width TOYOTA RAV4 1996 Service Repair Manual

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

1999 Toyota RAV4
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)

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
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Sunday, November 22, 2009 10:22:27 AMPage 51 © 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.

Fig. 30: 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 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 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
under ENGINE SPECIFICATIONS.
CYLINDER BLOCK ASSEMBLY

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:31 AMPage 44 © 2005 Mitchell Repair Information Company, LLC.

6. Main bearing size mark ("1", "2", "3", "4" or "5") is located on side of main bearing. See Fig. 39 . 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
. 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. 38
. See TORQUE
SPECIFICATIONS .
11. Ensure crankshaft main bearing oil clearance and crankshaft end play are within specification. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
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)

1997 Toyota RAV4
2.0L 4-CYL 1997-98 ENGINES Toyota 2.0L 4-Cylinder
Microsoft
Sunday, November 22, 2009 10:23:31 AMPage 53 © 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.

On models equipped with anti-lock brake systems, ALWAYS observe the following cautions:
DO NOT attempt to bleed hydraulic system without first referring to the appropriate ANTI-LOCK
BRAKE SYSTEM article in the BRAKES Section.
DO NOT mix tire sizes. As long as tires remain close to the original diameter, increasing the width is
acceptable. Rolling diameter must be identical for all 4 tires. Some manufacturers recommend tires of the
same brand, style and type. Failure to follow this precaution may cause inaccurate wheel speed readings.
Use ONLY recommended brake fluids. DO NOT use silicone brake fluids in an ABS-equipped vehicle.
BATTERY WARNING
REPLACING BLOWN FUSES
BRAKE PAD WEAR INDICATOR
Indicator will cause a squealing or scraping noise, warning that brake pads need replacement.
CATALYTIC CONVERTER CAUTION: The anti-lock brake system contains electronic equipment that can be
susceptible to interference caused by improperly installed or high output
radio transmitting equipment. Since this interference could cause the
possible loss of the anti-lock braking capability, such equipment should
be installed by qualified professionals.
WARNING:When battery is disconnected, vehicles equipped with computers may
lose memory data. When battery power is restored, driveability problems
may exist on some vehicles. These vehicles may require a relearn
procedure. See COMPUTER RELEARN PROCEDURES article in GENERAL
INFORMATION section.
CAUTION: Before replacing a blown fuse, remove ignition key, turn off all lights and
accessories to avoid damaging the electrical system. Be sure to use fuse
with the correct indicated amperage rating. The use of an incorrect
amperage rating fuse may result in a dangerous electrical system
overload.
CAUTION: Continued operation of vehicle with a severe malfunction could cause
converter to overheat, resulting in possible damage to converter and
vehicle.
CAUTION: Any modification to the exhaust system on turbo models, which reduces
exhaust backpressure, will lead to lean fuel mixtures and excessive spark
advance. This could cause serious engine damage.

1999 Toyota RAV4
MAINTENANCE INFORMATION 1997-99 MAINTENANCE Toyota Maintenance Information
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Sunday, November 22, 2009 10:32:42 AMPage 8 © 2005 Mitchell Repair Information Company, LLC.

Fig. 9: Exploded View Of Transfer Left Case
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 10: Exploded View Of Transfer Lower Valve Body

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Reassembly
1. Install NEW transfer lower valve body gaskets. Install plate. Ensure transfer lower valve body springs are
installed in correct locations. See TRANSFER LOWER VALVE BODY SPRING
SPECIFICATIONS table. Ensure retainers are same height, width and thickness. Lower transfer lower
valve body into place.
2. Install 6 bolts and tighten to 58 INCH lbs. (6.6 N.m). Install NEW "O" ring on control solenoid and coat
with ATF. Install 2 bolts and control solenoid. Tighten bolts to 58 INCH lbs. (6.6 N.m).
3. Install NEW "O" ring on control solenoid wiring and coat with ATF. Install solenoid wiring and bolt.
Tighten bolt to 58 INCH lbs. (6.6 N.m). Install solenoid connector.
4. Install NEW transfer case gaskets and valve body strainer. Install NEW transfer valve body gasket. Install
transfer valve body cover. Tighten 8 bolts to 97 INCH lbs. (11 N.m). Install NEW "O" ring on plug and
coat with ATF. Install plug and tighten to 65 INCH lbs. (7.4 N.m).
TRANSFER LOWER VALVE BODY SPRING SPECIFICATIONS
SpringFree Length - In. (mm)Number Of Coils
Center Differential Clutch Control Valve1.150 (29.20)15.5

1999 Toyota RAV4
1999 TRANSFER CASES Toyota A-540H Overhaul
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