Nut31 (42)
Front Catalytic Converter-To-Exhaust Manifold Bolt/Nut45 (61)
Front Exhaust Pipe-To-Front Catalytic Converter Nut46 (62)
Front Exhaust Pipe-To-Rear Exhaust Pipe Bolt/Nut35 (47)
Front Suspension Crossmember Bolt
Bolt At Body152 (206)
Bolt At Lower Control Arm101 (137)
Fuel Line-To-Fuel Filter Union Bolt21 (28)
Fuel Pipe-To-Delivery Pipe Union Bolt25 (34)
Generator Adjusting Bracket Bolt20 (27)
Generator Mounting Bracket Bolt31 (42)
Intake Manifold Bolt/Nut14 (19)
Intake Manifold Brace Bolt31 (42)
Main Bearing Cap Bolt (4) 43 (58)
No. 1 & No. 2 Idler Pulley Bolt31 (42)
Oil Cooler Relief Valve58 (79)
Oil Pump Sprocket Nut18 (24)
Oxygen Sensor-To-Exhaust Manifold Nut15 (20)
Oxygen Sensor-To-Front Catalytic Converter33 (45)
Power Steering Pump Bolt32 (43)

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
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Sunday, November 22, 2009 10:22:27 AMPage 58 © 2005 Mitchell Repair Information Company, LLC.

ENGINE SPECIFICATIONS
Power Steering Pump Mounting Bracket-To-Cylinder Block Bolt32 (43)
Spark Plug13 (18)
Spark Plug Tube39 (53)
Stabilizer Bar Link-To-Lower Control Arm Nut
2-Door Vehicles33 (45)
4-Door Vehicles54 (73)
Stabilizer Bar-To-Frame Mount Bolt22 (30)
Starter Bolt29 (39)
Steering Gear Assembly-To-Front Suspension Crossmember Bolt/Nut 83 (113)
Stiffener Plate Bolt27 (37)
Throttle Body Bolt/Nut14 (19)
Tie Rod Nut41 (56)
Valve Cover Nut33 (45)
Wheel Lug Nut76 (103)
INCH Lbs. (N.m)
ABS Speed Sensor Bolt71 (8.0)
Clutch Release Cylinder Bolt106 (12.0)
Coolant By-Pass Pipe-To-Water Pump Nut82 (9.3)
Crankshaft Position Sensor Bolt71 (8.0)
Fuel Delivery Pipe-To-Cylinder Head Bolt115 (13.0)
No. 3 Timing Belt Cover Bolt69 (7.8)
Oil Baffle Plate-To-Cylinder Block Bolt/Nut48 (5.4)
Oil Cooler-To-Cylinder Block Nut78 (8.8)
Oil Pan Bolt/Nut48 (5.4)
Oil Pump Body Cover Bolt78 (8.8)
Oil Pump Pick-Up Tube Bolt/Nut48 (5.4)
Oil Pump-To-Cylinder Block Bolt78 (8.8)
Rear Plate-To-Cylinder Block Bolt82 (9.3)
Rear Seal Housing Bolt115 (13.0)
Thermostat Housing Nut78 (8.8)
Water Pump-To-Cylinder Block Bolt (5) 78 (8.8)
Water Pump-To-Water Pump Cover Bolt78 (8.8)
(1)Tighten bolts to specification in sequence. See Fig. 22 and Fig. 23 .
(2)Tighten bolts to specification in sequence. See Fig. 15 .
(3)Tighten nut to 115 INCH lbs. (13.0 N.m).
(4)Tighten bolts to specification in sequence. See Fig. 36 .
(5)Tighten bolts to specification in sequence. See Fig. 28 .

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
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Sunday, November 22, 2009 10:22:27 AMPage 59 © 2005 Mitchell Repair Information Company, LLC.

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
Microsoft
Sunday, November 22, 2009 10:22:27 AMPage 60 © 2005 Mitchell Repair Information Company, LLC.

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
Microsoft
Sunday, November 22, 2009 10:22:27 AMPage 61 © 2005 Mitchell Repair Information Company, LLC.

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
Microsoft
Sunday, November 22, 2009 10:22:27 AMPage 62 © 2005 Mitchell Repair Information Company, LLC.

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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Sunday, November 22, 2009 10:22:27 AMPage 63 © 2005 Mitchell Repair Information Company, LLC.

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
Microsoft
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
Microsoft
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
Microsoft
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
Microsoft
Sunday, November 22, 2009 10:23:30 AMPage 2 © 2005 Mitchell Repair Information Company, LLC.