1996 TOYOTA RAV4 Engine

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.

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.)

Z11709
26 mm
(1.02 in.)
P05299
P05301
SST
Z00072
Cut Position
− ENGINE MECHANICALCYLINDER BLOCK
EM−97
1996 RAV4 (RM447U)
(b) Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 26 mm (1.02 in.) from
the piston head.
(c) Calculate the amount of each cylinder is to be rebored as
follows:
Size to be rebored = P + C − H
P = Piston diameter
C = Piston oil clearance
0.120 − 0.140 mm (0.0047 − 0.0055 in.)
H = Allowance for honing
0.02 mm (0.0008 in.) or less
(d) Bore and hone the cylinders to calculated dimensions.
Maximum honing: 0.02 mm (0.0008 in.)
NOTICE:
Excess honing will destroy the finished roundness.
3. REPLACE CRANKSHAFT FRONT OIL SEAL
HINT:
There are 2 methods ((a) and (b)) to replace the oil seal.
(a) If the oil pump is removed from the cylinder block:
(1) Using a screwdriver and hammer, tap out the oil
seal.
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the oil pump body edge.
SST 09226−10010
(3) Apply MP grease to the oil seal lip.
(b) If the oil pump is installed to the cylinder block:
(1) Using a knife, cut off the oil seal lip.
(2) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Tape the screw-
driver tip.

EM7361
SST
EM7362
P19502
SST
P04023
Cut Position
P19503
SST EM−98
− ENGINE MECHANICALCYLINDER BLOCK
1996 RAV4 (RM447U)
(3) Apply MP grease to a new oil seal lip.
(4) Using SST and a hammer, tap in the oil seal until its
surface is flush with the oil pump body edge.
SST 09226−10010
4. REPLACE CRANKSHAFT REAR OIL SEAL
HINT:
there are 2 methods ((a) and (b)) to replace the oil seal.
(a) If the rear oil seal retainer is removed from the cylinder
block:
(1) Using a screwdriver and hammer, tap out the oil
seal.
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the rear oil seal retainer
edge.
SST 09223−15030, 09608−30022 (09608−05010)
(3) Apply MP grease to the oil seal lip.
(b) If rear oil seal retainer is installed to cylinder block:
(1) Using a knife, cut off the oil seal lip.
(2) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Tape the screw-
driver tip.
(3) Apply MP grease to a new oil seal lip.
(4) Using SST and a hammer, tap in the oil seal until its
surface is flush with the rear oil seal retainer edge.
SST 09223−15030, 09608−30022 (09608−05010)