1996 TOYOTA RAV4 oil

S01653
1 2
S01646
S01647
S01645
S01432
EM−36
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
(c) Disconnect the engine wire protector from the 2 mounting
bolts of the No. 2 timing belt cover in the sequence shown.
(d) Remove the 4 nuts, grommets, head cover and gasket.
HINT:
Arrange the grommets in the correct order, so that they can be
reinstalled into their original positions. This minimizes any pos-
sibility of oil leakage due to reuse of the grommets in different
positions.
27. DISCONNECT ENGINE WIRE
(a) Remove the 2 bolts, and disconnect the engine wire pro-
tector from the LH side of the intake manifold.
(b) Disconnect the 4 injector connectors.
(c) w/ A/C:
Disconnect the A/C compressor connector.
(d) Disconnect the crankshaft position sensor connector.
(e) Disconnect the 3 clamps from the No. 2 timing bet cover
and generator drive belt adjusting bar.
(f) Disconnect the engine wire protector from the 2 brackets
on the front side of the intake manifold.
(g) Remove the RH scuff plate, RH cowl side trim and RH
floor carpet center cover.
(h) Disconnect the 2 ECM connectors.
(i) Disconnect the 2 connectors from the connectors on the
bracket.
(j) Disconnect the Connector from the J/B No. 4.
(k) Disconnect the wire clamp from the bracket.
(l) Pull out the engine wire from the cabin.
(m) Take out the engine wire between the cylinder head and
intake manifold.
28. DISCONNECT TIMING BELT FROM CAMSHAFT TIM-
ING PULLEY (See page EM−15)
29. REMOVE CAMSHAFT TIMING PULLEY (See page
EM−15)
30. REMOVE NO. 1 IDLER PULLEY AND TENSION
SPRING

S01649
S01789
S01794
10 − 45°
Knock
Pin
P03445
Service
BoltDrive Gear
Sub−Gear
− ENGINE MECHANICALCYLINDER HEAD
EM−37
1996 RAV4 (RM447U)
31. REMOVE NO. 3 TIMING BELT COVER
Remove the 3 bolts and timing belt cover.
NOTICE:
Support the timing belt, so the meshing of the crank-
shaft timing pulley and timing belt does not shift..
Be careful not to drop anything inside the timing belt
cover
Do not allow the belt to come into contact with oil, wa-
ter or dust.
32. REMOVE CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being removed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, the follow-
ing steps should be carried out.
(a) Remove the exhaust camshaft.
(1) Set the knock pin of the intake camshaft at 10 − 45°
BTDC of camshaft angle.
HINT:
The above angle allows No. 2 and No. 4 cylinder cam lobes of
the exhaust camshaft to push their valve lifters evenly.
(2) Secure the exhaust camshaft sub gear to drive gear
with a service bolt.
Recommended service bolt:
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 − 20 mm (0.63 − 0.79 in.)

S01777
80 − 11 5°
Knock
Pin
S01769
S01771
1 2
3 45 6
S01768
− ENGINE MECHANICALCYLINDER HEAD
EM−39
1996 RAV4 (RM447U)
(b) Remove the intake camshaft.
(1) Set the knock pin of the intake camshaft at 80 −
11 5° BTDC of camshaft angle.
HINT:
The above angle allows the No. 1 and No. 3 cylinder cam lobes
of intake camshaft to push their valve lifters evenly.
(2) Remove the 2 bolts, front bearing cap and oil seal.
(3) Uniformly loosen and remove the 6 bolts on the No.
1, No. 3 and No.4 bearing caps, in several passes,
in the sequence shown.
NOTICE:
Do not remove the No. 2 bearing cap bolts at this stage.
(4) Remove the No. 1, No. 3 and No. 4 bearing caps.
(5) Alternately loosen and remove the 2 bolts on the
No. 2 bearing cap.
HINT:
As the 2 No. 2 bearing cap bolts are loosened, make sure
that the camshaft is lifted out straight and level, after
breaking adhesion on the front bearing cap.
If the camshaft is not being lifted out straight and level, re-
tighten the 2 No. 2 bearing cap bolts. Do steps (e) to (a)
and reset the knock pin of the intake camshaft at 80 −
11 5° BTDC, and repeat steps (b) to (e) once again.
NOTICE:
Do not pry on or attempt to force the camshaft with a tool
or other object.
(6) Remove the No. 2 bearing cap and camshaft.

S01795
Oil Pressure
Switch EM−42
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
39. REMOVE OIL PRESSURE SWITCH

EM0ER−01
P03264
P03265
− ENGINE MECHANICALCYLINDER HEAD
EM−43
1996 RAV4 (RM447U)
DISASSEMBLY
1. REMOVE VALVE LIFTERS AND SHIMS
2. REMOVE VALVES
(a) Using SST, compress the valve spring and remove the 2
keepers.
SST 09202−70020 (09202−00010)
(b) Remove the spring retainer, valve spring, valve and
spring seat.
(c) Using needle−nose pliers, remove the oil seal.

EM1Q0−01
P15443
P15444
P03267
P03268
P03149
EM−44
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
INSPECTION
1. CLE AN TO P SURFACE S OF PIS TO NS AND CY L-
INDER BLOCK
(a) Turn the crankshaft, and bring each piston to top dead
center (TDC). Using a gasket scraper, remove all the car-
bon from the piston top surface.
(b) Using a gasket scraper, remove all the gasket material
from the cylinder block surface.
(c) Using compressed air, blow carbon and oil from the bolt
holes.
CAUTION:
Protect your eyes when using high−pressure compressed
air.
2. CLEAN CYLINDER HEAD
(a) Using a gasket scraper, remove all the gasket material
from the cylinder block contact surface.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
(b) Using a wire brush, remove all the carbon from the com-
bustion chamber.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
(c) Using a valve guide bushing brush and solvent, clean all
the guide bushings.

Z00051
Z00052
Z00054
44.5°
EM0181
Margin Thickness EM−46
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
5. INSPECT VALVE STEMS AND GUIDE BUSHINGS
(a) Using a caliper gauge, measure the inside diameter of the
guide bushing.
Bushing inside diameter:
6.010 − 6.030 mm (0.2366 − 0.2374 in.)
(b) Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
Intake5.970 − 5.985 mm (0.2350 − 0.2356 in.)
Exhaust5.965 − 5.980 mm (0.2348 − 0.2354 in.)
(c) Subtract the valve stem diameter measurement from the
guide bushing inside diameter measurement.
Standard oil clearance:
Intake0.025 − 0.060 mm (0.0010 − 0.0024 in.)
Exhaust0.030 − 0.065 mm (0.0012 − 0.0026 in.)
Maximum oil clearance:
Intake0.08 mm (0.0031 in.)
Exhaust0.10 mm (0.0039 in.)
If the clearance is greater than maximum, replace the valve and
guide bushing (See page EM−52).
6. INSPECT AND GRIND VALVES
(a) Grind the valve enough to remove pits and carbon.
(b) Check that the valve is ground to the correct valve face
angle.
Valve face angle: 44.5°
(c) Check the valve head margin thickness.
Standard margin thickness:
0.8 − 1.2 mm (0.031 − 0.047 in.)
Minimum margin thickness: 0.5 mm (0.020 in.)
If the margin thickness is less than minimum, replace the valve.

EM0281
EM1628
EM2011
EM2538
EM3322
Free Distance
− ENGINE MECHANICALCYLINDER HEAD
EM−49
1996 RAV4 (RM447U)
(c) Using a spring tester, measure the tension of the valve
spring at the specified installed length.
Installed tension:
164 − 189 N (16.7 − 19.3 kgf, 36.8 − 42.5 lbf)
at 34.7 mm (1.366 in.)
If the installed tension is not as specified, replace the valve
spring.
9. INSPECT CAMSHAFTS
(a) Inspect the circle runout.
(1) Place the camshaft on V−blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.04 mm (0.0016 in.)
If the circle runout is greater than maximum, replace the cam-
shaft.
(b) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake42.01 − 42.11 mm (1.6539 − 1.6579 in.)
Exhaust40.06 − 40.16 mm (1.5772 − 1.5811 in.)
Minimum cam lobe height:
Intake41.90 mm (1.6496 in.)
Exhaust39.95 mm (1.5728 in.)
If the cam lobe height is less than minimum, replace the cam-
shaft.
(c) Using a micrometer, measure the journal diameter.
Journal diameter:
26.959 − 26.975 mm (1.0614 − 1.0620 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
(d) Using vernier calipers, measure the free distance be-
tween the gear spring ends.
Free distance: 22.5 − 22.9 mm (0.886 − 0.902 in.)
If the free distance is not as specified, replace the gear spring.