1996 TOYOTA RAV4 Service Repair Manual

S01374
Cover
Connector
− ENGINE MECHANICALENGINE UNIT
EM−79
1996 RAV4 (RM447U)
25. INSTALL GENERATOR (See page CH−19)
26. INSTALL CHARCOAL CANISTER
27. CONNECT ENGINE WIRE TO RELAY BOX NO. 2
(a) Connect the engine wire to the relay block No.2 with the
2 nuts.
(b) Connect the connector.
(c) Install the upper cover.
(d) Connect the relay block No. 2 to the body with the 2 bolts.
28. INSTALL ACCELERATOR CABLE TO THROTTLE
BODY, CABLE BRACKET AND CLAMPS
29. INSTALL AIR CLEANER CASE AND CAP
30. INSTALL BATTERY
31. FILL WITH TRANSAXLE OIL
32. FILL WITH ENGINE OIL
33. FILL WITH ENGINE COOLANT
34. START ENGINE AND CHECK FOR LEAKS
35. PERFORM ENGINE ADJUSTMENT
36. CHECK FRONT WHEEL ALIGNMENT
37. INSTALL ENGINE UNDER COVERS
38. INSTALL ENGINE HOOD
39. ROAD TEST VEHICLE
Check for abnormal noises, shock slippage, correct shift points
and smooth operation.
40. RECHECK ENGINE COOLANT AND OIL LEVELS

EM0EY−03
See page EM−99
EM−80
− ENGINE MECHANICALCYLINDER BLOCK
1996 RAV4 (RM447U)
CYLINDER BLOCK
COMPONENTS

P15297
M/T
EM1BB−02
P15299
A/T
P13432
P15304
RH Engine
Mounting
Bracket
PS Pump
Bracket
S01580
1
3
2
− ENGINE MECHANICALCYLINDER BLOCK
EM−81
1996 RAV4 (RM447U)
DISASSEMBLY
1. M/T:
REMOVE FLYWHEEL
Remove the 8 bolts and flywheel.
2. A/T:
REMOVE DRIVE PLATE
Remove the 8 bolts, front plate, drive plate and rear spacer.
3. REMOVE REAR END PLATE
Remove the bolt and end plate.
4. INSTALL ENGINE TO ENGINE STAND FOR DIS-
ASSEMBLY
5. REMOVE RH ENGINE MOUNTING BRACKET
Remove the 3 bolts and mounting bracket.
6. REMOVE PS PUMP BRACKET
Remove the 3 bolts and PS pump bracket.
7. REMOVE TIMING BELT AND PULLEYS (See page
EM−15)
8. REMOVE CYLINDER HEAD (See page EM−33)
9. REMOVE OIL PAN AND OIL PUMP (See page LU−7)
10. REMOVE GENERATOR DRIVE BELT ADJUSTING
BAR, WATER PUMP AND WATER PUMP COVER AS-
SEMBLY
(a) Remove the bolt and adjusting bar.
(b) Remove the 3 bolts in the sequence shown, remove the
water pump, water pump cover assembly and O−ring.
11. REMOVE OIL COOLER (See page LU−18)

S01631
SST
P05527
P13434
P13435
P13436
EM−82
− ENGINE MECHANICALCYLINDER BLOCK
1996 RAV4 (RM447U)
12. REMOVE KNOCK SENSOR
Using SST, remove the knock sensor.
SST 09816−30010
13. REMOVE REAR OIL SEAL RETAINER
Remove the 6 bolts, retainer and gasket.
14. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while mov-
ing the connecting rod back and forth.
Standard thrust clearance:
0.160 − 0.312 mm (0.0063 − 0.0123 in.)
Maximum thrust clearance: 0.35 mm (0.0138 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly. If necessary, replace the crankshaft.
15. REMOVE CONNECTING ROD CAPS AND CHECK OIL
CLEARANCE
(a) Check the matchmarks on the connecting rod and cap to
ensure correct reassembly.
(b) Remove the 2 connecting rod cap nuts.

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.)