TOYOTA RAV4 1996 Service Repair Manual

ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
(3)Tighten nut to 115 INCH lbs. (13.0 N.m).
(4)Tighten bolts to specification in sequence. See Fig. 38 .
(5)Tighten bolts to specification in sequence. See Fig. 29 .
ApplicationSpecification
Displacement122 Cu. In. (2.0L)
Bore3.39" (86.0 mm)
Stroke3.39" (86.0 mm)
Compression Ratio9.5:1
Fuel SystemSFI
1997
Horsepower @ RPM120 @ 5400
Torque Ft. Lbs. @ RPM125 @ 4600
1998
California
Horsepower @ RPM125 @ 5400
Torque Ft. Lbs. @ RPM130 @ 4600
Except California
Horsepower @ RPM127 @ 5400
Torque Ft. Lbs. @ RPM132 @ 4600
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)

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
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CONNECTING RODS
CONNECTING RODS
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)
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. 39 .
ApplicationIn. (mm)
Piston Pin Bushing
Bore Diameter.8663-.8668 (22.005-22.017)
Piston Pin Oil Clearance (1)
Standard.0002-.0004 (.005-.010)

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
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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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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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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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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
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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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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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1999-2000 SUSPENSION
Front - Avalon, Camry, Camry Solara, Celica, Corolla, Echo, RAV4 & Sienna
DESCRIPTION
Vehicles are equipped with front wheel drive and independent MacPherson strut (shock absorber) front
suspension. RAV4 can also be equipped with all wheel drive. Suspension consists of vertically mounted strut
assemblies, control arms, and stabilizer bar. Shock absorbers are mounted between inner fender and steering
knuckle. Tie rod ends connect rack and pinion steering to steering knuckle. Ball joint connects steering knuckle
to lower control arm. On some models, a suspension crossmember is used. A stabilizer bar attaches to lower
control arms.
ADJUSTMENTS & INSPECTION
WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
BALL JOINT CHECKING
Remove ball joint and place in vise, with ball joint stud pointing upward. Flip stud back and forth about 5 times.
Reinstall the ball joint nut. Place torque wrench on ball joint nut and turn nut continuously 1 turn every 2 to 4
seconds. Read torque measurement on 5th turn. See BALL JOINT TURNING TORQUE
SPECIFICATIONS table. If torque is not within specification, replace ball joint.
BALL JOINT TURNING TORQUE SPECIFICATIONS
WHEEL BEARING CHECKING NOTE: See SPECIFICATIONS & PROCEDURES
article in WHEEL ALIGNMENT.
NOTE: Ball joint must be removed for the following checking procedure. See LOWER
CONTROL ARM and BALL JOINTS under REMOVAL & INSTALLATION.
ApplicationINCH Lbs. (N.m)
Avalon, Camry, Camry Solara & Sienna8.7-30 (1-3.4)
Celica
19998.7-26 (1-2.9)
20008.7-43 (1-4.0)
Corolla8.7-26 (1-2.9)
Echo5.2-30 (.59-3.4)
RAV413-43 (1.5-5.0)
NOTE: Wheel bearings are not adjustable. Whenever bearings are removed, replace
with NEW bearings, races and oil seals.

1999 Toyota RAV4
1999-2000 SUSPENSION Front - Avalon, Camry, Camry Solara, Celica, Corolla, Echo, RAV4 & Sienna

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 1 © 2005 Mitchell Repair Information Company, LLC.
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Sunday, November 22, 2009 10:36:38 AMPage 1 © 2005 Mitchell Repair Information Company, LLC.

1. Remove front wheel. Remove brake caliper and disc. Support caliper out of way. Using dial indicator
placed near center of axle hub, check backlash by moving hub in bearing shaft direction. If backlash
exceeds .002" (.05 mm), replace bearing.
2. Check deviation at axle hub surface, outside of hub bolt by moving hub with twisting motion. If deviation
is more than .002" (.05 mm), replace bearing. Reinstall disc, brake caliper and front wheel. See Fig. 1
and
Fig. 2
.
Fig. 1: Identifying Hub Components (Camry Shown; Avalon, Camry Solara, Echo & Sienna Similar)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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 2 © 2005 Mitchell Repair Information Company, LLC.