1996 TOYOTA RAV4 oil

EM3371
Plastigage
EM3310
P00263
EM−50
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
(e) Inspect the journal oil clearance.
(1) Clean the bearing caps and camshaft journals.
(2) Check that bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps and cyl-
inder head as a set.
(3) Place the camshafts on the cylinder head.
(4) Lay a strip of Plastigage across each of the cam-
shaft journals.
(5) Install the bearing caps (See page EM−55).
NOTICE:
Do not turn the camshaft.
(6) Remove the bearing caps.
(7) Measure the Plastigage at its widest point.
Standard oil clearance:
0.025 − 0.062 mm (0.0010 − 0.0024 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the cam-
shaft. If necessary, replace the bearing caps and cylinder head
as a set.
(8) Completely remove the Plastigage.
(f) Inspect the camshaft thrust clearance.
(1) Install the camshaft (See page EM−55).
(2) Using a dial indicator, measure the thrust clearance
while moving the camshaft back and forth.
Standard thrust clearance:
Intake0.045 − 0.100 mm (0.0018 − 0.0039 in.)
Exhaust0.030 − 0.085 mm (0.0012 − 0.0033 in.)
Maximum thrust clearance:
Intake0.12 mm (0.0047 in.)
Exhaust0.10 mm (0.0039 in.)
If the thrust clearance is greater than maximum, replace the
camshaft. If necessary, replace the bearing caps and cylinder
head as a set.

EM3308
EM3372
EM2196
Z03030
Z03031
Exhaust
− ENGINE MECHANICALCYLINDER HEAD
EM−51
1996 RAV4 (RM447U)
(g) Inspect the camshaft gear backlash.
(1) Install the camshafts without installing the exhaust
cam sub−gear (See page EM−55).
(2) Using a dial indicator, measure the backlash.
Standard backlash:
0.020 − 0.200 mm (0.0008 − 0.0079 in.)
Maximum backlash: 0.30 mm (0.0188 in.)
If the backlash is greater then maximum, replace the cam-
shafts.
10. INSPECT VALVE LIFTERS AND LIFTER BORES
(a) Using a caliper gauge, measure the lifter bore diameter
of the cylinder head.
Lifter bore diameter:
31.000 − 31.018 mm (1.2205 − 1.2212 in.)
(b) Using a micrometer, measure the lifter diameter.
Lifter diameter:
30.966 − 30.976 mm (1.2191 − 1.2195 in.)
(c) Subtract the lifter diameter measurement from the lifter
bore diameter measurement.
Standard oil clearance:
0.024 − 0.052 mm (0.0009 − 0.0020 in.)
Maximum oil clearance: 0.07 mm (0.0028 in.)
If the oil clearance is greater than maximum, replace the lifter.
If necessary, replace the cylinder head.
11. INSPECT INTAKE MANIFOLD
Using a precision straight edge and feeler gauge, measure the
surface contacting the cylinder head for warpage.
Maximum warpage: 0.30 mm (0.0118 in.)
If warpage is greater than maximum, replace the manifold.
12. INSPECT EXHAUST MANIFOLD
Using a precision straight edge and feeler gauge, measure the
surface contacting the cylinder head for warpage.
Maximum warpage: 0.30 mm (0.0118 in.)
If warpage is greater than maximum, replace the manifold.

EM0ET−02
P03274
SST
Z00573
SSTIntake
Painted
BlackExhaust
Painted
Brown
P03265
SST
P03276
EM−54
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
REASSEMBLY
HINT:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all slid-
ing and rotating surfaces.
Replace all gaskets and oil seals with new ones.
1. INSTALL VALVES
(a) Using SST, push in a new oil seal.
SST 09201−41020
HINT:
The intake valve oil seal is brown and the exhaust valve oil seal
is black.
(b) Install the valve, spring seat, valve spring and spring re-
tainer.
(c) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202−70020 (09202−00010)
(d) Using a plastic−faced hammer, lightly tap the valve stem
tip to assure proper fit.
2. INSTALL VALVE LIFTERS AND SHIMS
(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.

EM1B9−02
P13638
Adhesive
S01764
S01763
S01648
− ENGINE MECHANICALCYLINDER HEAD
EM−55
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL OIL PRESSURE SWITCH
(a) Apply adhesive to 2 or 3 threads.
Adhesive:
Part No. 08833−00080, THREE BOND 1344 or equiva-
lent
(b) Install the oil pressure switch.
2. INSTALL INJECTORS AND DELIVERY PIPE (See page
SF−23)
3. INSTALL AIR HOSE FOR AIR ASSIST SYSTEM
Connect the air hose to the cylinder head port.
4. INSTALL INTAKE MANIFOLD
Install a new gasket and the intake manifold with the 6 bolts and
2 nuts. Uniformly tighten the bolts and nuts in several passes.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
5. INSTALL AIR TUBE
(a) Install the air tube and hose clamp with the 2 bolts.
(b) Connect the air hose to the intake manifold.
6. INSTALL CYLINDER HEAD AND INTAKE MANIFOLD
ASSEMBLY
(a) Place the cylinder head on the cylinder block.
(1) Place a new cylinder head gasket in position on the
cylinder block.
NOTICE:
Be careful of the installation direction.
(2) Place the cylinder head in position on the cylinder
head gasket.

S01799
1086 1 3 9
4257
S01796
90°
90°Painted Mark
S01786
Z00058
(3)
(2)
(1) EM−56
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
(b) Install the cylinder head bolts.
HINT:
The cylinder head bolts are tightened in 2 progressive
steps (steps (b) and (d)).
If any cylinder head bolt is broken or deformed, replace
it.
(1) Apply a light coat of engine oil on the threads and
under the heads of the cylinder head bolts.
(2) Install and uniformly tighten the 10 cylinder head
bolts and plate washers, in several passes, in the
sequence shown.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
If any one of the cylinder head bolts does not meet the torque
specification, replace the cylinder head bolt.
(3) Mark the front of the cylinder head bolt head with
paint.
(4) Retighten the cylinder head bolts 90° in the se-
quence shown above.
(5) Check that the painted mark is now at a 90° angle
to front.
7. INSTALL SPARK PLUG TUBES
(a) Clean the cylinder head tube holes of any residual adhe-
sive, oil or foreign particles. Remove any oil with kerosene
or gasoline.
(b) Screw the threads of the spark plug tube coated with
adhesive into the cylinder head.
(c) Using the spark plug tube nut and a 30 mm socket
wrench, tighten the spark plug tubes.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
8. ASSEMBLE EXHAUST CAMSHAFT
(a) Mount the hexagon wrench head portion of the camshaft
in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Install the camshaft gear spring (1), camshaft sub gear (2)
and wave washer (3).
HINT:
Align the pins on the gears with the spring ends.

P05618
Turn
ADrive Gear
Sub−Gear B
S01778
80 − 11 5°
Knock
Pin
S01790
EM3373
2 − 3 mm
(0.08 − 0.12 in.)
Seal
Packing
− ENGINE MECHANICALCYLINDER HEAD
EM−57
1996 RAV4 (RM447U)
(c) Using snap ring pliers, install the snap ring.
(d) Insert a service bolt A into the service hole of the camshaft
sub gear.
(e) Using a screwdriver, align the holes of the camshaft drive
gear and sub gear by turning camshaft sub gear clock-
wise, and install a service bolt B.
NOTICE:
Be careful not to damage the camshaft.
(f) Align the gear teeth of the drive gear and sub gear, and
tighten the service bolt B.
9. INSTALL CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being installed. 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) Install the intake camshaft.
(1) Apply MP grease to the thrust portion of the cam-
shaft.
(2) Place the intake camshaft at 80 − 11 5° BTDC of
camshaft angle on the cylinder head.
HINT:
The above angle arrows the No. 1 and No. 3 cylinder cam lobes
of the intake camshaft to push their valve lifters evenly.
(3) Apply MP grease to a new oil seal lip.
(4) Install the oil seal as far as the deepest part of the
cylinder head.
(5) Apply seal packing to the No. 1 bearing cap as
shown.
Seal packing: Part No. 08826−00080 or equivalent

S01770
S01772
9
10 3
45
61
27
8
S01776
10 − 45°
Knock
Pin
S01773
Assembly
Timing Reference
Mark
Mark EM−58
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
(6) Install the bearing caps in their proper locations.
(7) Apply a light coat of engine oil on the threads and
under the heads of the bearing cap bolts.
(8) Install and uniformly tighten the 10 bearing cap
bolts, in several passes, in the sequence shown.
Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)
(b) Install the exhaust camshaft.
(1) Set the knock pin of the intake camshaft at 10 − 45°
BTDC of camshaft angle.
HINT:
The above angle allows the No. 2 and No. 4 cylinder cam lobes
of the exhaust camshaft to push their valve lifters evenly.
(2) Apply MP grease to the thrust portion of the cam-
shaft.
(3) Engage the exhaust camshaft gear to the intake
camshaft gear by matching the timing marks on
each gear.
(4) Roll down the exhaust camshaft onto the bearing
journals while engaging gears with each other.
NOTICE:
There are also assembly reference marks on each gear as
shown in the illustration. Do not use these marks.
(5) Turn the intake camshaft clockwise or counterclock-
wise a little until the exhaust camshaft sits in the
bearing journals evenly without rocking the cam-
shaft on the bearing journals.
NOTICE:
It is very important to replace the camshaft in the bearing
journals evenly while tightening bearing caps in the subse-
quent steps.

S01805
S01793
9 10
3 45 6
1 2
7 8
EM7797
Seal Packing
S01649
S01645
− ENGINE MECHANICALCYLINDER HEAD
EM−59
1996 RAV4 (RM447U)
(6) Install the bearing caps in their proper locations.
(7) Apply a light coat of engine oil on the threads and
under the heads of the bearing cap bolts.
(8) Install and uniformly tighten the 10 bearing cap
bolts, in several passes, in the sequence shown.
Torque: 19 N·m (190 kgf·cm, 14 ft·lbf)
(9) Remove the service bolt B.
10. CHECK AND ADJUST VALVE CLEARANCE (See page
EM−5)
11. INSTALL SEMI−CIRCULAR PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the semi−circular plug grooves.
Seal packing: Part No. 08826−00080 or equivalent
(c) Install the 2 semi−circular plugs to the cylinder head.
12. INSTALL NO. 3 TIMING BELT COVER
Install the timing belt cover with the 3 bolts.
Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf)
13. TEMPORARILY INSTALL NO. 1 IDLER PULLEY AND
TENSION SPRING (See page EM−20)
14. INSTALL CAMSHAFT TIMING PULLEY AND TIMING
BELT (See page EM−20)
15. INSTALL ENGINE WIRE
(a) Install the engine wire protector to the 2 brackets on the
front side of the intake manifold.
(b) Connect the 4 injector connectors.
HINT:
The No. 1 and No. 3 injector connectors are brown, and the No.
2 and No. 4 injector connectors are gray.