1996 TOYOTA RAV4 Engine

P13437
P13438
P02892
P03216
Plastigage
P13442
− ENGINE MECHANICALCYLINDER BLOCK
EM−83
1996 RAV4 (RM447U)
(c) Using a plastic−faced hammer, lightly tap the connecting
rod bolts and lift off the connecting rod cap.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(g) Lay a strip of Plastigage across the crank pin.
(h) Install the connecting rod cap (See page EM−99).
NOTICE:
Do not turn the crankshaft.
(i) Remove the connecting rod cap (See procedure (b) and
(c) above).
(j) Measure the Plastigage at its widest point.
Standard oil clearance:
STD0.024 − 0.055 mm (0.0009 − 0.0022 in.)
U/S 0.250.023 − 0.069 mm (0.0009 − 0.0027 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.

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).

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.