1996 TOYOTA RAV4 engine oil

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.

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.