3sfe ENGINE 1999 2000 PDF

1999 Toyota RAV4
1999-2000 ENGINES 2.0L 4-Cylinder
1999-2000 ENGINES
2.0L 4-Cylinder
ENGINE IDENTIFICATION
NOTE: For repair procedures not covered in this article, see ENGINE OVERHAUL
PROCEDURES article in GENERAL INFORMATION.
Engine serial number is stamped on rear of cylinder block. See Fig. 1 .
ENGINE IDENTIFICATION CODE

Engine Code
2.0L 4-Cylinder 3S-FE
Fig. 1: Identifying Engine Serial Number

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
ADJUSTMENTS
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1999 Toyota RAV4
VALVE CLEARANCE ADJUSTMENT
NOTE: Adjust valve clearance with engine cold.
1. Disconnect power steering fluid reservoir, PCV hoses, cable brackets and control cables for access to
valve cover. Disconnect spark plug wires from spark plugs.
2. Disconnect engine wiring harness protector at rear of timing belt cover for access to valve cover. When
disconnecting engine wiring harness protector, remove bolt on intake manifold side of engine first, and
then bolt on exhaust manifold side of engine.
3. Remove nuts, grommets, valve cover and gasket. Note location of grommets for reassembly reference, as
grommets must be installed in original location.
4. Rotate crankshaft clockwise, as viewed from timing belt end of engine, so cylinder No. 1 is at TDC on
compression stroke, and timing mark on crankshaft pulley aligns with "0" mark on timing belt cover.
Cylinder No. 1 is front cylinder at timing belt end of engine.
5. Ensure valve lifters are loose on cylinder No. 1 and tight on cylinder No. 4. If conditions are not as
described, rotate crankshaft clockwise one complete revolution (360 degrees).
6. With cylinder No. 1 at TDC on compression stroke, check valve clearance on specified valves. Perform
STEP 1 in illustration. See Fig. 2 . Using feeler gauge, measure and record valve clearance between valve
lifter and camshaft.
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1999 Toyota RAV4
Fig. 2: Checking Valve Clearance

7. To check remaining valves, rotate crankshaft clockwise, viewed from timing belt end of engine, one
complete revolution (360 degrees) until cylinder No. 4 cylinder is at TDC on compression stroke.
Measure and record valve clearance on specified valves. Perform STEP 2 in illustration. See Fig. 2 .
8. Ensure valve clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS table.
VALVE CLEARANCE SPECIFICATIONS (1)

Application In. (mm)
Intake Valve .007-.011 (.19-.29)
Exhaust Valve .011-.015 (.29-.38)
(1) Adjust valve clearance with engine cold.
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1999 Toyota RAV4
9. If valve clearance requires adjustment, rotate camshaft so lobe on valve to be adjusted is facing upward,
away from valve lifter. Rotate valve lifter so notch on valve lifter is toward spark plug.
10. Use Valve Clearance Adjuster (SST 09248-55040) to remove adjusting shim. Using SST "A" of valve
clearance adjuster, push downward on valve lifter. Place SST "B" between camshaft and valve lifter with
side marked with No. 9 at designated position. See Fig. 3 . Remove SST "A".
Fig. 3: Adjusting Valve Clearance

11. Using small screwdriver and magnet, remove adjusting shim. Measure and record thickness of adjusting
shim removed. Using measured valve clearance and adjusting shim thickness, select proper replacement
adjusting shim. See Fig. 4 and Fig. 5 .
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Fig. 4: Intake Valve Adjusting Shim Selection Chart

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Fig. 5: Exhaust Valve Adjusting Shim Selection Chart

12. Install replacement adjusting shim. Recheck valve clearance. Apply sealant at front and rear valve cover
areas on cylinder head. See Fig. 6 . Using NEW gasket, install valve cover.
Fig. 6: Applying Sealant On Cylinder Head

13. Install grommets in original location with marking on grommet aligned in designated area. See Fig. 7 .
Install and tighten valve cover nuts to specification. See TORQUE SPECIFICATIONS .
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Fig. 7: Aligning Valve Cover Grommets

TROUBLE SHOOTING
To trouble shoot mechanical engine components, see appropriate table in TROUBLE SHOOTING article in
GENERAL INFORMATION.
REMOVAL & INSTALLATION
NOTE: For reassembly reference, label all electrical connectors, vacuum hoses and
fuel lines before removal. Also place mating marks on engine hood and other
major assemblies before removal.
CAUTION: When battery is disconnected, vehicle computer and memory systems

may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle.
CAUTION: To prevent air bag deployment, disconnect negative battery cable and wait
at least 90 seconds before working on vehicle.
FUEL PRESSURE RELEASE
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1. Remove driver-side rear seat and floor panel cover for access to fuel pump electrical connector.
2. Disconnect fuel pump electrical connector. Start engine and allow engine to idle until engine stalls. Turn
ignition off.
3. Reconnect fuel pump electrical connector. Reinstall floor panel cover and driver-side rear seat.
4. Disconnect negative battery cable. Place an approved gasoline container under fuel line. Cover fuel line
connection with shop towel.
5. Slowly loosen fuel line connection to release fuel pressure. Once fuel pressure is released, fuel system
components may be serviced.
ENGINE
Removal
1. Engine and transaxle are removed as an assembly from bottom of engine compartment. Release fuel
pressure. See FUEL PRESSURE RELEASE . Remove hood, battery and battery tray. Drain cooling
system, and engine and transaxle oil.
2. Disconnect control cables at throttle body. Remove air cleaner assembly and air cleaner case. Remove
bolts, and disconnect relay box from body. Relay box is located near driver-side strut tower. See Fig. 8 .
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Fig. 8: Identifying Relay Box, Electrical Connector & Engine Wiring Harness
3. Remove upper cover from relay box. Disconnect electrical connector from relay box. See Fig. 8 . Remove
nuts, and disconnect engine wiring harness from relay box.
4. Remove charcoal canister. Remove accessory drive belt and generator. Disconnect upper and lower
radiator hoses. Remove thermostat housing from front of engine.
5. Disconnect necessary electrical connectors, coolant hoses, vacuum hoses and fuel lines for engine
removal.
6. Remove scuff plate from passenger-side door opening and passenger-side kick panel. Remove center
console trim panel from passenger-side of center console. See Fig. 9 .
Fig. 9: Identifying ECM & Electrical Connectors

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7. Disconnect 2 electrical connectors from Engine Control Module (ECM) and 2 electrical connectors on
bracket. See Fig. 9 . Disconnect electrical connector for relay box located behind passenger-side kick
panel.
8. Disconnect engine wiring harness clamp located on engine wiring harness, near firewall. Pull engine
wiring harness out through firewall.
9. Raise and support vehicle. Remove lower engine covers. On M/T models, remove clutch release cylinder
with hose attached, and secure aside. Disconnect transaxle control cables from transaxle. Remove starter
and transaxle ground cable. On A/T, and 4WD vehicles with M/T, disconnect transaxle oil cooler hoses.
10. On A/T models, disconnect transaxle control cable from front suspension crossmember and engine mount
center member. Disconnect connectors, plug wires, strap and hoses from top of engine. On 4WD M/T,
disconnect ground strap from engine cowl. Disconnect differential lock control solenoid connector.
11. Using 14-mm deep socket wrench, remove 2 bolts holding front exhaust pipe to front TWC. Remove 2
bolts and 2 nuts holding front exhaust pipe to TWC. Remove front exhaust pipe and 2 gaskets.
12. Disconnect A/C compressor connector. Remove 2 bolts, nut and stud bolt. Disconnect A/C compressor
from engine, and secure aside. On 4WD vehicles, remove rear drive shaft. On all models, remove front
drive shaft.
13. Remove front wheel and engine undercover. On M/T vehicles drain gear oil. On A/T models, drain
transmission fluid. On vehicles with ABS, remove bolt and ABS speed sensor. Remove cotter pin, lock
cap and lock nut.
14. Disconnect tie rod from steering knuckle. Disconnect stabilizer bar link from lower control arm.
Disconnect lower ball joint from lower control arm.
15. Using soft-face hammer, tap axle shaft from hub assembly. Pull steering knuckle outward and separate
axle shaft from hub assembly.
16. On 2WD A/T models, remove axle shaft bearing bracket bolts for right (passenger-side) axle shaft. See
Fig. 10 . Remove right axle shaft assembly from transaxle and axle shaft bearing bracket.
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Fig. 10: Removing Right (Passenger-Side) Axle Shaft (2WD A/T Models)
17. On 2WD M/T models, remove snap ring and axle shaft retaining bolt from axle shaft bearing bracket for
right (passenger-side) axle shaft. See Fig. 11 . Remove right axle shaft assembly from transaxle and axle
shaft bearing bracket.
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Fig. 11: Removing Right (Passenger-Side) Axle Shaft (2WD M/T Models)
18. On 2WD models, use hammer and brass drift or a slide hammer and Drive Shaft Remover Attachment
(09520-01010) to remove left (driver-side) axle shaft from transaxle. See Fig. 12 .
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Fig. 12: Removing Left (Driver-Side) Axle Shaft (2WD Models) Or Right (Passenger-Side) Axle
Shaft (4WD Models)
19. On 4WD models, use hammer and brass drift or a slide hammer and Drive Shaft Remover Attachment
(09520-01010) to remove right (passenger-side) axle shaft from transaxle. See Fig. 12 . Use pry bar to
remove left (driver-side) axle shaft from transaxle. See Fig. 13 .
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Fig. 13: Removing Left (Driver-Side) Axle Shaft (4WD Models)

20. Remove stabilizer bar-to-frame mount bolts. Remove stabilizer bar with mounting brackets and
insulators. Remove 2 steering gear assembly-to-front suspension crossmember bolts/nuts located at each
end of steering gear assembly.
21. Support engine with hoist. Remove engine mount crossmember-to-front suspension crossmember nuts.
Front suspension crossmember mounts between both lower control arms.
22. Support front suspension crossmember with floor jack. Remove front suspension crossmember bolts and
front suspension crossmember.
23. Remove front (exhaust manifold side) engine mount-to-engine mount crossmember bolts. Remove engine
mount crossmember-to-body bolts. Remove engine mount crossmember.
24. Remove power steering pump with hoses attached, and secure aside. Remove left (transaxle side) engine
mounting bracket-to-engine mount bolts/nuts. Remove right (timing belt side) engine mounting bracket-
to-engine mount bolts/nuts. Lower engine from engine compartment.
Installation
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1. Install engine in engine compartment. Loosely install right (timing belt side) engine mounting bracket-to-
engine mount bolts/nuts.
2. Install and tighten left (transaxle side) engine mounting bracket-to-engine mount bolts/nuts to
specification. See TORQUE SPECIFICATIONS . Tighten right (timing belt side) engine mounting
bracket-to-engine mount bolts/nuts to specification.
3. Install power steering pump. Install and tighten bolts to specification. See TORQUE
SPECIFICATIONS . Install engine mount crossmember with front (exhaust manifold side) engine
mount-to-engine mount crossmember bolts and engine mount crossmember-to-body bolts loosely
installed. DO NOT tighten bolts at this time
4. Install front suspension crossmember on body with bolts loosely installed. Loosely install engine mount
crossmember-to-front suspension crossmember nuts and steering gear assembly-to-front suspension
crossmember bolts/nuts. DO NOT tighten bolts/nuts at this time.
5. Install and tighten front suspension crossmember bolts to specification. See TORQUE
SPECIFICATIONS .
6. Tighten steering gear assembly-to-front suspension crossmember bolts/nuts and then engine mount
crossmember-to-front suspension crossmember nuts to specification. See TORQUE
SPECIFICATIONS .
7. Tighten front (exhaust manifold side) engine mount-to-engine mount crossmember bolts and then engine
mount crossmember-to-body bolts to specification. See TORQUE SPECIFICATIONS .
8. To install remaining components, reverse removal procedure. Before installing axle shafts coat axle shaft
seals in transaxle with grease.
NOTE: All axle shafts, except right (passenger-side) axle shaft on 2WD models,
use a snap ring on end of axle shaft. Ensure NEW snap ring is installed.
9. On all axle shafts except right (passenger-side) axle shaft on 2WD models, install NEW snap ring on end
of axle shaft. Position snap ring on end of axle shaft with opening facing downward.
10. Install axle shaft by lightly tapping axle shaft into transaxle. Ensure axle shaft moves inward and outward
approximately .079-.120" (2.00-3.00 mm) and cannot be pulled from transaxle.
11. On 2WD M/T models, when installing right (passenger-side) axle shaft, install NEW axle shaft retaining
bolt. Tighten axle shaft retaining bolt to specification. See TORQUE SPECIFICATIONS .
12. On 4WD models, ensure reference marks on drive shaft flanges are aligned. Ensure mounting bracket on
drive shaft center support bearing is straight and perpendicular to drive shaft before tightening bolts to
specification.
13. Use NEW gasket and NEW nuts when installing front exhaust pipe on catalytic converter. Ensure all
bolts/nuts are loosely installed before tightening to specification.
14. Adjust fluid levels and control cables. On 2WD models with A/T, use Dexron-II ATF. On 4WD models
with A/T, use Type "T" ATF. On all M/T models, use SAE 75-90 GL-5 gear oil.
CYLINDER HEAD & MANIFOLDS
NOTE: On 4WD models, manufacturer recommends engine removal for servicing of

cylinder head and manifolds. See ENGINE .
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Removal
1. Release fuel pressure. See FUEL PRESSURE RELEASE . Drain cooling system. Raise and support
vehicle. Remove right lower engine cover.
2. Disconnect control cables at throttle body. Remove air cleaner assembly and air cleaner case. Remove
accessory drive belt and generator.
3. Remove front exhaust pipe. Remove exhaust manifold and heat insulator assembly. Disconnect oxygen
sensor (except California) or Air/Fuel (A/F) ratio sensor (California), and remove exhaust manifold and
heat shield. Remove sensors from exhaust manifold and front catalytic converter, if equipped.
4. Remove heat insulator from front exhaust pipe. Remove throttle body and gasket. Remove ignition coils
with spark plug wires attached.
5. Disconnect necessary electrical connectors, coolant hoses and vacuum hoses from cylinder head and
intake manifold. Remove coolant outlet, coolant by-pass pipe and gaskets.
6. Disconnect hoses and ground strap. Remove union bolt, and disconnect fuel line at fuel filter. Remove
EGR valve and vacuum modulator. Disconnect power steering idle-up hoses from air tube.
7. Remove 2 bolts and accelerator cable bracket. Disconnect PCV hoses, cable brackets and control cables
for access to valve cover. Disconnect engine wiring harness protector at rear of timing belt cover for
access to valve cover. Remove nuts, grommets, valve cover and gasket. Note location of grommets for
reassembly reference, as grommets must be installed in original location.
8. Remove bolts, and disconnect engine wiring harness protector from left side of intake manifold.
Disconnect electrical connectors at injectors, A/C compressor and crankshaft position sensor. Remove
engine wiring harness clamps from timing belt cover and generator drive belt adjusting bar.
9. Remove scuff plate from passenger-side door opening and passenger-side kick panel. Remove right side
cowl side trim and floor carpet center cover. Disconnect 2 electrical connectors from Engine Control
Module (ECM), and 2 electrical connectors on bracket. See Fig. 9 . Disconnect electrical connector for
relay box located behind passenger-side kick panel.
10. Disconnect engine wiring harness clamp located on engine wiring, near firewall. Pull engine wiring
harness out through firewall. Remove engine wiring harness from between cylinder head and intake
manifold.
11. Disconnect timing belt from camshaft timing pulley. Remove camshaft timing pulley. Remove No. 1 idler
pulley and tension spring. See TIMING BELT . Remove 3 bolts and timing belt cover. See Fig. 14 .
After removing timing belt from camshaft sprocket, support timing belt so belt does not come off
crankshaft sprocket.
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Fig. 14: Exploded View Of Camshaft & Cylinder Head Components

12. Remove camshafts. See CAMSHAFT

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CAUTION: Cylinder head bolts must be loosened in proper sequence to prevent

cylinder head warpage.
13. Loosen cylinder head bolts in proper sequence using several steps. See Fig. 15 . Remove cylinder head
bolts, washers, cylinder head with intake manifold. If cylinder head is difficult to remove, carefully pry
between cylinder head and block using a screwdriver. DO NOT damage contact surfaces between
cylinder head and block. Remove cylinder head gasket from cylinder block.
Fig. 15: Cylinder Head Bolt Removal & Installation Sequence

14. Remove air tube bolted onto side of intake manifold. Remove bolts/nuts, intake manifold and gasket from
cylinder head. Disconnect air hose from cylinder head port. Remove air hose.
15. Remove fuel delivery pipe-to-cylinder head bolts. Remove fuel delivery pipe from cylinder head.
Remove fuel injectors and spacers from cylinder head. Remove oil pressure switch from side of cylinder
head.
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Inspection
1. Inspect cylinder head warpage at cylinder block, exhaust manifold and intake manifold surfaces. Replace
cylinder head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE
SPECIFICATIONS.
2. Inspect cylinder block deck surface for warpage. Replace cylinder block if deck surface warpage exceeds
specification. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS.
3. Inspect intake and exhaust manifold machined surfaces for warpage. Replace component if warpage
exceeds .0118" (.300 mm). Inspect camshaft and components. See CAMSHAFT .
4. Measure valve lifter diameter and bore diameter. Ensure oil clearance is within specification. Replace
components if not within specification. See VALVE LIFTERS table under ENGINE
SPECIFICATIONS.
Installation
1. Apply adhesive to 2 or 3 threads of oil pressure switch, and install switch. Install NEW insulator at
bottom of fuel injector and NEW grommet on top of fuel injector. Coat NEW "O" rings with gasoline and
install on fuel injector.
2. Install 2 spacers on cylinder head. Install fuel injectors on cylinder head. Install fuel delivery pipe on fuel
injectors. Using twisting motion, push fuel injectors into fuel delivery pipe.
3. Install and slightly tighten fuel delivery pipe-to-cylinder head bolts. Ensure all fuel injectors rotate
smoothly. If fuel injector fails to rotate smoothly, check for improperly installed or damaged "O" rings.
4. Position electrical connector on fuel injector facing toward top of engine. Tighten fuel delivery pipe-to-
cylinder head bolts to specification. See TORQUE SPECIFICATIONS .
5. Using NEW gasket, install intake manifold. Install and tighten bolts/nuts to specification. See TORQUE
SPECIFICATIONS . Install air tube on side of intake manifold.
6. Install adjusting shims and valve lifters in original location on cylinder head (if removed). Ensure valve
lifters rotate smoothly in cylinder head.
7. Install NEW gasket for cylinder head on cylinder block. Ensure all holes in gasket align with holes in
cylinder block.
8. Install cylinder head. Coat threads and bolt-to-cylinder contact surfaces on cylinder head bolts with
engine oil. Install and tighten cylinder head bolts in several steps, to specification in sequence. See Fig.
15 . See TORQUE SPECIFICATIONS .
9. If removed, install spark plug tubes. Install camshafts using proper procedure. See CAMSHAFT . Install
No. 3 timing belt cover. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS .
10. To install remaining components, reverse removal procedure. If camshaft or cylinder head components
are serviced, adjust valve clearance. See VALVE CLEARANCE ADJUSTMENT under
ADJUSTMENTS.
11. Before installing gasket and valve cover, apply sealant at front and rear valve cover areas on cylinder
head. See Fig. 6 . Using NEW gasket, install valve cover.
12. Install grommets in original location with marking on grommet aligned in designated area. See Fig. 7 .
Install and tighten valve cover nuts to specification. See TORQUE SPECIFICATIONS .
13. Install VSV for EGR. Connect ground cable to intake manifold with bolt. Connect knock sensor
connector. Connect power steering idle-up air hoses to air tube. On A/T models, connect A/T throttle
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control cable to intake manifold. On all models, install NEW gasket and EGR valve with union nut and 2
nuts. Install vacuum modulator to clamp on intake manifold. Connect vacuum hoses to EGR VSV.
Connect fuel inlet hose to fuel filter
14. Connect vacuum sensor hose to gas filter, and brake booster vacuum hose to intake manifold. Install
throttle body. Install NEW "O" ring on coolant by-pass pipe, and NEW gasket on water pump cover
before installing coolant by-pass pipe. Apply soapy water solution to "O" ring before installing coolant
by-pass pipe. Install by-pass pipe.
15. Install NEW gasket and water outlet. Connect radiator, water by-pass and heater water hoses. Connect
ECT sensor and sender gauge connectors. Connect oil pressure switch.
16. Install ignition coils, manifold stay and spark plug wires. Connect wire clamp to manifold stay. Connect
spark plug wires to spark plugs and clamps on cylinder head cover. Connect ignition coil connectors.
17. Install 2 heat insulators. Install lower heat insulator. On California models, install A/F sensor to exhaust
manifold. All others, install oxygen sensor (bank 1 sensor 1) to exhaust manifold.
18. Using a new gasket, install exhaust manifold and heat insulator assembly. Install right-side exhaust
manifolds stay (California). Install left-side exhaust manifold stay. Install upper manifold heat insulator.
Connect A/F sensor connectors (California), or Oxygen sensor (bank 1 sensor 1).
19. Use NEW gasket and NEW nuts when installing front exhaust pipe. Ensure all bolts/nuts are loosely
installed on front exhaust pipe before tightening to specification. See TORQUE SPECIFICATIONS
20. Install generator and air cleaner and cap. Connect accelerator cable to throttle body and cable bracket. On
A/T models, connect throttle cable to throttle body and cable bracket. On all models, start engine and
check for leaks. Recheck engine coolant and oil level. Install right-side engine undercover.
CRANKSHAFT FRONT SEAL
Removal & Installation (Oil Pump Installed)
1. Remove timing belt and crankshaft sprocket. See TIMING BELT . Using a knife, cut lip from seal. Pry
seal from oil pump housing. DO NOT damage sealing surfaces.
2. To install, apply grease to lip of new seal. Using hammer and Seal Installer (SST 09226-10010), install
seal until seal surface is even with oil pump housing. To install remaining components, reverse removal
procedure.
Removal & Installation (Oil Pump Removed)
Using hammer and drift, remove seal from oil pump housing. To install, use hammer and Seal Installer (SST
09226-10010). Install seal until seal surface is even with oil pump housing. Apply grease to lip of new seal.
TIMING BELT
CAUTION: If reusing timing belt, mark direction of timing belt rotation, and place
reference mark on timing belt at camshaft sprocket for reassembly
reference. Also, place reference mark on timing belt at upper edge of No. 1
timing belt cover. DO NOT bend, twist or turn timing belt inside-out. DO
NOT expose timing to oil, water or steam.
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Removal
1. Disconnect negative battery cable. Remove power steering fluid reservoir with mounting bracket.
Remove accessory drive belts. Remove generator and generator mounting bracket. Remove wiring
brackets for access to timing belt covers.
2. On models with Anti-Lock Brake System (ABS), disconnect electrical connectors and brake lines from
ABS actuator. ABS actuator is located in front of passenger-side strut tower. Remove ABS actuator
mounting bracket-to-body bolts/nuts. Remove ABS actuator with mounting bracket.
3. Raise and support vehicle. Remove passenger-side lower engine cover. Remove passenger-side front
wheel.
4. Using floor jack, slightly raise engine to remove weight from right (timing belt side) engine mount at
timing belt cover. Remove right (timing belt side) engine mount from body and mounting bracket on
cylinder block for access to timing belt covers.
5. Remove spark plugs. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. Remove
right (timing belt side) engine mounting bracket from front of cylinder block.
6. Disconnect engine wiring harness protector from rear of No. 2 timing belt cover. When disconnecting
engine wiring harness protector, remove bolt on intake manifold side of engine first and then bolt on
exhaust manifold side of engine.
7. Remove No. 2 timing belt cover. See Fig. 16 . Install crankshaft pulley on crankshaft. Temporarily install
crankshaft pulley bolt.
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Fig. 16: Exploded View Of Timing Belt & Components

compression stroke and timing mark on crankshaft pulley aligns with "0" mark on timing belt cover.
9. Ensure hole in camshaft sprocket aligns with alignment mark on camshaft bearing cap. See Fig. 17 . If
hole in camshaft sprocket is not aligned with alignment mark, rotate crankshaft clockwise one full
revolution.
Fig. 17: Aligning Camshaft Timing Marks

10. Loosen No. 1 idler pulley bolt. See Fig. 16 . Move No. 1 idler pulley outward, as far as possible, away
from timing belt. Temporarily retighten No. 1 idler pulley bolt.
11. Remove timing belt from camshaft sprocket. Hold crankshaft pulley and remove crankshaft pulley bolt.
Using puller, remove crankshaft pulley. DO NOT allow crankshaft to rotate when removing crankshaft
pulley.
12. Remove No. 1 timing belt cover. See Fig. 16 . Note direction of timing belt guide installation. See Fig.
16 . Remove timing belt guide.
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13. If reusing timing belt, mark direction of timing belt rotation and place reference marks on timing belt and
crankshaft sprocket for reassembly reference. Remove timing belt from crankshaft sprocket.
14. Remove idler pulleys (if necessary). If removing camshaft sprocket, use spanner wrench to hold camshaft
sprocket and remove camshaft sprocket bolt. Remove camshaft sprocket.
15. If removing crankshaft sprocket, use puller to pull crankshaft sprocket from crankshaft. If removing oil
pump sprocket, hold oil pump sprocket by installing spanner wrench in holes on front of oil pump
sprocket. Remove oil pump sprocket nut. Remove spanner wrench and oil pump sprocket.
Inspection
1. Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate freely.
Replace components if damaged or worn.
2. Ensure free length of tension spring is within specification. See TENSION SPRING
SPECIFICATIONS table. Measure tension required to extend tension spring to specified installed
length. Replace tension spring if tension is not within specification. See TENSION SPRING
SPECIFICATIONS table.
TENSION SPRING SPECIFICATIONS

Application Specification
Free Length 1.653" (42.00 mm)
Tension At Spring Installed Length (1) 7.0-8.5 lbs. (3.15-3.85 kg)
(1) Installed length of spring is 1.988" (50.5 mm).
Installation
1. If installing oil pump sprocket, align cutout areas on oil pump sprocket with areas on oil pump shaft.
Install oil pump sprocket. Install and tighten oil pump sprocket nut to specification while holding oil
pump sprocket with spanner wrench. See TORQUE SPECIFICATIONS .
2. If installing crankshaft sprocket, align crankshaft sprocket with key in crankshaft. Install crankshaft
sprocket with sensor teeth toward cylinder block. See Fig. 16 .
3. Install No. 2 idler pulley (if removed). Install and tighten bolt to specification. See TORQUE
SPECIFICATIONS . Ensure idler pulley is clean and rotates smoothly.
4. Install No. 1 idler pulley and tension spring (if removed). DO NOT tighten bolt at this time. Ensure pivot
hole on No. 1 idler pulley mounting flange engages with pin on front of cylinder block.
5. Move idler pulley away from timing belt area as far as possible. Temporarily tighten No. 1 idler pulley
bolt. Ensure idler pulley is clean and rotates smoothly.
6. If installing camshaft sprocket, align pin groove in camshaft sprocket with pin in camshaft. Install
camshaft sprocket. Install and tighten camshaft sprocket bolt to specification. See TORQUE
SPECIFICATIONS . Using crankshaft pulley bolt, rotate crankshaft so key on crankshaft is at 12
o'clock position.
CAUTION: If reusing timing belt, ensure reference mark on timing belt aligns
with reference mark placed on crankshaft sprocket, and timing belt is
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installed in original direction of rotation.
7. Ensure all sprockets and idler pulleys are clean. Install timing belt on crankshaft sprocket, oil pump
sprocket, water pump sprocket, No. 1 idler pulley and then No. 2 idler pulley.
8. Install timing belt guide with cupped side away from crankshaft sprocket and flat side toward timing belt.
Install No. 1 timing belt cover.
9. Remove crankshaft pulley bolt. Align crankshaft pulley key groove with key in crankshaft. Install
crankshaft pulley. Temporarily install and tighten crankshaft pulley bolt.
10. If using new timing belt, go to step 15 . If reusing timing belt, ensure reference mark placed on timing
belt aligns with upper edge of No. 1 timing belt cover when timing mark on crankshaft pulley aligns with
"0" mark on No. 1 timing belt cover. If reference mark is aligned, proceed to step 15 .
11. If reference mark is below surface of No. 1 timing belt cover, pull upward on water pump side of timing
belt while rotating crankshaft pulley counterclockwise. Align reference mark with surface of No. 1 timing
belt cover.
12. After aligning matchmark, hold timing belt and rotate crankshaft pulley clockwise so timing mark on
crankshaft pulley aligns with "0" mark on No. 1 timing belt cover.
13. If reference mark is above surface of No. 1 timing belt cover, pull upward on No. 1 idler pulley side of
timing belt while rotating crankshaft pulley clockwise. Align reference mark with surface of No. 1 timing
belt cover.
14. After aligning matchmark, hold timing belt and rotate crankshaft pulley counterclockwise so timing mark
on crankshaft pulley aligns with "0" mark on No. 1 timing belt cover.
15. Install timing belt on camshaft sprocket. If reusing timing belt, ensure reference mark on timing belt
aligns with reference mark placed on camshaft sprocket. Ensure tension exists on timing belt between
crankshaft and camshaft sprockets.
16. Loosen No. 1 idler pulley bolt 1/2 turn. Rotate crankshaft pulley 2 full revolutions clockwise from TDC
to TDC. DO NOT rotate crankshaft counterclockwise.
17. Ensure timing mark on crankshaft pulley aligns with "0" mark on No. 1 timing belt cover, and hole in
camshaft sprocket aligns with alignment mark on camshaft bearing cap. See Fig. 17 . If timing marks are
not aligned, remove timing belt and reinstall.
18. Rotate crankshaft clockwise 1 7/8 revolutions and align crankshaft pulley "0" mark with 45-degree
Before Top Dead Center (BTDC) mark on No. 1 timing belt cover. See Fig. 18 .
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Fig. 18: Aligning Crankshaft Pulley With 45-Degree BTDC Mark

19. Tighten No. 1 idler pulley bolt to specification. See TORQUE SPECIFICATIONS . Install right (timing
belt side) engine mounting bracket on front of cylinder block with bolts loosely installed. DO NOT
tighten bolts at this time.
20. Install No. 2 timing belt cover. Install engine wire harness and engine wire harness protector on rear of
No. 2 timing belt cover. When installing engine wire harness protector, install bolt on exhaust manifold
side of engine first, and then bolt on intake manifold side of engine.
21. Remove crankshaft pulley bolt and crankshaft pulley. Tighten right (timing belt side) engine mounting
bracket-to-cylinder block bolts to specification. See TORQUE SPECIFICATIONS .
22. Reinstall crankshaft pulley. Install and tighten crankshaft pulley bolt to specification. See TORQUE
SPECIFICATIONS .
23. Install right (timing belt side) engine mount on body and mounting bracket on cylinder block. Tighten
right (timing belt side) engine mount-to-body bolts to specification. See TORQUE
SPECIFICATIONS .
24. Tighten right (timing belt side) mounting bracket-to-engine mount bolts/nuts to specification. See
TORQUE SPECIFICATIONS . To install remaining components, reverse removal procedure. On
models with ABS, bleed brake system after install ABS actuator. See HYDRAULIC SYSTEM
BLEEDING in appropriate article in BRAKES.
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VALVE LIFTER
Removal
Remove camshaft. See CAMSHAFT . Note location of adjusting shims and valve lifters for reassembly
reference. Remove adjusting shims and valve lifters from cylinder head.
Inspection
Inspect components for damage. Measure valve lifter diameter and bore diameter. Ensure oil clearance is within
specification. Replace components if not within specification. See VALVE LIFTERS table under ENGINE
SPECIFICATIONS.
Installation
To install, reverse removal procedure. Ensure components are installed in original location and valve lifters
rotate smoothly in cylinder head. If camshaft, adjusting shims or valve lifters are replaced, check valve
clearance. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS.
CAMSHAFT
Removal (Exhaust Side)
1. Remove timing belt and camshaft sprocket. See TIMING BELT . Remove No. 3 timing belt cover. See
Fig. 14 .
2. Disconnect power steering fluid reservoir, PCV hoses, cable brackets and control cables for access to
valve cover. Disconnect spark plug wires from spark plugs. Remove nuts, grommets, valve cover and
gasket. Note location of grommets for reassembly reference, as grommets must be installed in original
location.
CAUTION: Camshafts must be properly positioned to lift camshaft straight from

cylinder head to prevent damage to cylinder head and camshaft. DO
NOT pry or force camshafts from cylinder head or component
damage will result.
3. For servicing of exhaust camshaft, rotate intake camshaft so knock pin is 10-45 degrees from vertical
position. See Fig. 19 . This aids in exhaust camshaft removal by using camshaft lobes on cylinders No. 2
and 4 to push on valve lifters.
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Fig. 19: Positioning Camshafts

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4. Secure sub-gear to main gear on exhaust camshaft with a 6 x 1.0 x 18 mm service bolt "B". See Fig. 20 .
Before removing camshaft bearing cap bolts, ensure torsional spring force of sub-gear is secured by
service bolt "B".
Fig. 20: Securing Sub Gear-To-Main Gear

NOTE: Camshaft bearing caps are numbered for location, and have an arrow on
top of cap. Front camshaft bearing cap on intake camshaft and rear
camshaft bearing cap on exhaust camshaft are not numbered. All other
camshaft bearing caps are numbered starting with No. 1 at timing belt end
of engine. Arrow on top of camshaft bearing cap must point toward timing
belt end of engine. See Fig. 21 .
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Fig. 21: Identifying Camshaft Bearing Caps

5. Remove bolts and rear camshaft bearing cap from exhaust camshaft. Remove bolts from No. 1, 2 and 4
camshaft bearing caps on exhaust camshaft in proper sequence. See Fig. 22 . DO NOT remove bolts from
No. 3 camshaft bearing cap at this time. Remove No. 1, 2 and 4 camshaft bearing caps from exhaust
camshaft.
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Fig. 22: Exhaust Camshaft Bearing Cap Bolt Removal & Installation Sequence
6. Alternately loosen bolts on No. 3 camshaft bearing cap on exhaust camshaft. Ensure exhaust camshaft is
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lifted upward as No. 3 camshaft bearing cap bolts are loosened.

7. If exhaust camshaft is not lifted upward, reinstall all camshaft bearing caps. Reposition intake camshaft
so knock pin is 10-45 degrees from vertical position. See Fig. 19 . Repeat steps 5) and 6) . Remove No. 3
camshaft bearing cap and exhaust camshaft.
Removal (Intake Side)
1. Remove distributor, if equipped. Rotate intake camshaft so knock pin is 80-115 degrees from vertical
position. See Fig. 19 . This aids in intake camshaft removal by using camshaft lobes on cylinders No. 1
and 3 to push on valve lifters.
2. Remove bolts, front camshaft bearing cap and oil seal from intake camshaft. Remove bolts from No. 1, 3
and 4 camshaft bearing caps on intake camshaft in proper sequence. See Fig. 23 . DO NOT remove bolts
from No. 2 camshaft bearing cap at this time. Remove No. 1, 3 and 4 camshaft bearing caps from intake
camshaft.
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Fig. 23: Intake Camshaft Bearing Cap Bolt Removal & Installation Sequence
3. Alternately loosen bolts on No. 2 camshaft bearing cap on intake camshaft. Ensure intake camshaft is
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lifted upward as No. 2 camshaft bearing cap bolts are loosened.

4. If intake camshaft is not lifted upward, reinstall all camshaft bearing caps. Reposition intake camshaft so
knock pin is 80-115 degrees from vertical position. See Fig. 19 . Repeat steps 9) and 10) . Remove No. 2
camshaft bearing cap and intake camshaft.
5. If removing sub-gear from exhaust camshaft, mount camshaft in soft-jaw vise on hexagonal area of
camshaft. Install service bolt "A" in camshaft. See Fig. 24 .
Fig. 24: Removing & Installing Sub-Gear On Main Gear

6. Using screwdriver, rotate sub-gear clockwise and remove service bolt "B". Remove snap ring, wave
washer, sub-gear and camshaft gear spring from exhaust camshaft. See Fig. 14 .
7. Note location of adjusting shims and valve lifters for reassembly reference. Remove adjusting shims and
valve lifters from cylinder head (if necessary).
Inspection
1. Inspect components for damage. Check camshaft journal diameter, lobe height and journal runout.
Replace camshaft if not within specification. See CAMSHAFT table under ENGINE
SPECIFICATIONS. Install camshaft in cylinder head.
2. Using Plastigage, check camshaft oil clearance with camshaft bearing cap bolts tightened to specification
in sequence. See Fig. 22 and Fig. 23 . See TORQUE SPECIFICATIONS .
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3. Check camshaft end play with camshaft bearing cap bolts tightened to specification. Replace camshaft
and/or cylinder head if camshaft end play is not within specification. See CAMSHAFT table under
ENGINE SPECIFICATIONS.
4. Install both camshafts in cylinder head without sub-gear installed on exhaust camshaft. Install and tighten
camshaft bearing cap bolts to specification in sequence. See Fig. 22 and Fig. 23 . See TORQUE
SPECIFICATIONS .
5. Using dial indicator, check gear backlash between gears on camshafts. Replace camshafts if gear backlash
exceeds specification. See CAMSHAFT table under ENGINE SPECIFICATIONS.
6. Measure length of camshaft gear spring. Replace camshaft gear spring if distance is not within
specification. See CAMSHAFT table under ENGINE SPECIFICATIONS. Measure valve lifter diameter
and bore diameter. Ensure oil clearance is within specification. Replace components if not within
specification. See VALVE LIFTERS table under ENGINE SPECIFICATIONS.
Installation
1. If installing sub-gear on exhaust camshaft, install camshaft gear spring, sub-gear, wave washer and snap
ring on exhaust camshaft. Ensure pins on main gear and sub-gear engage with ends of camshaft gear
spring.
2. Install service bolt "A" on sub-gear. See Fig. 24 . Using screwdriver, rotate sub-gear clockwise and align
hole in sub-gear with hole on main gear. Install service bolt "B". Remove service bolt "A".
3. Install adjusting shims and valve lifters in original location on cylinder head (if removed). Ensure valve
lifters rotate smoothly in cylinder head.
4. Coat thrust surfaces of camshafts with multipurpose grease. To install intake camshaft, rotate intake
camshaft so knock pin is at 80-115 degrees from vertical position, and install into cylinder head. See Fig.
19 .
5. Coat seal lip of NEW oil seal for intake camshaft with grease. Install oil seal onto front of intake camshaft
until oil seal is fully seated in cylinder head. Apply sealant to front camshaft bearing cap for intake
camshaft. See Fig. 25 .
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Fig. 25: Applying Sealant To Front Camshaft Bearing Cap

6. Install front camshaft bearing cap for intake camshaft onto cylinder head. Install remaining camshaft
bearing caps for intake camshaft onto cylinder head in numerical sequence with arrow pointing toward
timing belt end of engine. See Fig. 21 .
7. Coat threads and bolt head-to-camshaft bearing cap contact surfaces of camshaft bearing cap bolts with
engine oil. Install and tighten camshaft bearing cap bolts to specification in sequence using several steps.
See Fig. 23 . See TORQUE SPECIFICATIONS .
8. To install exhaust camshaft, rotate intake camshaft so knock pin is 10-45 degrees from vertical position.
See Fig. 19 . Install exhaust camshaft so timing mark aligns with timing mark on intake camshaft. DO
NOT use assembly reference marks. See Fig. 26 . Ensure exhaust camshaft is fully seated in cylinder
head.
NOTE: It may be necessary to slightly rotate intake camshaft so exhaust camshaft

fully seats in cylinder head.
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Fig. 26: Aligning Camshaft Timing Marks

9. Install camshaft bearing caps for exhaust camshaft on cylinder head in numerical sequence with arrow
pointing toward timing belt end of engine. See Fig. 21 .
10. Coat threads and bolt head-to-camshaft bearing cap contact surfaces of camshaft bearing cap bolts with
engine oil. Install and tighten camshaft bearing cap bolts to specification in sequence using several steps.
See Fig. 22 . See TORQUE SPECIFICATIONS .
11. Remove service bolt "B" from camshaft gear. See Fig. 24 . Install No. 3 timing belt cover. Install and
tighten bolts to specification. See TORQUE SPECIFICATIONS . Install timing belt using proper
procedure. See TIMING BELT .
12. Check valve clearance. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS. Apply
sealant in grooves on rear side of semi-circular plugs located on exhaust camshaft side of cylinder head.
Install semi-circular plugs in cylinder head.
13. Before installing gasket and valve cover, apply sealant at front and rear valve cover areas on cylinder
head. See Fig. 6 .
14. Using NEW gasket, install valve cover. Install grommets in original location with marking on grommet
aligned in designated area. See Fig. 7 . Install and tighten valve cover nuts to specification. See
TORQUE SPECIFICATIONS .
15. If installing distributor, install NEW "O" ring on distributor. Coat "O" ring with engine oil.
compression stroke and timing mark on crankshaft pulley aligns with "0" mark on timing belt cover.
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17. Ensure slot area on intake camshaft is vertically positioned. Rotate coupling on distributor so cutout
aligns with alignment mark on distributor housing.
18. Install distributor so center of flange on distributor is aligned with bolt hole on cylinder head. Install
distributor hold-down bolt(s). Adjust ignition timing.
CRANKSHAFT REAR OIL SEAL
NOTE: On 4WD models, manufacturer recommends removing engine with transaxle for
transaxle removal. On 2WD models, transaxle may be removed with engine in
vehicle.
Removal
Remove transaxle, clutch assembly (if equipped) and flywheel/drive plate. Using a knife, cut seal lip from oil
seal. Pry oil seal from rear seal housing. DO NOT damage sealing surfaces.
Installation
1. Ensure all sealing surfaces are clean. Apply grease to seal lip of new oil seal. Using Oil Seal Installer
(SST 09223-15030), install oil seal into rear seal housing until oil seal is even with surface of rear seal
housing.
2. Apply Loctite to flywheel/drive plate bolts. Install flywheel/drive plate. Install bolts and tighten to
specification using a crisscross pattern. See TORQUE SPECIFICATIONS . To install remaining
components, reverse removal procedure.
WATER PUMP
Removal
1. Disconnect negative battery cable. Drain cooling system. Remove timing belt and idler pulley(s) as
needed for access to water pump. See TIMING BELT .
2. Disconnect lower radiator hose from thermostat housing. Remove generator adjusting bracket. Remove
coolant by-pass pipe-to-water pump nuts. See Fig. 27 .
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Fig. 27: Exploded View Of Typical Water Pump & Components

3. Remove water pump bolts in sequence. See Fig. 28 . Remove water pump, water pump cover and "O"
rings. See Fig. 27 . Remove water pump-to-water pump cover bolts. Remove water pump and gasket
from water pump cover.
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Fig. 28: Water Pump Bolt Removal & Installation Sequence

Installation
1. To install, reverse removal procedure. Use NEW gaskets and NEW "O" rings. Apply soapy water
solution to coolant by-pass pipe "O" ring before installing water pump.
2. Tighten water pump bolts to specification in sequence. Tightening coolant by-pass pipe-to-water pump
nuts. See Fig. 28 . See TORQUE SPECIFICATIONS . To install remaining components, reverse
removal procedure. Fill cooling system.
OIL PAN
Removal
1. Disconnect negative battery cable. Raise and support vehicle. Remove lower engine covers. Drain engine
oil. Remove oil dipstick. Remove front exhaust pipe from between front catalytic converter on exhaust
manifold and rear exhaust pipe for access to oil pan.
2. Remove stiffener plate at rear of oil pan for access to oil pan. Stiffener plate fits between sides of cylinder
block and front of transaxle. Remove bolts/nuts and oil pan.
Installation
1. Ensure sealing surfaces are clean. Apply bead of sealant at center of oil pan sealing surface, between
bolt/nut holes and on inside of bolt/nut holes.
2. Install oil pan. Install and tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS .
3. To install remaining components, reverse removal procedure. Use NEW gasket and NEW nuts when
installing front exhaust pipe onto catalytic converter. Ensure all bolts/nuts are loosely installed before
tightening to specification. See TORQUE SPECIFICATIONS .
OVERHAUL
CYLINDER HEAD
Cylinder Head
1. Inspect cylinder head warpage at cylinder block, exhaust manifold and intake manifold areas. Replace
cylinder head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE
SPECIFICATIONS.
2. Install camshaft into cylinder head. Using Plastigage, check camshaft oil clearance with camshaft bearing
cap bolts tightened to specification in sequence. See Fig. 22 and Fig. 23 . See TORQUE
SPECIFICATIONS .
3. Check camshaft end play with camshaft bearing cap bolts tightened to specification. Replace camshaft
and/or cylinder head if camshaft oil clearance or end play is not within specification. See CAMSHAFT
table under ENGINE SPECIFICATIONS.
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4. Ensure valve lifter bore diameter in cylinder head is within specification. See VALVE LIFTERS table
under ENGINE SPECIFICATIONS.
Valve Springs
Ensure valve spring free length, pressure and out-of-square are within specification. See VALVES & VALVE
SPRINGS table under ENGINE SPECIFICATIONS.
CAUTION: Valve stems oil seals are painted a different color on top of oil seal for
specified valve application. Intake valve stem oil seal is Brown and
exhaust valve stem oil seal is Black. Ensure valve stem oil seal is installed
in proper location.
Valve Stem Oil Seals
Intake valve stem oil seal is Brown. Exhaust valve stem oil seal is Black. Ensure proper valve stem oil seal is
installed. Lubricate valve stem oil seal with engine oil. Install valve stem oil seal using Oil Seal Installer (SST
09201-41020).
Valve Guides
1. Ensure valve guide inside diameter is within specification. See CYLINDER HEAD table under ENGINE
SPECIFICATIONS. Replace valve guide if inside diameter exceeds specification.
2. To replace valve guide, heat cylinder head to 176-212°F (80-100°C). Using a hammer and Valve Guide
Remover/Installer (SST 09201-01060), drive valve guide from camshaft side of cylinder head.
3. Measure cylinder head valve guide bore inside diameter. If bore inside diameter is .4325-.4335" (10.985-
11.012 mm), use standard valve guide. If bore inside diameter is .4344-.4355" (11.035-11.062 mm), use
oversize valve guide.
4. If bore inside diameter exceeds .4335" (11.012 mm), machine valve guide bore to .4344-.4355" (11.035-
11.062 mm) for oversize valve guide. If bore inside diameter exceeds .4355" (11.062 mm), replace
cylinder head.
5. Intake valve guide is 1.516" (38.50 mm) long. Exhaust valve guide is 1.594" (40.50 mm) long. Ensure
proper valve guide is installed.
6. To install valve guide, heat cylinder head to 176-212°F (80-100°C). Using hammer and valve guide
remover/installer, drive valve guide in from camshaft side of cylinder head until valve guide installed
height is .315-.346" (8.00-8.80 mm). Valve guide installed height is measured from top of valve guide to
cylinder head surface. See Fig. 29 .
7. On all valve guide applications, use .236" (6.00 mm) reamer to ream valve guide to obtain correct valve
stem-to-guide oil clearance. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.
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Fig. 29: Measuring Valve Guide Installed Height

Valve Seat
Ensure valve seat angle and seat width are within specification. See CYLINDER HEAD table under ENGINE
SPECIFICATIONS. Valve seat replacement information is not available from manufacturer.
Valves
Ensure minimum refinish length, stem diameter and valve margin are within specification. See VALVES &
VALVE SPRINGS table under ENGINE SPECIFICATIONS.
Valve Seat Correction Angles
Use 30-degree and 45-degree stones to lower valve seat contact area. Use 45-degree and 75-degree stones to
raise valve seat contact area.
VALVE TRAIN
Valve Lifters
Ensure valve lifter diameter, bore diameter and oil clearance are within specification. See VALVE LIFTERS
CYLINDER BLOCK ASSEMBLY

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Piston & Rod Assembly
1. Ensure connecting rod and connecting rod cap are marked with matching cylinder number for reassembly
reference. Piston, connecting rod and connecting rod must be installed with front mark toward timing belt
end of engine. See Fig. 31 .
2. Before disassembling piston and connecting rod, try to move piston back and forth on piston pin. Replace
piston and piston pin as a set, if any movement is felt.
3. Remove 2 compression rings using a piston ring expander. Remove 2 oil rings and oil ring expander by
hand. Using Piston Pin Remover/Replacer (09221-25026), press piston pin from piston, and remove
connecting rod. See Fig. 32 .
4. Ensure piston pin diameter is within specification. See PISTONS, PINS & RINGS table under ENGINE
SPECIFICATIONS. Ensure connecting rod bend, twist and piston pin bore diameter (connecting rod
small end) are within specification. See CONNECTING RODS table under ENGINE
SPECIFICATIONS.
5. If piston pin bore diameter is not within specification, replace connecting rod assembly. See
CONNECTING RODS table under ENGINE SPECIFICATIONS.
6. Using hand pressure, ensure nut rotates easily on connecting rod bolt. If nut fails to rotate easily, use
caliper to measure connecting rod bolt outside diameter .59" (15.0 mm) from end of bolt. Standard
connecting rod bolt outside diameter is .3094-.3150" (7.860-8.000 mm). Replace connecting rod bolt and
nut assembly if bolt outside diameter is less than .2992" (7.600 mm).
7. Pistons with different diameters are used. Piston diameter is identified by size mark ("1", "2" or "3")
stamped on top of piston. See Fig. 30 .
Fig. 30: Identifying Piston Size Marks

8. To determine piston diameter, measure piston skirt diameter .91-1.024" (23-26 mm) from top of piston, at
90-degree angle to piston pin. Ensure piston diameter is within size mark specification. See PISTONS,
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PINS & RINGS table under ENGINE SPECIFICATIONS.

9. To reassemble, position piston and connecting rod so front mark (cavity) on top of piston aligns with
front mark (protrusion) on connecting rod. See Fig. 31 . Coat piston bore and piston pin with engine oil.
Using Piston Pin Remover/Replacer (09221-25026), press piston pin into piston and connecting rod. See
Fig. 32 .
Fig. 31: Identifying Piston Front Marks

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Fig. 32: Removing & Installing Piston Pin

Fitting Pistons
1. Different diameter pistons are used. Piston diameter is identified by size mark ("1", "2" or "3") stamped
on top of piston. See Fig. 30 .
2. Different cylinder bore diameters are used. Cylinder bore diameter may be identified by size mark ("1",
"2" or "3") stamped on cylinder block deck surface. See Fig. 33 .
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Fig. 33: Identifying Cylinder Bore Size Marks (Typical)

3. To determine piston-to-cylinder clearance, measure piston diameter and cylinder bore diameter. Measure
piston skirt diameter .91-1.024" (23-26 mm) from top of piston.
4. Measure cylinder bore diameter at 3 different positions, 90 degrees apart, .39" (10.0 mm) from top and
bottom of cylinder bore, and at center of cylinder bore. Ensure piston diameter and cylinder bore diameter
are within specification. See PISTONS, PINS & RINGS and CYLINDER BLOCK tables under
5. Calculate piston-to-cylinder clearance. Replace piston, or bore cylinder block for oversize pistons, if
clearance is not within specification. See PISTONS, PINS & RINGS table under ENGINE
SPECIFICATIONS. Pistons are available in .020" (.50 mm) oversize. If replacing piston, ensure
replacement piston contains same size mark as size mark on cylinder block.
Piston Rings
1. Ensure piston ring end gap and side clearance are within specification. See PISTONS, PINS & RINGS
2. Install oil ring expander and 2 side rails by hand. Using a piston ring expander, install No. 2 compression
ring with 2N or 2T identification mark facing up. Using a piston ring expander, install No. 1 compression
ring with 1N or "T" identification mark facing up. Ensure compression rings and oil side rails are
positioned correctly. See Fig. 34 .
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Fig. 34: Positioning Piston Rings

Rod Bearings
1. Ensure connecting rod and connecting rod cap are marked with matching cylinder number for reassembly
reference. Ensure connecting rod is installed so front mark (protrusion) at center of connecting rod is
toward timing belt end of engine. Front mark (protrusion) on connecting rod cap must also face timing
belt end of engine. See Fig. 31 .
2. Connecting rod cap and rod bearing are stamped with size mark ("1", "2" or "3"). See Fig. 35 . Ensure
size marks on connecting rod cap and rod bearing are same.
NOTE: If replacing rod bearing, ensure size mark on replacement rod bearing is
same as size mark on original rod bearing.
3. Rod bearing thickness is determined by size mark. See ROD BEARING SPECIFICATIONS table.
4. Ensure nut rotates easily on connecting rod bolt. If nut fails to rotate easily, use caliper to measure
connecting rod bolt outside diameter at .59" (15.0 mm) from end of bolt. Replace connecting rod bolt and
nut as an assembly if bolt outside diameter is less than .2992" (7.600 mm).
5. Install connecting rod cap with front mark (protrusion) toward timing belt end of engine. See Fig. 31 .
Coat threads of connecting rod bolts and nut-to-connecting rod cap surface with engine oil before
tightening nuts to specification. See TORQUE SPECIFICATIONS .
6. Ensure bearing oil clearance and connecting rod side play are within specification. See CRANKSHAFT,
MAIN & CONNECTING ROD BEARINGS and CONNECTING RODS tables under ENGINE
SPECIFICATIONS.
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ROD BEARING SPECIFICATIONS

Bearing Size Mark Bearing Thickness - In. (mm)
"1" .0584-.0586 (1.484-1.488)
"2" .0586-.0587 (1.488-1.492)
"3" .0587-.0589 (1.492-1.496)
Fig. 35: Identifying Connecting Rod Cap & Rod Bearing Size Marks
Crankshaft & Main Bearings
1. Main bearing caps are numbered on top of cap for location reference. No. 1 main bearing cap is at timing
belt end of engine and No. 5 is at flywheel/drive plate end of engine. Ensure arrow on top of main bearing
cap points toward timing belt end of engine.
2. Remove main bearing cap bolts in sequence. See Fig. 36 . Remove main bearing caps, crankshaft, thrust
bearings and main bearings.
3. Cylinder block main bearing bore inside diameter is identified by main bearing bore size mark ("1", "2"
or "3") stamped on cylinder block. See Fig. 37 . Front size mark indicates No. 1 main bearing bore and
rear size mark indicates No. 5 main bearing bore.
4. Crankshaft main bearing journal diameter is identified by main bearing journal size mark ("0", "1" or "2")
located on crankshaft counterweight. See Fig. 37 .
5. Ensure crankshaft runout, journal diameter, taper and out-of-round are within specification. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE
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SPECIFICATIONS.
6. Main bearing size mark ("1", "2", "3", "4" or "5") is located on side of main bearing. See Fig. 37 . If
replacing main bearing, ensure size mark on replacement main bearing is same as size mark on original
main bearing.
7. If main bearing size mark cannot be obtained, add size marks on cylinder block and crankshaft to
determine size mark of main bearing to be used. For example, if size mark on cylinder block is "2" and
size mark on crankshaft is "1", use main bearing with size mark "3".
NOTE: Different width main bearings are used. Install wide main bearing on No. 3
journal and narrow main bearings on all other journals.
8. Main bearing thickness is determined by size mark. See MAIN BEARING SPECIFICATIONS table.
Install main bearings, thrust bearings, crankshaft and main bearing caps.
9. Ensure main bearing caps are properly installed in numerical sequence with No. 1 at timing belt end, and
No. 5 at flywheel/drive plate end of engine. Ensure arrow on top of main bearing cap points toward
timing belt end of engine.
10. Coat threads and bolt-to-main bearing cap contact surfaces on main bearing cap bolts with engine oil.
Install and tighten main bearing cap bolts to specification in sequence. See Fig. 36 . See TORQUE
SPECIFICATIONS .
11. Ensure crankshaft main bearing oil clearance and crankshaft end play are within specification. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE
SPECIFICATIONS. Replace thrust bearing if end play is not within specification.
MAIN BEARING SPECIFICATIONS

Bearing Size Mark Bearing Thickness - In. (mm)
No. 3 Main Bearing
"1" .07842-.07854 (1.9920-1.9950)
"2" .07854-.07866 (1.9950-1.9980)
"3" .07866-.07877 (1.9980-2.0010)
"4" .07877-.07889 (2.0010-2.0040)
"5" .07889-.07901 (2.0040-2.0070)
All Others
"1" .07862-.07874 (1.9970-2.0000)
"2" .07874-.07885 (2.0000-2.0030)
"3" .07885-.07897 (2.0030-2.0060)
"4" .07897-.07909 (2.0060-2.0090)
"5" .07909-.07921 (2.0090-2.0120)
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Fig. 36: Main Bearing Cap Bolt Removal & Installation Sequence
Fig. 37: Identifying Cylinder Block, Crankshaft & Main Bearing Size Marks
Thrust Bearing
Install thrust bearing on No. 3 main bearing with grooves facing toward crankshaft, and away from cylinder
block and main bearing cap. Replace thrust bearing if crankshaft end play is not within specification. See
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CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.
Cylinder Block
1. Inspect cylinder block deck surface warpage. Replace cylinder block if deck warpage exceeds
2. Different cylinder bore diameters are used. Cylinder bore diameter may be identified by size mark ("1",
"2" or "3") on cylinder block deck surface. See Fig. 37 .
3. Measure cylinder bore diameter at 2 different places, 90 degrees apart at .39" (10.0 mm) from top and
bottom of cylinder bore and at center of cylinder bore. Ensure cylinder bore diameter is within
4. Bore cylinder block for oversize pistons if cylinder bore diameter is not within specification. Pistons are
available in .020" (.50 mm) oversize.
5. Install main bearing caps in numerical sequence with No. 1 at timing belt end, and No. 5 at flywheel/drive
plate end of engine. Ensure arrow on top of main bearing cap points toward timing belt end of engine.
6. Install and tighten main bearing cap bolts to specification in sequence. See Fig. 36 . See TORQUE
SPECIFICATIONS .
7. Ensure main bearing bore inside diameter is within specification. See CYLINDER BLOCK table under
NOTE: Main bearing bore inside diameter is identified by main bearing bore size mark
("1", "2" or "3") stamped on cylinder block. See Fig. 37 .
ENGINE OILING
ENGINE LUBRICATION SYSTEM
Crankshaft driven oil pump provides pressurized engine lubrication. Oil cooler is installed between oil filter and
cylinder block.
Crankcase Capacity
Drain and refill capacity with oil filter is approximately 4.3 qts. (4.1L). Dry fill capacity is approximately 4.8
qts. (4.6L).
Oil Pressure
With engine at normal operating temperature, oil pressure should be at least 4.3 psi (0.3 kg/cm2 ) at idle and 36-
71 psi (2.5-5.0 kg/cm2 ) at 3000 RPM.
OIL PUMP
Removal & Disassembly
1. Remove timing belt, No. 2 idler pulley, crankshaft sprocket and oil pump sprocket. See TIMING BELT
Microsoft
1999 Toyota RAV4
under REMOVAL & INSTALLATION. Remove oil pan. See OIL PAN under REMOVAL &
INSTALLATION.
2. Remove oil pump pick-up tube, gasket and oil baffle plate. Disconnect electrical connector for crankshaft
position sensor located on from of oil pump housing. Remove bolt and crankshaft position sensor from
front of oil pump housing.
3. Remove oil pump-to-cylinder block bolts. Using soft-face hammer, tap oil pump housing from cylinder
block. To disassemble oil pump, remove oil pump body cover bolts, oil pump body cover and "O" ring.
Disassemble oil pump components. See Fig. 38 . Remove oil pump oil seal and crankshaft front oil seal
(if necessary).
Fig. 38: Exploded View Of Oil Pump

Inspection
1. Inspect components for damage. Coat relief valve with engine oil and ensure relief valve slides freely in
bore of oil pump housing. Replace relief valve and/or oil pump housing if relief fails to slide freely.
2. Install rotors in oil pump housing. Using feeler gauge, measure driven rotor-to-oil pump housing
clearance. Replace rotor assembly or oil pump housing if clearance exceeds specification. See OIL
PUMP SPECIFICATIONS table.
3. Using feeler gauge, measure rotor tip clearance between tip of drive rotor and tip of driven rotor. Tip of
drive rotor is on outside of rotor and tip of driven rotor is on inside of rotor. Replace rotor assembly if
clearance exceeds specification. See OIL PUMP SPECIFICATIONS table.
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1999 Toyota RAV4
OIL PUMP SPECIFICATIONS

Driven Rotor-To-Oil Pump Housing Clearance
Standard .0039-.0063 (.100-.160)
Wear Limit .0079 (.200)
Rotor Tip Clearance
Standard .0016-.0063 (.040-.160)
Wear Limit .0079 (.200)
Reassembly & Installation
1. To reassemble, reverse disassembly procedure. Ensure reference marks (dot area) on rotors face toward
oil pump body cover, away from oil pump housing.
2. Using hammer and Oil Seal Installer (SST 09950-60010), install NEW crankshaft front oil seal (if
removed) until oil seal surface is even with oil pump housing. Coat lip of oil seal with grease.
3. Install NEW oil pump oil seal (if removed) until oil seal surface is even with oil pump body cover. Coat
lip of oil seal with grease.
4. Install oil pump body cover using NEW "O" ring. Install and tighten oil pump body cover bolts to
specification. See TORQUE SPECIFICATIONS . Using NEW gasket, install oil pump on cylinder
block.
5. Ensure 2 longest oil pump-to-cylinder block bolts are located in lowest outside holes nearest to oil pan
flange on each side of oil pump. Tighten oil pump-to-cylinder block bolts to specification. See TORQUE
SPECIFICATIONS . To install remaining components, reverse removal procedure.
OIL COOLER
Removal
1. Oil cooler is mounted between oil filter and cylinder block. Disconnect negative battery cable. Drain
cooling system.
2. Remove passenger-side lower engine cover. Remove front exhaust pipe from between front catalytic
converter on exhaust manifold and rear exhaust pipe. Remove generator.
3. Remove exhaust manifold with catalytic converter and heat insulators for access to oil cooler. Remove oil
filter. Disconnect coolant hoses from oil cooler. Remove oil cooler relief valve and plate washer from
center of oil cooler housing. Remove oil cooler-to-cylinder block nut. Remove oil cooler, gasket and "O"
ring.
Inspection
1. Inspect oil cooler for damage. Apply air pressure to coolant hose pipe on oil cooler. Ensure air flows
through oil cooler, and oil cooler is not restricted. Replace oil cooler if damage or restricted.
2. Using wooden stick, push inward on check valve located in center of oil cooler relief valve. Push inward
from threaded end (opposite oil filter threads) on oil cooler relief valve. Replace oil cooler relief valve if
check valve fails to move.
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1999 Toyota RAV4
Installation
1. To install, reverse removal procedure. Use a NEW "O" ring and gasket. Coat "O" ring with engine oil.
Coat threads and area below head of oil cooler relief valve with engine oil.
2. Install oil cooler with oil cooler-to-cylinder block nut and oil cooler relief valve loosely installed. Tighten
oil cooler relief valve, and then nut, to specification. See TORQUE SPECIFICATIONS .
3. Use NEW gasket and NEW nuts when installing front exhaust pipe to catalytic converter. Ensure all
bolts/nuts are loosely installed before tightening to specification. See TORQUE SPECIFICATIONS .
Add engine oil as needed. Fill cooling system.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
ABS Actuator Mounting Bracket-To-Body Bolt/Nut 14 (19)
A/C Compressor Bolt/Nut
Bolt 27 (37)
Nut 20 (27)
Stud Bolt 34 (46)
Axle Shaft Bearing Bracket Bolt
2WD A/T Models 47 (64)
Axle Shaft Bearing Bracket-To-Cylinder Block Bolt
2WD A/T & M/T Models 47 (64)
Axle Shaft Nut 159 (216)
Axle Shaft Retaining Bolt
2WD M/T Models 24 (33)
Ball Joint-To-Lower Control Arm Bolt/Nut 94 (127)
Brake Line-To-ABS Actuator Nut 11 (15)
Camshaft Bearing Cap Bolt (1) 14 (19)
Camshaft Sprocket Bolt 40 (54)
Connecting Rod Nut
Step 1 18 (24)
Step 2 Additional 90
Degrees
Coolant Outlet Nut 11 (15)
Crankshaft Pulley Bolt 80 (108)
Cylinder Head Bolt (2)
Step 1 36 (49)
Step 2 Additional 90
Degrees
Distributor Hold-Down Bolt 14 (19)
Drive Shaft Center Support Bearing Bolt
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1999 Toyota RAV4
4WD Models 27 (37)

Drive Shaft Flange Bolt/Nut
4WD Models 54 (73)
EGR Valve
Nut (3)
Union Nut 43 (58)

Engine Mounts & Brackets
Front (Exhaust Manifold Side) Engine Mount-To-Engine Mount 59 (80)
Crossmember Bolt
Left (Transaxle Side) Engine Mounting Bracket-To-Engine Mount Bolt/Nut 47 (64)
Right (Timing Belt Side) Engine Mounting Bracket-To-Cylinder Block Bolt 38 (52)
Right (Timing Belt Side) Engine Mount-To-Body Bolt 47 (64)
Right (Timing Belt Side) Engine Mounting Bracket-To-Engine Mount Bolt/Nut
Bolt 27 (37)
Nut 38 (52)
Engine Mount Crossmember-To-Body Bolt 26 (35)
Exhaust Manifold Nut 36 (49)
Flywheel/Drive Plate Bolt
A/T 61 (83)
M/T 65 (88)
Front Catalytic Converter Brace Bolt/Nut 31 (42)
Front Catalytic Converter-To-Exhaust Manifold Bolt/Nut 45 (61)
Front Exhaust Pipe-To-Front Catalytic Converter Nut 46 (62)
Front Exhaust Pipe-To-Rear Exhaust Pipe Bolt/Nut 35 (47)
Front Suspension Crossmember Bolt
Bolt At Body 152 (206)
Bolt At Lower Control Arm 101 (137)
Fuel Line-To-Fuel Filter Union Bolt 21 (28)
Fuel Pipe-To-Delivery Pipe Union Bolt 25 (34)
Generator Adjusting Bracket Bolt 20 (27)
Generator Mounting Bracket Bolt 31 (42)
Intake Manifold Bolt/Nut 14 (19)
Intake Manifold Brace Bolt 31 (42)
Main Bearing Cap Bolt (4) 43 (58)
No. 1 & No. 2 Idler Pulley Bolt 31 (42)
Oil Cooler Relief Valve 58 (79)
Oil Pump Sprocket Nut 18 (24)
Oxygen Sensor-To-Exhaust Manifold Nut 15 (20)
Oxygen Sensor-To-Front Catalytic Converter 33 (45)
Power Steering Pump Bolt 32 (43)
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1999 Toyota RAV4
Power Steering Pump Mounting Bracket-To-Cylinder Block Bolt 32 (43)

Spark Plug 13 (18)
Spark Plug Tube 39 (53)
Stabilizer Bar Link-To-Lower Control Arm Nut
2-Door Vehicles 33 (45)
4-Door Vehicles 54 (73)
Stabilizer Bar-To-Frame Mount Bolt 22 (30)
Starter Bolt 29 (39)
Steering Gear Assembly-To-Front Suspension Crossmember Bolt/Nut 83 (113)
Stiffener Plate Bolt 27 (37)
Throttle Body Bolt/Nut 14 (19)
Tie Rod Nut 41 (56)
Valve Cover Nut 33 (45)
Wheel Lug Nut 76 (103)
INCH Lbs. (N.m)
ABS Speed Sensor Bolt 71 (8.0)
Clutch Release Cylinder Bolt 106 (12.0)
Coolant By-Pass Pipe-To-Water Pump Nut 82 (9.3)
Crankshaft Position Sensor Bolt 71 (8.0)
Fuel Delivery Pipe-To-Cylinder Head Bolt 115 (13.0)
No. 3 Timing Belt Cover Bolt 69 (7.8)
Oil Baffle Plate-To-Cylinder Block Bolt/Nut 48 (5.4)
Oil Cooler-To-Cylinder Block Nut 78 (8.8)
Oil Pan Bolt/Nut 48 (5.4)
Oil Pump Body Cover Bolt 78 (8.8)
Oil Pump Pick-Up Tube Bolt/Nut 48 (5.4)
Oil Pump-To-Cylinder Block Bolt 78 (8.8)
Rear Plate-To-Cylinder Block Bolt 82 (9.3)
Rear Seal Housing Bolt 115 (13.0)
Thermostat Housing Nut 78 (8.8)
Water Pump-To-Cylinder Block Bolt (5) 78 (8.8)
Water Pump-To-Water Pump Cover Bolt 78 (8.8)
(1) Tighten bolts to specification in sequence. See Fig. 22 and Fig. 23 .
(2) Tighten bolts to specification in sequence. See Fig. 15 .
(3) Tighten nut to 115 INCH lbs. (13.0 N.m).
ENGINE SPECIFICATIONS
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1999 Toyota RAV4
GENERAL SPECIFICATIONS
Displacement 122 Cu. In. (2.0L)
Bore 3.39" (86.0 mm)
Stroke 3.39" (86.0 mm)
Compression Ratio 9.5:1
Fuel System SFI
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

Crankshaft
End Play
Standard .0008-.0087 (.020-.220)
Wear Limit .0118 (.300)
Maximum Runout .0024 (.060)
Main Bearings
Journal Diameter (1)
Size Mark "0" 2.1653-2.1655 (54.998-55.003)
Size Mark "1" 2.1651-2.1653 (54.993-54.998)
Size Mark "2" 2.1649-2.1651 (54.988-54.993)
Journal Out-Of-Round .0008 (.020)
Journal Taper .0008 (.020)
Oil Clearance
Standard Crankshaft Journal
No. 3 Journal
Standard .0010-.0017 (.025-.044)
Wear Limit .0031 (.080)
All Other Journals
Standard .0006-.0013 (.015-.034)
Wear Limit .0031 (.080)
.010" (.25 mm) Undersize Crankshaft Journal
No. 3 Journal
Standard .0011-.0026 (.027-.067)
Wear Limit .0031 (.080)
All Other Journals
Standard .0007-.0023 (.019-.059)
Wear Limit .0031 (.080)
Connecting Rod Bearings
Journal Diameter
Standard 2.0466-2.0472 (51.985-52.000)
Undersized .010" (.25 mm) 2.0372-2.0376 (51.745-51.755)
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1999 Toyota RAV4
Journal Out-Of-Round .0008 (.020)

Journal Taper .0008 (.020)
Oil Clearance
Standard Crankshaft Journal
Standard .0009-.0022 (.024-.055)
Wear Limit .0031 (.080)
.010" (.25 mm) Undersize Crankshaft Journal
Standard .0009-.0027 (.024-.069)
Wear Limit .0031 (.080)
(1) Main bearing journal diameter is determined by size mark stamped on crankshaft. See Fig. 37 .
CONNECTING RODS
Piston Pin Bushing
Bore Diameter .8660-.8665 (21.997-22.009)
Piston Pin Oil Clearance (1)
Standard .0002-.0004 (.005-.010)
Wear Limit .0020 (.050)
Maximum Bend .002 Per 3.94 (.05 Per 100.0)
Maximum Twist .0059 Per 3.94 (.150 Per 100.0)
Side Play
Standard .0063-.0123 (.160-.312)
Wear Limit .0138 (.350)
(1) Piston pin oil clearance is the difference between the inside diameter of the connecting rod piston pin
bushing bore and the outside diameter of the piston pin.
PISTONS, PINS & RINGS

Pistons
Clearance
Standard .0056-.0064 (.143-.163)
Wear Limit .0072 (.183)
Diameter (1)
Size Mark "1" 3.3798-3.3802 (85.847-
85.857)
Size Mark "2" 3.3802-3.3806 (85.857-
85.867)
Size Mark "3" 3.3806-3.3810 (85.867-
85.877)
Over Size .1969" (.50 mm) 3.3995-3.4007 (86.347-
Microsoft
1999 Toyota RAV4
86.377)
Pins
Diameter .8660-.8665 (21.997-22.009)
Piston Fit (2)
Rod Fit (Oil Clearance)

Standard .0002-.0004 (.005-.011)
Wear Limit .0020 (.050)
Rings
No. 1
End Gap (3)
Standard .0106-.0185 (.270-.470)
Wear Limit .0421 (1.070)
Side Clearance .0012-.0028 (.030-.070)
No. 2
End Gap (3)
Standard .0177-.0256 (.450-.650)
Wear Limit .0492 (1.250)
Side Clearance .0012-.0028 (.030-.070)
No. 3 (Oil)
End Gap (3)
Standard .0056-.0064 (.143-.163)
Wear Limit .0072 (.183)
(1) Piston diameter is determined by size mark stamped on top of piston. See Fig. 30 .
(2) Piston pin has an interference fit and pin must be pressed into connecting rod and piston.
(3) Using a piston with rings removed, push ring into cylinder bore 4.33" (110 mm) from the top.
CYLINDER BLOCK
Cylinder Bore (1)
Size Mark "1" 3.3858-3.3862 (86.000-86.010)
Size Mark "2" 3.3862-3.3866 (86.010-86.020)
Size Mark "3" 3.3866-3.3870 (86.020-86.030)
Maximum Standard Size 3.3949 (86.230)
.020" (.50 mm) Oversize 3.4146 (86.731)
Maximum Deck Warpage .0020 (.050)
Main Bearing Bore I.D. (2)
Size Mark "1" 2.3236-2.3239 (59.020-59.026)
Size Mark "2" 2.3239-2.3241 (59.026-59.032)
Size Mark "3" 2.3241-2.3243 (59.032-59.038)
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1999 Toyota RAV4
(1) Cylinder bore diameter is determined by size mark on cylinder block deck surface. See Fig. 33 .
(2) Main bearing bore I.D. is determined by main bearing bore size mark on cylinder block. See Fig. 37 .
VALVES & VALVE SPRINGS

Intake Valves
Face Angle 44.5°
Minimum Margin .020" (.50 mm)
Minimum Refinish Length 3.823" (97.10 mm)
Stem Diameter .2350-.2356" (5.970-5.985
mm)
Exhaust Valves
Face Angle 44.5°
Minimum Margin .020" (.50 mm)
Minimum Refinish Length 3.858" (98.00 mm)
Stem Diameter .2348-.2354" (5.965-5.980
mm)
Valve Springs
Free Length 1.6520-1.6531" (41.96-41.99
mm)
Out-Of-Square Limit .079" (2.00 mm)
Lbs. @ In. (kg @ mm)
Pressure 37-43 @ 1.366 (16.7-19.5 @
34.70)
CYLINDER HEAD
Maximum Warpage
Cylinder Block Surface .0020" (.050 mm)
Intake & Exhaust Manifold Surface .0031" (.080 mm)
Valve Seats
Intake Valve
Seat Angle 45°
Seat Width .039-.055" (1.00-1.40 mm)
Exhaust Valve
Seat Angle 45°
Seat Width .039-.055" (1.00-1.40 mm)
Valve Guides
Intake Valve
Valve Guide Cylinder Head Bore I.D.
Standard Valve Guide .4325-.4335" (10.985-11.012
Microsoft
1999 Toyota RAV4
mm)
Oversize Valve Guide .4344-.4355" (11.035-11.062
mm)
Valve Guide I.D. .2366-.2374" (6.010-6.030 mm)
Valve Guide Installed Height .315-.346" (8.00-8.80 mm)
Valve Stem-To-Guide Oil Clearance
Standard .0010-.0024" (.025-.060 mm)
Wear Limit .0031" (.080 mm)
Exhaust Valve
Valve Guide Cylinder Head Bore I.D.
Standard Valve Guide .4325-.4335" (10.985-11.012
mm)
Oversize Valve Guide .4344-.4355" (11.035-11.062
mm)
Valve Guide I.D. .2366-.2374" (6.010-6.030 mm)
Valve Guide Installed Height .315-.346" (8.00-8.80)
Valve Stem-To-Guide Oil Clearance
Standard .0012-.0026" (.030-.065 mm)
Wear Limit .0039" (.100 mm)
CAMSHAFT
End Play
Intake Camshaft
Standard .0018-.0039 (.045-.100)
Wear Limit .0047 (.120)
Exhaust Camshaft
Standard .0012-.0033 (.030-.085)
Wear Limit .0039 (.100)
Gear Backlash
Standard .0008-.0079 (.020-.200)
Wear Limit .0118 (.300)
Gear Spring Free Length .886-.902 (22.50-22.91)
Journal Diameter 1.0614-1.0620 (26.959-26.975)
Journal Runout .0016 (.040)
Lobe Height
Intake Camshaft
Standard 1.6539-1.6579 (42.010-
42.110)
Wear Limit 1.6496 (41.900)
Exhaust Camshaft
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1999 Toyota RAV4
Standard 1.5772-1.5811 (40.060-

40.160)
Wear Limit 1.5728 (39.950)
Oil Clearance
Standard .0010-.0024 (.025-.062)
Wear Limit .0039 (.100)
VALVE LIFTERS
Bore Diameter 1.2205-1.2211 (31.000-31.016)
Lifter Diameter 1.2191-1.2195 (30.966-30.976)
Oil Clearance
Standard .0009-.0020 (.024-.052)
Wear Limit .0028 (.070)
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1999 Toyota RAV4

1999-2000 ENGINES 2.0L 4-Cylinder

Engine serial number is stamped on rear of cylinder block. See Fig. 1 .

ENGINE IDENTIFICATION CODE

Fig. 1: Identifying Engine Serial Number

VALVE CLEARANCE ADJUSTMENT

NOTE: Adjust valve clearance with engine cold.

Fig. 2: Checking Valve Clearance

VALVE CLEARANCE SPECIFICATIONS (1)

Fig. 3: Adjusting Valve Clearance

Fig. 4: Intake Valve Adjusting Shim Selection Chart

Fig. 5: Exhaust Valve Adjusting Shim Selection Chart

Fig. 6: Applying Sealant On Cylinder Head

Fig. 7: Aligning Valve Cover Grommets

REMOVAL & INSTALLATION

CAUTION: When battery is disconnected, vehicle computer and memory systems

FUEL PRESSURE RELEASE

Fig. 9: Identifying ECM & Electrical Connectors

Fig. 13: Removing Left (Driver-Side) Axle Shaft (4WD Models)

CYLINDER HEAD & MANIFOLDS

NOTE: On 4WD models, manufacturer recommends engine removal for servicing of

Fig. 14: Exploded View Of Camshaft & Cylinder Head Components

12. Remove camshafts. See CAMSHAFT

CAUTION: Cylinder head bolts must be loosened in proper sequence to prevent

Fig. 15: Cylinder Head Bolt Removal & Installation Sequence

CRANKSHAFT FRONT SEAL

Removal & Installation (Oil Pump Installed)

Removal & Installation (Oil Pump Removed)

Fig. 16: Exploded View Of Timing Belt & Components

Fig. 17: Aligning Camshaft Timing Marks

TENSION SPRING SPECIFICATIONS

installed in original direction of rotation.

Fig. 18: Aligning Crankshaft Pulley With 45-Degree BTDC Mark

Removal (Exhaust Side)

CAUTION: Camshafts must be properly positioned to lift camshaft straight from

Fig. 19: Positioning Camshafts

Fig. 20: Securing Sub Gear-To-Main Gear

Fig. 21: Identifying Camshaft Bearing Caps

lifted upward as No. 3 camshaft bearing cap bolts are loosened.

Removal (Intake Side)

lifted upward as No. 2 camshaft bearing cap bolts are loosened.

Fig. 24: Removing & Installing Sub-Gear On Main Gear

Fig. 25: Applying Sealant To Front Camshaft Bearing Cap

NOTE: It may be necessary to slightly rotate intake camshaft so exhaust camshaft

Fig. 26: Aligning Camshaft Timing Marks

CRANKSHAFT REAR OIL SEAL

Fig. 27: Exploded View Of Typical Water Pump & Components

Fig. 28: Water Pump Bolt Removal & Installation Sequence

Valve Stem Oil Seals

Fig. 29: Measuring Valve Guide Installed Height

Valve Seat Correction Angles

CYLINDER BLOCK ASSEMBLY

Piston & Rod Assembly

Fig. 30: Identifying Piston Size Marks

PINS & RINGS table under ENGINE SPECIFICATIONS.

Fig. 31: Identifying Piston Front Marks

Fig. 32: Removing & Installing Piston Pin

Fig. 33: Identifying Cylinder Bore Size Marks (Typical)

Fig. 34: Positioning Piston Rings