TOYOTA RAV4 1996 Service Repair Manual

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).

P13449
Z11716
No. 1
No. 2No. 3 No. 4No. 5
Mark
1, 2 or 3
Mark
0, 1 or 2
Mark
1, 2, 3, 4 or 5 No. 5
No. 4
EXAMPLE: Cylinder block ”2” + Crankshaft ”1”
= Total number 3 (Use bearing ”3”)
Number marked
Cylinder block
Crankshaft
Use bearing123
1
111 2
22
22
333445 000 EM−86
− ENGINE MECHANICALCYLINDER BLOCK
1996 RAV4 (RM447U)
(j) Measure the Plastigage at its widest point.
Standard clearance:
No. 3 STD
U/S 0.250.025 − 0.044 mm (0.0010 − 0.0017 in.)
0.027 − 0.067 mm (0.0011 − 0.0026 in.)
Others STD
U/S 0.250.015 − 0.034 mm (0.0006 − 0.0013 in.)
0.019 − 0.059 mm (0.0007 − 0.0023 in.)
Maximum clearance: 0.08 mm (0.0031 in.)
HINT:
If replacing the cylinder block subassembly, the bearing stan-
dard clearance will be:
No. 30.027 − 0.054 mm (0.0001 − 0.0021 in.)
Others0.017 − 0.044 mm (0.0007 − 0.0017 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.
HINT:
If using a standard bearing, replace it with one having the same
number. If the number of the bearing cannot be determined, se-
lect the correct bearing by adding together the numbers im-
printed on the cylinder block and crankshaft, then selecting the
bearing with the same number as the total. There are 5 sizes
of standard bearings, marked ”1”, ”2”, ”3”, ”4” and ”5” according-
ly.
Reference
Cylinder block main journal bore diameter:
Mark ”1”59.020 − 59.026 mm (2.3236 − 2.3239 in.)
Mark ”2”59.026 − 59.032 mm (2.3239 − 2.3241 in.)
Mark ”3”59.032 − 59.038 mm (2.3241 − 2.3243 in.)
Crankshaft main journal diameter:
Mark ”0”54.998 − 55.003 mm (2.1653 − 2.1655 in.)
Mark ”1”54.993 − 54.998 mm (2.1651 − 2.1653 in.)
Mark ”2”54.988 − 54.993 mm (2.1649 − 2.1651 in.)

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.

P15329
P00116
EM−88
− ENGINE MECHANICALCYLINDER BLOCK
1996 RAV4 (RM447U)
22. DISCONNECT CONNECTING ROD FROM PISTON
(a) Using a small screwdriver, pry out the 2 snap rings.
(b) Gradually heat the piston to 80 − 90°C (176 − 194°F).
(c) Using a plastic−faced hammer and brass bar, lightly tap
out the piston pin and remove the connecting rod.
HINT:
The piston and pin are matched set.
Arrange the pistons, pins, rings, connecting rods and
bearings in the correct order.

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.

S01639
A
B
C FrontThrust
Direction
Axial
Direction
10 mm
(0.39 in.) 1
2
1
2
10 mm
(0.39 in.)
S01617
S01242
S01243
EM−90
− ENGINE MECHANICALCYLINDER BLOCK
1996 RAV4 (RM447U)
Using a cylinder gauge, measure the cylinder bore diame-
ter at positions A, B and C in the thrust and axial direc-
tions.
Standard diameter:
Mark ”1”86.000 − 86.010 mm (3.3858 − 3.3862 in.)
Mark ”2”86.010 − 86.020 mm (3.3862 − 3.3866 in.)
Mark ”3”86.020 − 86.030 mm (3.3866 − 3.3870 in.)
Maximum diameter:
STD86.23 mm (3.3949 in.)
O/S 0.5086.73 mm (3.4146 in.)
If the diameter is greater than maximum, rebore all the 4 cylin-
ders and replace all the 4 pistons (See page EM−96). If neces-
sary, replace the cylinder block.
(d) Remove the cylinder ridge.
If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer,
grind the top of the cylinder.
3. CLEAN PISTON
(a) Using a gasket scraper, remove the carbon from the pis-
ton top.
(b) Using a groove cleaning tool or broken ring, clean the pis-
ton ring grooves.

S01244
P16540
Front
Mark
(Cavity)Mark 1, 2 or 3
Z11709
26 mm
(1.02 in.)
− ENGINE MECHANICALCYLINDER BLOCK
EM−91
1996 RAV4 (RM447U)
(c) Using solvent and a brush, thoroughly clean the piston.
NOTICE:
Do not use a wire brush.
4. INSPECT PISTON AND CONNECTING ROD
(a) Inspect the piston oil clearance.
HINT:
There are 3 sizes of the standard piston diameter, marked ”1”,
”2” and ”3” accordingly. The mark is stamped on the piston top.
(1) Using a micrometer, measure the piston diameter at
right angles to the piston pin center line, 20.5 mm
(0.807 in.) from the piston head.
Piston diameter:
STD Mark ”1”
Mark ”2”
Mark ”3”85.870 − 85.880 mm (3.3807 − 3.3811 in.)
85.880 − 85.890 mm (3.3811 − 3.3815 in.)
85.890 − 85.900 mm (3.3815 − 3.3819 in.)
O/S 0.5086.370 − 86.400 mm (3.4004 − 3.4016 in.)
(2) Measure the cylinder bore diameter in the thrust
directions (See step 2).
(3) Subtract the piston diameter measurement from the
cylinder bore diameter measurement.
Standard oil clearance:
0.12 − 0.14 mm (0.0047 − 0.0055 in.)
Maximum oil clearance: 0.16 mm (0.0063 in.)
If the oil clearance is greater than maximum, replace all the 4
pistons and rebore all the 4 cylinders (See page EM−96). If nec-
essary, replace the cylinder block.

Z19572
Mark 1, 2 or 3
No. 1 No. 2No. 3
No. 4
Mark
1, 2 or 3
Front Mark
(Cavity)
S01245
EM0224
Top of
Cylinder Block
110 mm
(4.33 in.)
EM7639
EM−92
− ENGINE MECHANICALCYLINDER BLOCK
1996 RAV4 (RM447U)
HINT:
Use new cylinder block:
Use a piston with the same number mark as the cylinder bore
diameter marked on the cylinder block.
(b) Inspect the piston ring groove clearance.
Using a feeler gauge, measure the clearance between
new piston ring and the wall of the ring groove.
Ring groove clearance:
0.030 − 0.070 mm (0.0012 − 0.0028 in.)
If the clearance is not as specified, replace the piston.
(c) Inspect the piston ring end gap.
(1) Insert the piston ring into the cylinder bore.
(2) Using a piston, push the piston ring a little beyond
the bottom of the ring travel, 110 mm (4.33 in.) from
the top of the cylinder block.
(3) Using a feeler gauge, measure the end gap.
Standard end gap:
No. 10.270 − 0.500 mm (0.0106 − 0.0197 in.)
No. 20.270 − 0.510 mm (0.0106 − 0.0201 in.)
Oil (Side rail)0.200 − 0.550 mm (0.0079 − 0.0217 in.)
Maximum end gap:
No. 11.10 mm (0.0433 in.)
No. 21.11 mm (0.0437 in.)
Oil (Side rail)1.15 mm (0.0453 in.)

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.