check engine TOYOTA RAV4 1996 Service Repair Manual

N00932
Mark
1, 2 or 3Mark
1, 2 or 3
S01617
P13438
P13444
P13445
10
8
4
37951 62 EM−84
− ENGINE MECHANICALCYLINDER BLOCK
1996 RAV4 (RM447U)
HINT:
If using a standard bearing, replace it with one having the same
number marked on the connecting rod cap. There are 3 sizes
of standard bearings, marked ”1”, ”2” and ”3” accordingly.
Standard sized bearing center wall thickness:
Mark ”1”1.484 − 1.488 mm (0.0584 − 0.0586 in.)
Mark ”2”1.488 − 1.492 mm (0.0586 − 0.0587 in.)
Mark ”3”1.492 − 1.496 mm (0.0587 − 0.0589 in.)
(k) Completely remove the Plastigage.
16. R E M O V E P I S TO N A N D C O N N E C T I N G R O D A S-
SEMBLIES
(a) Using a ridge reamer, remove all the carbon from the top
of the cylinder.
(b) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(c) Push the piston, connecting rod assembly and upper
bearing through the top of the cylinder block.
HINT:
Keep the bearings, connecting rod and cap together.
Arrange the piston and connecting rod assemblies in the
correct order.
17. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while prying
the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.020 − 0.220 mm (0.0008 − 0.0087 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washer as a set.
Thrust washer thickness:
2.440 − 2.490 mm (0.0961 − 0.0980 in.)
18. REMOVE MAIN BEARING CAPS AND CHECK OIL
CLEARANCE
(a) Uniformly loosen and remove the 10 main bearing cap
bolts in several passes, in the sequence shown.

N00923
P13407
P13408
P13447
Plastigage
P13448
10
84 3
79
5
1
6
2
− ENGINE MECHANICALCYLINDER BLOCK
EM−85
1996 RAV4 (RM447U)
(b) Using the removed main bearing cap bolts, pry the main
bearing cap back and forth, and remove the 5 main bear-
ing caps, 5 lower bearings and 2 lower thrust washers
(No.3 main bearing cap only).
HINT:
Keep the lower bearing and main bearing cap together.
Arrange the main bearing caps and lower thrust washers
in the correct order.
(c) Lift out the crankshaft.
HINT:
Keep the upper bearing and upper thrust washers together with
the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and
scratches.
If the journal or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
(h) Install the main bearing caps (See page EM−99).
NOTICE:
Do not turn the crankshaft.
(i) Remove the main bearing caps (See procedure (a) and
(b) above).

P13407
P13424
S01239
− ENGINE MECHANICALCYLINDER BLOCK
EM−87
1996 RAV4 (RM447U)
Standard sized bearing center wall thickness:
No. 3
Mark ”1”1.992 − 1.995 mm (0.0784 − 0.0785 in.)
Mark ”2”1.995 − 1.998 mm (0.0785 − 0.0787 in.)
Mark ”3”1.998 − 2.001 mm (0.0787 − 0.0788 in.)
Mark ”4”2.001 − 2.004 mm (0.0788 − 0.0789 in.)
Mark ”5”2.004 − 2.007 mm (0.0789 − 0.0790 in.)
Others
Mark ”1”1.997 − 2.000 mm (0.0786 − 0.0787 in.)
Mark ”2”2.000 − 2.003 mm (0.0787 − 0.0789 in.)
Mark ”3”2.003 − 2.006 mm (0.0789 − 0.0790 in.)
Mark ”4”2.006 − 2.009 mm (0.0790 − 0.0791 in.)
Mark ”5”2.009 − 2.012 mm (0.0791 − 0.0792 in.)
(k) Completely remove the Plastigege.
19. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the 5 upper bearings and 2 upper thrust washers
from the cylinder block.
HINT:
Arrange the main bearing caps, bearings and thrust washers in
the correct order.
20. CHECK FIT BETWEEN PISTON AND PISTON PIN
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
21. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring expander by hand.
HINT:
Arrange the piston rings in correct order only.

S01618
EM1Q3−01
Z16365
S01619
S07299
Mark 1, 2 or 3
No. 1 No. 2 No. 3 No. 4
− ENGINE MECHANICALCYLINDER BLOCK
EM−89
1996 RAV4 (RM447U)
INSPECTION
1. CLEAN CYLINDER BLOCK
(a) Remove the gasket material.
Using a gasket scraper, remove all the gasket material
from the top surface of the cylinder block.
(b) Clean the cylinder block.
Using a soft brush and solvent, thoroughly clean the cylin-
der block.
2. INSPECT CYLINDER BLOCK
(a) Inspect for flatness.
Using a precision straight edge and feeler gauge, mea-
sure the surfaces contacting the cylinder head gasket for
warpage.
Maximum warpage: 0.05 mm (0.0020 in.)
If warpage is greater than maximum, replace the cylinder block.
(b) Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all the 4 cylinders and re-
place all the 4 pistons (See page EM−96). If necessary, replace
the cylinder block.
(c) Inspect the cylinder bore diameter.
HINT:
There are 3 sizes of the standard cylinder bore diameter,
marked ”1”, ”2” and ”3” accordingly. The mark is stamped on the
top of the cylinder block.

S01246
Z00064
Z00065
EM7538
− ENGINE MECHANICALCYLINDER BLOCK
EM−93
1996 RAV4 (RM447U)
If the end gap is greater than maximum, replace the piston ring.
If the end gap is greater than maximum, even with a new piston
ring, rebore all the 4 cylinders (see page EM−96) or replace the
cylinder block.
(d) Inspect the piston pin fit.
At 60°C (140°F), you should be able to push the piston
pin into the piston pin hole with your thumb.
(e) Using a rod aligner and feeler gauge, check the connect-
ing rod alignment.
(1) Check for out−of−alignment.
Maximum out−of−alignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If out−of−alignment is greater than maximum, replace the con-
necting rod assembly.
(2) Check for twist
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.
(f) Inspect the piston pin oil clearance.
(1) Using a caliper gauge, measure the inside diameter
of the connecting rod bushing.
Bushing inside diameter:
22.005 − 22.017 mm (0.8663 − 0.8668 in.)

EM0227
P13428
P13429
15 mm
(0.59 in.) EM−94
− ENGINE MECHANICALCYLINDER BLOCK
1996 RAV4 (RM447U)
(2) Using a micrometer, measure the piston pin diame-
ter.
Piston pin diameter:
21.997 − 22.009 mm (0.8660 − 0.8665 in.)
(3) Subtract the piston pin diameter measurement from
the bushing inside diameter measurement.
Standard oil clearance:
0.005 − 0.011 mm (0.0002 − 0.0004 in.)
Maximum oil clearance: 0.05 mm (0.0020 in.)
If the oil clearance is greater than maximum, replace the bush-
ing (See page EM−96). If necessary, replace the piston and pis-
ton pin as a set.
(g) Inspect the connecting rod bolts.
(1) Install the cap nut to the connecting rod bolt. Check
that the cap nut can be turned easily by hand to the
end of the thread.
(2) If the cap nut cannot be turned easily, measure the
outside diameter of the connecting rod bolt with a
vernier caliper.
Standard diameter:
7.860 − 8.000 mm (0.3094 − 0.3150 in.)
Minimum diameter: 7.60 mm (0.2992 in.)
HINT:
If the location of this area cannot be judged by visual inspection,
measure the outer diameter at the location shown in the illustra-
tion.
If the outside diameter is less than minimum, replace the con-
necting rod bolt and nut as a set.

P13414
EM3553
− ENGINE MECHANICALCYLINDER BLOCK
EM−95
1996 RAV4 (RM447U)
5. INSPECT CRANKSHAFT
(a) Inspect for circle runout.
(1) Place the crankshaft on V−blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
(b) Inspect the main journals and crank pins.
(1) Using a micrometer, measure the diameter of each
main journal and crank pin.
Main journal diameter:
STD54.988 − 55.003 mm (2.1653 − 2.1655 in.)
U/S 0.2554.745 − 54.755 mm (2.1553 − 2.1557 in.)
Crank pin diameter:
STD51.985 − 52.000 mm (2.0466 − 2.0472 in.)
U/S 0.2551.745 − 51.755 mm (2.0372 − 2.0376 in.)
If the diameter is not as specified, check the oil clearance (See
page EM−81). If necessary, grind or replace the crankshaft.
(2) Check each main journal and crank pin for taper
and out−of−round as shown.
Maximum taper and out−of−round:
0.02 mm (0.0008 in.)
If the taper and out−of−round is greater than maximum, replace
the crankshaft.
6. IF NECESSARY, GRIND AND HONE MAIN JOURNALS
AND/OR CRANK PINS
Grind and hone the main journals and/or crank pins to the fin-
ished undersized diameter (See procedure in step 5). Install
new main journal and/or crankshaft pin undersized bearings.

EM1Q2−01
EM1321
SST
EM7329
Oil Hole
P01038
EM1322
EM−96
− ENGINE MECHANICALCYLINDER BLOCK
1996 RAV4 (RM447U)
REPLACEMENT
1. REPLACE CONNECTING ROD BUSHINGS
(a) Using SST and a press, press out the bushing.
SST 09222−30010
(b) Align the oil holes of a new bushing and the connecting
rod.
(c) Using SST and a press, press in the bushing.
SST 09222−30010
(d) Using a pin hole grinder, hone the bushing to obtain the
standard specified clearance (See page EM−89) be-
tween the bushing and piston pin.
(e) Check the piston pin fit at normal room temperature. Coat
the piston pin with engine oil, and push it into the connect-
ing rod with your thumb.
2. REPLACE OVERSIZED (O/S) PISTONS FOR CYLIN-
DER BORING
HINT:
Bore all the 4 cylinders for the O/S piston outside diame-
ter.
Replace all the piston rings with ones to match the O/S
pistons.
(a) Keep 4 new O/S pistons.
O/S 0.50 piston diameter:
86.370 − 86.400 mm (3.4004 − 3.4016 in.)

P13450
P13448
Z17147
Front Mark
(Cavity)
FrontPush
P13451
Front Mark
(Protrusion)
P13441
− ENGINE MECHANICALCYLINDER BLOCK
EM−101
1996 RAV4 (RM447U)
(b) Install the 5 main bearing caps in their proper locations.
HINT:
Each bearing cap has a number and front mark.
(c) Apply a light coat of engine oil on the threads and under
the heads of the main bearing cap bolts.
(d) Install and uniformly tighten the 10 bolts of the main bear-
ing caps, in several passes, in the sequence shown.
Torque: 59 N·m (600 kgf·cm, 43 ft·lbf)
(e) Check that the crankshaft turns smoothly.
(f) Check the crankshaft thrust clearance (See page
EM−81).
8. INSTALL PISTON AND CONNECTING ROD AS-
SEMBLES
(a) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(b) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
9. INSTALL CONNECTING ROD CAPS
(a) Place the connecting rod cap on the connecting rod.
(1) Match the numbered connecting rod cap with the
connecting rod.
(2) Install the connecting rod cap with the front mark
facing forward.
(b) Install the connecting rod cap nuts.
HINT:
The cap nuts are tightened in 2 progressive steps (steps
(b) and (d)).
If any one of the connecting rod bolts is broken or de-
formed, replace it.
(1) Apply a light coat of engine oil on the threads and
under the nuts of the connecting rod cap.
(2) Install and alternately tighten the 2 cap nuts in sev-
eral passes.

P13453
Painted Mark
90°90°
P05527
S01632
SST
P15371
New O−Ring EM−102
− ENGINE MECHANICALCYLINDER BLOCK
1996 RAV4 (RM447U)
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
If any one of the cap nuts does not meet the torque specifica-
tion, replace the connecting rod bolt and cap nut as a set.
(3) Mark the front of the cap nut with the paint.
(4) Retighten the cap nuts 90° as shown.
(5) Check that the painted mark is now at a 90° angle
to the front.
(c) Check that the crankshaft turns smoothly.
(d) Check the connecting rod thrust clearance (See page
EM−81).
10. INSTALL REAR OIL SEAL RETAINER
Install a new gasket and the retainer with the 6 bolts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
11. INSTALL KNOCK SENSOR
Using SST, install the knock sensor.
SST 09816−30010
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
12. INSTALL OIL COOLER AND OIL FILTER (See page
LU−20)
13. INSTALL WATER PUMP, WATER PUMP COVER AS-
SEMBLY AND GENERATOR DRIVE BELT ADJUSTING
BAR
(a) Install a new O−ring to the water pump cover.