Toyota rav4 service manual pdf

 

    Info · Safety Connect · Service Centers · Manuals & Warranties · Dashboard Lights · Toyota Genuine Parts · Maintenance Schedule · Service Coupons Discounts. Never worry about a lost manual again. Toyota online owners manuals and warranty guides are always just a few clicks away. Feb 7, Toyota RAV4 PDF Workshop and Repair manuals, Wiring Diagrams, Spare Parts Catalogue, Fault codes free download Toyota RAV4 Collision.

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    Toyota Rav4 Service Manual Pdf

    If you have a specific Toyota Rav4 Repair Manual Engine pdf in mind, you will definitely be pleased with the wide selection of books that we can provide you. Anybody know where I can download a factory service manual for a What you do is get a print driver that generates a PDF file (PDF Service Repair manuals for Toyota Yaris, Avensis, Camry, Tundra, Corolla, Verso , Echo, Auris, Tacoma, Land Cruiser, Rav4, Celica, 4Runner, Sienna, Avalon.

    Please make sure that you are posting in the form of a question. All models 96 - 12 This series offers do-it-yourselfers of all levels TOTAL maintenance, service, and repair information in an easy to use format. Each manual contains: Skip to main content. In stock. Usually ships within 3 to 4 days. Add to Cart. Ships from and sold by Midway Auto Supply. Other Sellers on site. Sold by: Shop Eddies. Have one to sell? Sell on site. Image Unavailable Image not available for Color: Details This item is sold by a third-party seller.

    Please try again later. Paperback Verified download. No one wants to look up stuff on their phone while they're all greasy, whereas getting your book all greasy at least shows you were trying to not forget anything!

    I'm the original owner of a RAV4 which has been a fabulous car. This is the first time I have worked on a car so I bought some tools tool shopping is totally addicting, btw and this book. I was a bit skeptical that the Chilton book could thoroughly cover model years which is essentially TWO different body styles and THREE different engines ' had the orginal engine, ' was a revised engine and was the new body style.

    But what the heck, I wanted to save money so I went with the Chilton. In the past few months I've done a bunch repairs: My initial gut feeling was right. Though the book did a great job guiding me on some repairs, I found some instructions and illustrations lacking thoughtfulness.

    Toyota Car manuals

    For example, their illustration states that the coolant hoses attached to the throttle body are the same for years ' and ' but in fact they are slightly different.

    This was just one of MANY slight mistakes throughout the book, and it was extremely frustrating especially for a beginner like me. And many of the instructions were very vague and bordering on incomplete like the seemingly simple task of removing the valve cover which required me removing way more parts than the instructions stated. I found myself constantly seeking help from online forums RAV4world.

    My dad has one for his Previa and it is way more complete with better instructions and more illustrations. This book might be fine for a seasoned mechanic, but for beginners like me, I would definitely suggest investing in the OEM Toyota manual.

    I've been through the electrical diagrams in this book several times looking for the ECU connector pins that drive the transmission solenoids. Maybe I'm looking in the wrong spot, but I sure don't see that information. The control wires to the automatic transmission seem like an important omission.

    I started working on cars as a college student using Chilton's and Haynes manuals. Us weekend mechanics should just stick with these and save our money.

    I would rather have a book to flip through than going through a CD to find what I am looking for. One person found this helpful. Great source of information. Chilton does a good job of breaking down the early Toyota Rav4 models in this book. It came in handy as a DIY home mechanic trying to save money on general maintenance.

    Would recommend to anyone, even non-mechanics! Lots of good info in here I read a lot of reviews before downloading The manual is great. I read a lot of reviews before downloading and this comes close to meeting my needs. Some reviews criticized the lack of info or the steps needed to do the task. Cars change sometimes dramatically from year to year.

    Hopefully, you have some mechanical backround and figure out what needs to be done. I do wish however that it explained more of how the AWD drivetrain works. God book for do it yourselfers. My husband and I were able to fix a problem with our Rav4 at a tenth of what it would have cost at the dealer. Good illustrations.

    Straightforward, easy to follow instructions. If one person came up with the concept for this book, he deserves the Nobel Prize. See all 19 reviews. After warming up the engine and then 5 minutes after the engine stop, oil level should be between the upper and lower marks on the dipstick. If low, check for leakage and add oil up to the upper dot mark. Remove the oil pressure switch.

    Install the oil pressure gauge. Do not fill with engine oil above the upper dot mark. Remove the oil pressure gauge. Apply adhesive to 2 or 3 threads of the oil pressure switch. Idle 29 kPa 0. Install the oil pressure switch.

    In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Wear protective clothing and gloves. Remove the oil filter cap. Remove the oil drain plug, and drain the oil into a container. Using SST, remove the oil filter. SST Fig. Check and clean the oil filter installation surface. Check the part number of the new oil filter is as same as old one.

    Do not use gasoline, thinners, or solvents. Apply clean engine oil to the gasket of a new oil filter. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.

    Clean and install the oil drain plug with a new gasket. Fill with fresh engine oil. Install the oil filter cap. Remove the 12 bolts and 2 nuts. Insert the blade of SST between the crank case and oil pan, and timing chain cover and oil pan, cut off applied sealer and remove the oil pan. Set the crankshaft key into the left horizontal position. Be careful not to damage the contact surface of the timing chain cover, crank case and oil pan. Remove the bolt, chain tensioner plate and spring.

    Using a screwdriver, hold the oil pump drive shaft sprocket as shown in Fig. Remove the nut, 2 sprockets and drive chain. Using a socket wrench 27 mm , remove the plug. Remove the valve spring and relief valve. If necessary, replace the cylinder block.

    If it does not, replace the relief valve. If necessary, replace the oil pump assembly. Inspect for the tip clearance. Using a feeler gauge, measure the clearance between the drive and driven rotor tips. Standard tip clearance: Maximum tip clearance: If the tip clearance is greater than the maximum, replace the rotors as a set.

    Inspect for the side clearance. Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight edge. Standard side clearance: Maximum side clearance: If the side clearance is greater than the maximum, replace the rotors as a set. Inspect for the body clearance. Using a feeler gauge, measure the clearance between the driven rotor and body.

    Standard body clearance: Maximum body clearance: If the body clearance is greater than the maximum, replace the rotors as a set. Using vernier calipers, measure the length of the 8 links with the chain dully stretched. Maximum chain elongation: If the elongation is greater than the maximum, replace the chain. Make the same measurements pulling at 3 or more places selected at random.

    Wrap the chain around the oil pump sprocket. Using vernier calipers, measure the sprocket diameter with the chain. If the diameter is less than the minimum, replace the chain and 2 sprockets. Vernier calipers must contact the chain rollers for measuring. Maximum wear: If the wear is greater than the maximum, replace the chain tensioner plate. Coat the relief valve with engine oil.

    Insert the relief valve and spring into the pump body hole. Using a socket wrench 27 mm , install the plug. Place a new gasket on the oil pump. Install the oil strainer with the 2 nuts. Set the crankshaft key into the left horizontal position and turn the cutout of the drive shaft to the top.

    Set the chain on the 2 sprockets as shown in Fig. Install the chain and 2 sprockets with the nut. Apply seal packing to the oil pan as shown in Fig. Seal packing: Do not use a solvent which will affect the painted surfaces. Avoid applying an excessive amount to the surface. Otherwise the material must be removed and reapplied. Install the oil pan with the 12 bolts and 2 nuts. VIN is located at top left corner of instrument panel. Vehicle certification label is located at left corner of driver's door.

    This label also contains the VIN. Flush oil cooler and oil cooler lines prior to transaxle installation. Oil cooling system contamination may cause premature transaxle failure. The UF transaxle is a 4-speed electronically controlled transaxle. Transaxle is equipped with a transfer case. Insert a turning tool into inner race of one-way clutch. Install Tester so it fits in notch of converter hub and outer race of one-way clutch.

    With converter in normal operating position, clutch should lock-up when turned counterclockwise and should rotate freely and smoothly when turned clockwise. If one-way clutch fails test in either direction, clean converter.

    Retest clutch. If clutch fails test, replace torque converter. Transaxle malfunctions may be caused by poor engine performance, improper adjustments, fluid condition or failure of hydraulic, mechanical or electronic components. Ensure all concerns have been properly checked prior to transaxle overhaul. Torque converter is a sealed unit and is serviced as a complete assembly.

    Perform the following tests to check for defective converter. Torque converter and transaxle cooler must be thoroughly cleaned and flushed if transaxle is contaminated.

    Toyota RAV4 Workshop Manual PDF

    Torque Converter Sleeve Runout Test 1. Temporarily mount torque converter to drive plate. Mount a dial indicator with needle resting on converter sleeve.

    Rotate converter. If runout exceeds. If converter is properly mounted and runout exceeds specifications, replace torque converter. Mark position of converter to ensure correct installation. Remove converter from drive plate. If installing a NEW drive plate, note position of spacers. Tighten bolts to 72 ft. Remove transfer case. Remove 2 bolts and 6 nuts. Using plastic hammer, drive transfer case from transaxle. Pull transfer case straight up to remove from transaxle.

    Remove round gasket and intermediate shaft. Remove nut, washer and control shift lever. Using a screwdriver, unstake lock tab.

    Remove oil line union and elbow. Remove and discard O rings from union and elbow. Remove input turbine and counter gear speed sensors from top of transaxle.

    Remove and discard speed sensor O rings. Remove transaxle test plug from transaxle case.

    DO NOT try to remove solenoid connector from transaxle case at this time. Place transaxle on wooden blocks. Remove 18 bolts, oil pan and gasket. Disconnect 5 shift solenoid connectors. Remove bolts, clamps and fluid temperature sensor.

    Remove transaxle wiring harness with solenoid connector from transaxle case. Remove 3 bolts and oil strainer. Remove and discard gasket from oil strainer. Remove 17 valve body bolts. Note bolt length and location for reassembly reference.

    Remove valve body assembly. Remove 3 apply gaskets, check ball body and spring. Remove underdrive clutch accumulator spring. Cover piston with shop towel during removal. Cover pistons with shop towel during removal. Using needle nose pliers, remove manual valve lever retainer spring. Remove 2 bolts, manual detent spring and cover.

    Remove 2 bolts and parking lock pawl bracket. Using a hammer and chisel, unstake and remove spacer. Using a pin punch and hammer, drive out roll pin. Ensure pin does not fall into transaxle case.

    Remove manual valve lever shaft and manual valve lever. Remove parking lock pawl rod from manual valve lever. Using a screwdriver, remove shaft oil seal. Position transaxle case with oil pump assembly facing upward. Using a dial indicator, measure input shaft end play. End play should be. Remove 16 transaxle housing bolts. Note bolt length and location during removal for reassembly reference. Use caution when removing transaxle housing.

    Differential assembly may attach to transaxle housing during removal.

    Remove 7 oil pump bolts and oil pump. Remove thrust bearing and bearing race from underdrive planetary gear assembly. Remove differential assembly. Remove 2 apply gaskets from front of transaxle case. Remove forward clutch from transaxle case. Remove multiple clutch hub and needle roller bearing from transaxle case. Remove one bolt and parking lock pawl clamp. Remove parking lock pawl shaft. Push parking lock pawl toward transaxle case to prevent interference during underdrive planetary gear assembly removal.

    Using both hands, remove underdrive planetary gear assembly. DO NOT allow planetary gear assembly to separate. Remove spring, pawl pin and parking lock pawl. Remove underdrive clutch assembly. Remove thrust bearing and bearing race. Using a screwdriver, remove No.

    Remove No. Note position of index marks on No. Note position of outer race retainer on No. Remove outer race retainer from No. Using a screwdriver, remove underdrive brake snap ring. Remove flange, 3 discs and 3 plates from transaxle case. Note location of components during removal for reassembly reference. Using appropriate press, compress underdrive brake piston return spring.

    Using snap ring expander, remove snap ring from underdrive brake. Remove piston return spring. Remove 11 bolts and transaxle rear cover. If necessary, tap on circumference of rear cover with plastic hammer to remove cover. Remove 2 oil seal rings from rear cover.

    Using appropriate puller, remove needle roller bearing, if necessary. Remove bolt, clamp and 2 brake apply pipes. Using a screwdriver, remove 2 apply gaskets from rear of transaxle case. Remove direct clutch with thrust bearing from transaxle case. Remove bearing race from direct clutch shaft side.

    Remove rear planetary sun gear assembly from transaxle case. Remove thrust bearing from rear planetary sun gear. Remove thrust washer No. Remove inner race from one-way clutch. Remove one-way clutch outer sleeve from transaxle case. Using a screwdriver, remove 2nd brake snap ring. Using a screwdriver, remove rear planetary gear snap ring. Remove rear planetary gear from transaxle case. Remove 2 bearing races, thrust bearings and front planetary sun gear from transaxle case.

    Using a hammer and chisel, unstake washer located on counter drive gear. Ensure all claws on washer are pushed down to allow socket to fit securely on nut.

    Using holding tool and socket, remove nut. Using appropriate adapter and press, remove front planetary gear from counter drive gear. Using a screwdriver, remove 2nd brake assembly snap ring.

    Remove brake hub with 2nd brake assembly. Remove brake hub from 2nd brake assembly. Using a screwdriver, remove snap ring and front planetary ring gear from brake hub. Using appropriate adapter and press, remove counter drive gear from transaxle case. Install and tighten 2 bolts opposite each other evenly on counter drive gear. Ensure clearance between counter drive gear and bearing race is about.

    Using bearing puller, remove rear tapered roller bearing from counter drive gear. Using a brass drift and hammer, remove bearing inner and outer races. Remove snap ring at underdrive brake piston from transaxle case. Using appropriate puller, remove needle roller bearing from transaxle case. Remove 2 oil seal rings from transaxle case. Using appropriate puller, remove cylindrical roller bearing from transaxle case.

    Remove oil seal ring from transaxle housing. Remove bolt, clamp and apply pipe from transaxle case. Remove 3 bolts and oil deflector if equipped from transaxle case. In the following step, stop press when piston return spring seat is lowered. This prevents spring seat from becoming deformed.

    DO NOT expand snap ring excessively. Remove 2 oil seal rings. Using T30 Torx socket, remove 11 bolts attaching oil pump body and stator shaft. Remove O ring from oil pump body. Note direction and location of drive and driven gears. Leave gears in oil pump body for inspection.

    Inspection 1. Check body clearance of driven gear. Push driven gear to one side of body. Using a feeler gauge, measure clearance. Body clearance should be. Maximum body clearance is. If body clearance exceeds specification, replace oil pump body. Using a feeler gauge, check tip clearance of driven gear. Measure between gear teeth and crescent-shaped part of oil pump body. Tip clearance is. Maximum tip clearance is.

    If tip clearance exceeds specification, replace oil pump body. Check side clearance of both gears. Use a steel straightedge and feeler gauge to measure side clearance of both gears. Clearance is. Replace gears as necessary. If side clearance is not within specification after gear replacement, replace oil pump body.

    Using a dial indicator, measure inside diameter of oil pump body bushing. Maximum inside diameter is 1. If inside diameter exceeds specification, replace oil pump body. Using a dial indicator, measure inside diameter of stator shaft bushing. Maximum inside diameter is. If inside diameter exceeds specification, replace stator shaft. Inspect front oil seal for cracks, damage or wear.

    Replace oil seal if necessary. Remove oil seal with slide hammer. Install a NEW oil seal. Seal is properly installed when it is flush with outer edge of pump body. Reassembly 1. Install front oil seal. Install driven gear and drive gear.

    Ensure top of gears are facing upward. Install stator shaft on oil pump body. Align bolt holes. Install 11 stator shaft-to-oil pump body bolts.

    Tighten bolts in crisscross pattern to 87 INCH lbs. Install 2 oil seal rings on oil pump. DO NOT expand ring ends excessively. Turn drive gear with screwdrivers to ensure a smooth rotation. DO NOT damage oil seal lip. Prior to disassembly, measure piston stroke of direct clutch.

    noititsojunchawk.ml: Chilton Toyota RAV4 () Repair Manual (): The Chilton Editors: Automotive

    Install direct clutch and needle roller bearing on transaxle rear cover. Piston stroke should be. If piston stroke is not within specification, inspect each component during disassembly. Remove direct clutch from transaxle rear cover. Using a screwdriver, remove snap ring from direct clutch drum.

    Remove flange, 3 discs and 3 plates. Position clutch balancer on a press. Compress piston return springs and remove snap ring. Remove clutch balancer and piston return springs from clutch drum. Install direct clutch on transaxle rear cover. Clean all parts except discs with solvent. Dry parts using compressed air.

    Inspect discs and plates for wear or burnt areas. If disc lining is peeled or discolored, replace discs as necessary. Replace all damaged components.

    Using vernier calipers, measure direct clutch piston return spring free length with spring mounted to spring seat. Free length should be. Replace springs as necessary.

    Coat piston with ATF. Using hand pressure, press piston into direct clutch drum. Ensure piston lip seal is NOTE: New discs must be soaked in ATF at least 15 minutes prior to reassembly. Install piston return springs and clutch balancer onto direct clutch drum. Set snap ring in position. Using appropriate press positioned on clutch balancer, compress piston return springs. Using snap ring expander, install snap ring in direct clutch drum groove. Ensure end gap of spring is not aligned with gaps in clutch balancer hub.

    Install 3 plates and 3 discs, starting with plate and alternating with disc. Install flange on top of disc. Install snap ring. Ensure end gap of snap ring is not aligned with cutouts of direct clutch drum. If disc, plate or flange have been replaced, check piston stroke.

    If piston stroke is not within specification, disassemble and reassemble direct clutch components. Measure piston stroke again. If measurement is still not within specification, replace flange.

    Flange is available in 6 thicknesses, from. Check direct clutch operation. Insert rear planetary sun gear into direct clutch. Ensure rear planetary sun gear rotates in both directions. If sun gear does not rotate as described, disassemble and inspect direct clutch. Prior to disassembly, measure piston stroke of forward clutch. Install forward clutch on oil pump assembly. Opening in oil pump is large. To prevent air from discharging, surround air nozzle with shop towel.

    Remove forward clutch from oil pump assembly. Using a screwdriver, remove snap ring from forward clutch drum. Remove flange, 4 discs and 4 plates. Using appropriate press, compress piston return springs. Using snap ring expander, remove snap ring. Remove press and piston return springs. Remove 2 O rings from piston.

    Ensure check ball is free in piston. Apply low air pressure to small hole in piston to check for air leakage around piston valve. Using vernier calipers, measure forward clutch piston return spring free length with spring mounted to spring seat. Free length should be 1.

    Using a dial indicator, measure inside diameter of multiple clutch hub bushing. If inside diameter exceeds specification, replace multiple clutch hub. Reassembly NOTE: New discs must be soaked in ATF for 15 minutes prior to reassembly. Install O rings on forward clutch piston.

    Using hand pressure, press piston into forward clutch drum. Ensure O rings are not damaged. Set piston return springs in position. Position spring seat on a press. Compress piston return springs. Using snap ring expander, install snap ring in forward clutch drum groove. Ensure end gap of spring is not aligned with gap in spring retainer hub. Install 4 plates and 4 discs, starting with plate and alternating with disc. Ensure end gap of snap ring is not aligned with cutouts of forward clutch drum.

    If piston stroke is not within specification, disassemble and reassemble forward clutch components. Flange is available in 5 thicknesses from. Coat thrust bearings with ATF and install.

    Check forward clutch operation. Insert multiple clutch hub into forward clutch. Ensure forward clutch rotates in both directions. If forward clutch does not rotate as described, disassemble and inspect forward clutch. Using appropriate press, position press on piston return springs and compress springs. Emissions Coverage 1 Coverages vary under Federal and California regulations. Our hybrid vehicles have set the standard for technology, efficiency and drivability. We think the world's most popular hybrids should have the warranties to match.

    The HV battery may have longer coverage under emissions warranty. Emissions Coverage: Toyota Genuine Parts are built to the highest standards of quality, durability and performance.

    Most have month coverage, and there aren't many, if any, companies that offer a longer guarantee. Genuine Toyota Parts are built to the highest standards of quality, durability and For accessories downloadd after the new vehicle download, the coverage is 12 months, regardless of mileage, from the date the accessory was installed on the vehicle, or the remainder of any applicable new vehicle warranty, whichever provides greater coverage, with the exception of car covers.

    Car covers are warranted for 12 months from the date of download and do not assume any coverage under the Toyota New Vehicle Limited Warranty. Every Toyota Certified Used Vehicle is put through a point quality insurance inspection, with each Used Hybrid tested to a point standard. Every Toyota Certified Used Vehicle is put through a point quality insurance To view or download additional manuals that take you down to the nuts and bolts of most Toyota models from and beyond, you may subscribe to our Technical Information System TIS at https: