1996 TOYOTA RAV4 Service Repair Manual

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.

P05613
P05614
TurnB
A
P05615
P05616
(1)
(2)
(3) EM−40
− ENGINE MECHANICALCYLINDER HEAD
1996 RAV4 (RM447U)
33. DISASSEMBLE EXHAUST CAMSHAFT
(a) Mount the camshaft in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Insert service bolt A into the service hole of the camshaft
sub gear.
(c) Using a screwdriver, turn the sub gear clockwise, and re-
move service bolt B.
NOTICE:
Be careful not to damage the camshaft.
(d) Using snap ring pliers, remove the snap ring.
(e) Remove the wave washer (1), camshaft sub gear (2) and
camshaft gear spring (3).

S01798
2
108
5 3
4
96 7 1
S01767
S01763
S01764
− ENGINE MECHANICALCYLINDER HEAD
EM−41
1996 RAV4 (RM447U)
34. REMOVE CYLINDER HEAD AND INTAKE MANIFOLD
ASSEMBLY
(a) Uniformly loosen and remove the 10 cylinder head bolts,
in several passes, in the sequence shown.
NOTICE:
Cylinder head warpage or cracking could result from re-
moving bolts in incorrect order.
(b) Lift the cylinder head from the dowels on the cylinder
block, and place the cylinder head on wooden blocks on
a bench.
HINT:
If the cylinder head is difficult to the lift off, pry between the cylin-
der head and cylinder block with a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.
35. REMOVE AIR TUBE
(a) Disconnect the air hose from the intake manifold.
(b) Remove the 2 bolts, hose clamp and air tube.
36. REMOVE INTAKE MANIFOLD
Remove the 6 bolts, 2 nuts and intake manifold and gasket.
37. REMOVE AIR HOSE FOR AIR ASSIST SYSTEM
Disconnect the air hose from the cylinder head port, and re-
move the air hose.
38. REMOVE DELIVERY PIPE AND INJECTORS (See
page SF−19)

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.

P03363
Z02749
Cylinder Block Side
Intake Manifold Side
Exhaust Manifold Side
P03269
EM0580
− ENGINE MECHANICALCYLINDER HEAD
EM−45
1996 RAV4 (RM447U)
(d) Using a soft brush and solvent, thoroughly clean the cylin-
der head.
3. INSPECT CYLINDER HEAD
(a) Inspect for flatness.
Using a precision straight edge and feeler gauge, mea-
sure the surfaces contacting the cylinder block and the
manifolds for warpage.
Maximum warpage:
Cylinder block side0.05 mm (0.0020 in.)
Manifold side0.08 mm (0.0031 in.)
If warpage is greater than maximum, replace the cylinder head.
(b) Inspect for cracks.
Using a dye penetrant, check the combustion chamber,
intake ports, exhaust ports and cylinder block surface for
cracks.
If cracked, replace the cylinder head.
4. CLEAN VALVES
(a) Using a gasket scraper, chip off any carbon from the valve
head.
(b) Using a wire brush, thoroughly clean the valve.

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.