Contents Wiring diagrams Section: Procedures All sections

Maintenance Information: Other Toyota RAV4 I

Procedures 17 illustrations ~2035 words

VIN CODE ID EXPLANATION

Numbers preceding the explanations in the legend below refer to the sequence of characters as listed on VIN identification label. See VIN example below.

VIN Code ID Explanation. Scheme 1

Scheme 1: VIN Code ID Explanation

SEVERE & NORMAL SERVICE DEFINITIONS

Service is recommended at mileage intervals based on vehicle operation and engine type. Service schedules are based on the following primary operating conditions

Light Service

  1. Light, non-commercial duty for distances greater than 5 miles in temperate climates above freezing and below 90°F (32°C).

Normal Service

  1. Driven More Than 10 Miles Daily
  2. No Operating Conditions From Severe Service Schedule

Severe Service (Unique Driving Conditions)

Note. Use the Severe Service schedule if the vehicle to be serviced is operated under ANY (one or more) of these conditions: Towing a trailer or using a camper or car-top carrier. Repeated short trips of less than 5 miles in temperatures below freezing. Extensive idling or low-speed driving for long distances as in heavy commercial use such as delivery, taxi or patrol car. Operating on rough, muddy or salt covered roads. Operating on unpaved or dusty roads.

CAMSHAFT TIMING BELT

Inspect timing belt at 60,000 miles or 48 months and thereafter inspect timing belt every 15,000 miles, or 12 months. Replace belt as necessary.

CAUTIONFailure to replace a faulty camshaft timing belt may result in serious engine damage.

The condition of camshaft drive belts should always be checked on vehicles which have more than 50,000 miles. Although some manufacturers do not recommend belt replacement at a specified mileage, others require it at 60,000-100,000 miles. A camshaft drive belt failure may cause extensive damage to internal engine components on most engines, although some designs do not allow piston-to-valve contact. These designs are often called Free Wheeling.

Many manufacturers changed their maintenance and warranty schedules in the mid-1980's to reflect timing belt inspection and/or replacement at 50,000-60,000 miles. Most service interval schedules in this manual reflect these changes.

Belts or components should be inspected and replaced if any of the following conditions exist

  1. Cracks Or Tears In Belt Surface
  2. Missing, Damaged, Cracked Or Rounded Teeth
  3. Oil Contamination
  4. Damaged Or Faulty Tensioners
  5. Incorrect Tension Adjustment

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Scheme 2: SERVICE POINT LOCATIONS

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Scheme 3

SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG)

WARNINGTo avoid injury from accidental air bag deployment, read and carefully follow all warnings and service precautions. See appropriate AIR BAG RESTRAINT SYSTEM article in ACCESSORIES/SAFETY EQUIPMENT.
CAUTIONDisconnect negative battery cable before servicing any air bag system, steering column or passenger side dash component. After any repair, turn ignition key to the ON position from passenger's side of vehicle in case of accidental air bag inflation

Note. See the AIR BAG RESTRAINT SYSTEM article in the ACCESSORIES/SAFETY EQUIPMENT Section.

Modifications or improper maintenance, including incorrect removal and installation of the Supplemental Restraint System (SRS), can adversely affect system performance. DO NOT cover, obstruct or change the steering wheel horn pad in any way, as such action could cause improper function of the system. Use only plain water when cleaning the horn pad. Solvents or cleaners could adversely affect the air bag cover and cause improper deployment of the system.

AIR CONDITIONING SERVICING

CAUTIONAvoid breathing R-134a refrigerant and PAG lubricant vapors, exposure may irritate eyes, nose and throat. To remove R-134a from system use R-134a recycling equipment that meets SAE J2210 specifications. If accidental system discharge occurs, ventilate work area before resuming service.
WARNINGR-134a service equipment or vehicle A/C systems SHOULD NOT be pressure tested or leak tested with compressed air. Some mixtures of air/R134a have shown to be combustible at elevated pressures. These mixtures are dangerous and may cause fire and/or explosions. See AIR CONDITIONING SERVICE article in GENERAL INFORMATION section.

ANTI-LOCK BRAKE SYSTEM

CAUTIONThe anti-lock brake system contains electronic equipment that can be susceptible to interference caused by improperly installed or high output radio transmitting equipment. Since this interference could cause the possible loss of the anti-lock braking capability, such equipment should be installed by qualified professionals.

On models equipped with anti-lock brake systems, ALWAYS observe the following cautions

  1. DO NOT attempt to bleed hydraulic system without first referring to the appropriate ANTI-LOCK BRAKE SYSTEM article in the BRAKES Section.
  2. DO NOT mix tire sizes. As long as tires remain close to the original diameter, increasing the width is acceptable. Rolling diameter must be identical for all 4 tires. Some manufacturers recommend tires of the same brand, style and type. Failure to follow this precaution may cause inaccurate wheel speed readings.
  3. Use ONLY recommended brake fluids. DO NOT use silicone brake fluids in an ABS-equipped vehicle.

BATTERY WARNING

WARNINGWhen battery is disconnected, vehicles equipped with computers may lose memory data. When battery power is restored, driveability problems may exist on some vehicles. These vehicles may require a relearn procedure. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION section.

REPLACING BLOWN FUSES

CAUTIONBefore replacing a blown fuse, remove ignition key, turn off all lights and accessories to avoid damaging the electrical system. Be sure to use fuse with the correct indicated amperage rating. The use of an incorrect amperage rating fuse may result in a dangerous electrical system overload.

BRAKE PAD WEAR INDICATOR

Indicator will cause a squealing or scraping noise, warning that brake pads need replacement.

CATALYTIC CONVERTER

CAUTIONContinued operation of vehicle with a severe malfunction could cause converter to overheat, resulting in possible damage to converter and vehicle.
CAUTIONAny modification to the exhaust system on turbo models, which reduces exhaust backpressure, will lead to lean fuel mixtures and excessive spark advance. This could cause serious engine damage.

ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS

WARNINGMany solid state electrical components can be damaged by static electricity (ESD). Some will display a warning label, but many will not. Discharge personal static electricity by touching a metal ground point on the vehicle prior to servicing any ESD sensitive component.

ENGINE OIL

CAUTIONNever use non-detergent or straight mineral oil.

FUEL SYSTEM SERVICE

WARNINGRelieve fuel system pressure prior to servicing any fuel system component (fuel injection models).

HALOGEN BULBS

WARNINGHalogen bulbs contain pressurized gas which may explode if overheated. DO NOT touch glass portion of bulb with bare hands. Eye protection should be worn when handling or working around halogen bulbs.

RADIATOR CAP

CAUTIONAlways disconnect the fan motor when working near the radiator fan. The fan is temperature controlled and could start at any time even when the ignition key is in the OFF position. DO NOT loosen or remove radiator cap when cooling system is hot.

RADIATOR FAN

WARNINGKeep hands away from radiator fan. Fan is controlled by a thermostatic switch which may come on or run for up to 15 minutes even after engine is turned off.

WARRANTY INFORMATION

CAUTIONDue to the different warranties offered in various regions and the variety of after-market extended warranties available, please refer to the warranty package that came with the vehicle to verify all warranty options.

NEW VEHICLE LIMITED WARRANTY

Covers any repair or replacement of parts which becomes necessary due to defects in materials or workmanship under normal use for 36 months or 36,000 miles from in-service date.

The items specified below are covered for a period different from the basic coverage

Air Conditioner

The air conditioner refrigerant charge is covered for the first 12 months, regardless of mileage, unless done as part of a warranty repair.

POWERTRAIN WARRANTY

Engine, transmission, front wheel drive, rear wheel drive and restraint system are warranted against defects in materials or workmanship under normal use for 5 years or 60,000 miles, whichever occurs first. See copy of warranty for specific components covered.

CORROSION PERFORATION WARRANTY

Covers any repair or replacement to body sheet metal which develops corrosion perforation (hole through panel), in normal use, due to defects in material or workmanship for a period of 5 years, regardless of mileage.

BATTERY WARRANTY

Covers replacement of defective original battery for first 12 months or 12,000 miles. After the first 12 months or 12,000 miles, warranty covers a pro-rated amount based on months in service, up to a maximum of 36 months.

EMISSION SYSTEM DEFECT WARRANTY (EXCEPT CALIFORNIA)

Warrants to the retail purchaser, and subsequent purchaser that vehicle was designed, built, and equipped so as to conform at the time of sale with applicable emission regulations and that it is free from defects in materials or workmanship which may cause the vehicle to fail to conform with applicable regulations for 5 years or 50,000 miles, whichever occurs first.

EMISSION SYSTEM PERFORMANCE WARRANTY (EXCEPT CALIFORNIA)

Covers all repairs, adjustments, or replacements if vehicle fails to conform to applicable emission standards and such failure results in the vehicle owner having to bear a penalty or other sanction under local, state or federal law for 5 years or 50,000 miles, whichever comes first. If the vehicle has been in use for more than 24 months or 24,000 miles, the manufacturer will make the necessary adjustments, repairs or replacements at no cost to the owner only when noncompliance is caused by failure of components which have been installed in the vehicle for the sole or primary purpose of reducing vehicle emissions. See copy of warranty for specific components covered.

EMISSION SYSTEM PERFORMANCE WARRANTY (CALIFORNIA)

For a period of 3 years or 50,000 miles, manufacturer will make all necessary repairs and adjustments to ensure vehicle passes a required Smog Check inspection.

EMISSION SYSTEM DEFECT WARRANTY (CALIFORNIA)

Warrants vehicle to be free of defects in materials or workmanship that may cause it to fail to conform with applicable California emission regulations for a period of 5 years or 50,000 miles, whichever occurs first. Certain emission-related parts are covered for repair or replacement for 7 years or 70,000 miles, whichever occurs first. See copy of warranty for specific components covered.

FUSES & CIRCUIT BREAKERS

Fuse box is located below instrument panel to left of steering column on all vehicles. An additional fuse and relay box located in the engine compartment.

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Scheme 4: FUSES & CIRCUIT BREAKERS

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Fuse & Circuit Breaker Identificatio - 1997

  1. 1 - AM2 10 Amp Multiport Fuel Injection System/Sequential Multiport Fuel Injection System, Charging System
  2. 2 - DOME 15 Amp Personal Lights, Open Door Warning Light, Clock
  3. 3 - EFI 15 Amp Multiport Fuel Injection System/Sequential Multiport Fuel Injection System
  4. 4 - HAZ-HORN 15 Amp Emergency Flashers, Horns
  5. 5 - ALT-S 5 Amp Charging system
  6. 6 - SPARE 15 Amp Spare fuse
  7. 7 - SPARE 7.5 Amp Spare fues
  8. 8 - H-LP (LH) 15 Amp Left-Hand Headlight
  9. 9 - H-LP (RH) 15 Amp Right-Hand Headlight
  10. 10 - DRL 7.5 Amp Daytime Running Light System
  11. 11 - H-LP LH-L 10 Amp Left Hand Headlight (Low Beam)
  12. 12 - H-LP RH-L 10 Amp Right Hand Headlight (Low Beam)
  13. 13 - H-LP LH-H 10 Amp Left Hand Headlight (High Beam)
  14. 14 - H-LP RH-H 10 Amp Right Hand Headlight (High Beam)
  15. 15 - TAIL 10 Amp Tail Lights, Parking Lights, License Plate Lights, Interior Lights
  16. 16 - GAUGE 10 Amp Gauges And Meters, Service Reminder Indicators (Except Discharge And Open Door Warning Lights), Back-up Lights, Air Conditioning System, Power Windows, Rear Window Defogger, Center Differential Lock System, Electronically Controlled Automatic Transaxle System
  17. 17 - TURN 7.5 Amp Turn Signal Lights
  18. 18 - CIG & RAD 15 Amp Cigarette Lighter, Clock, Car Audio System, Power Rear View Mirrors
  19. 19 - DEF-I/UP 7.5 Amp Multiport Fuel Injection System/Sequential Multiport Fuel Injection System
  20. 20 - IGN 7.5 Amp Multiport Fuel Injection System/Sequential Multiport Fuel Injection System, Discharge Warning Light
  21. 21 - ECU-IG 7.5 Amp Anti-Lock Brake Syste, Electronically Controlled Automatic Transmission System
  22. 22 - WIPER 20 Amp Windshield Wipers And Washer, Rear Window Wiper And Washer
  23. 23 - SRS 7.5 Amp SRS Airbag System
  24. 24 - OBD 7.5 Amp On-Board Diagnostic System
  25. 25 - STOP 10 Amp Stop Lights
  26. 26 - A/C 7.5 Amp Air Conditioning System
  27. 27 - MAIN No. 1 30 Amp Starting System, Headlights
  28. 28 - RDI FAN 30 Amp Electric Cooling Fan
  29. 29 - CDS FAN 30 Amp Electric Cooling Fan
  30. 30 - POWER 30 Amp Power Windows, Power Door Lock System
  31. 31 - DEF 30 Amp Rear Window Defogger
  32. 32 - AM 1 40 Amp CIG & RAD, WIPER, GAUGE, ECU-IG, TURN, TAIL, and PANEL fuses
  33. 33 - MAIN 80 Amp AM 2, HAZ-HORN, EFI, DOME, RADIO and ALT-S fuses
  34. 34 - ALT 100 Amp Tail lights, ABS, RADIO, HTR, AM 1, POWER, STOP and DEF fuses
  35. 35 - HTR 50 Amp Air Conditioning system
  36. 36 - ABS 60 Amp Anti-Lock brake system

Fuse & Circuit Breaker Identificatio - 1998

  1. 1 - H-LP (LH) 15 Amp Left-Hand Headlight
  2. 2 - H-LP (RH) 15 Amp Right-Hand Headlight
  3. 3 - SPARE 10 Amp Spare fuse
  4. 4 - SPARE 15 Amp Spare fuse
  5. 5 - AM2 5 Amp Multiport Fuel Injection System/Sequential Multiport Fuel Injection System, SRS Airbag System, Seat Belt Pretensioners, Starting System, Discharge Warning Light
  6. 6 - ALT-S 5 Amp Charging system
  7. 7 - HAZ 10 Amp Emergency Flashers
  8. 8 - EFI 20 Amp (USA) or 15 Amp (Canada) Multiport Fuel Injection System/Sequential Multiport Fuel Injection System
  9. 9 - DOME 15 Amp Personal Lights, Open Door Warning Light, Clock
  10. 10 - IGN 20 Amp Charging System
  11. 11 - H-LP LH-H 10 Amp Left Hand Headlight (High Beam)
  12. 12 - H-LP RH-H 10 Amp Right Hand Headlight (High Beam)
  13. 13 - H-LP LH-L 10 Amp Left Hand Headlight (Low Beam)
  14. 14 - H-LP RH-L 10 Amp Right Hand Headlight (Low Beam)
  15. 15 - SEAT-HTR 10 Amp No Circuit
  16. 16 - PWR OUTLET 15 Amp Power Outlet
  17. 17 - CIG 15 Amp Cigarette Lighter, Clock, Car Audio System, Power Rear View Mirrors, Electronically Controlled Automatic Transmission
  18. 18 - SRS-SCC 10 Amp SRS Airbag System, Seat Belt Pretensioners
  19. 19 - WIPER 20 Amp Windshield Wipers And Washer, Rear Window Wiper And Washer
  20. 20 - ECU-IG 10 Amp Electronically Controlled Automatic Transmission System, Rear Window Defogger, Center Differential Lock System, Electric Moon Roof, Multiport Fuel Injection System, Electric Cooling Fan, Anti-Lock Brake System, Cruise Control System
  21. 21 - TURN & GAUGE 10 Amp Turn Signal Lights, Gauges & Meters, Back-Up Lights, Service Reminder Indicators, Air Conditioning System, Daytime Running Light System
  22. 22 - STOP 10 Amp Stop Lights, High Mounted Stop Light, Electronically Controlled Automatic Transmission System, Anti-Lock Brake System
  23. 23 - TAIL 15 Amp Gauges & Meters, Emergency Flashers, Cigarette Lighter, Center Differential Lock System, Clock, Rear Window Defogger, Air Conditioning System, Electronically Controlled Automatic Transmission System, Car Audio System, Tail Lights, License Plate Lights, Parking Lights, Instrument Panel Light Control, Side Marker Lights
  24. 24 - OBD 10 Amp On-Board Diagnosis System
  25. 25 - SRS-B 10 Amp SRS Air Bag Warning Light
  26. 26 - HORN 10 Amp Horn
  27. 27 - DEFOG 20 Amp Rear Window Defogger
  28. 28 - DEF 30 Amp Rear Window Defogger
  29. 29 - A/C 10 Amp Air Conditioning System
  30. 30 - MAIN No. 1 40 Amp Starting System, H-LP (RH), H-LP (LH), H-LP RH-H, H-LP LH-H, H-LP RH-L, H-LP LH-L Fuses
  31. 31 - CDS FAN 30 Amp Electric Cooling Fans
  32. 32 - RDI FAN 30 Amp Electric Cooling Fans
  33. 33 - PWR 30 Amp Power Door Lock System, Electric Moon Roof, Power Windows
  34. 34 - ABS 50 Amp Anti-Lock Brake System
  35. 35 - MAIN 80 Amp IGN, HAZ, DOME, ALT-S, MAIN No.1, AM2, & EFI Fuses
  36. 36 - ALT 100 Amp HTR, ABS, RDI FAN, CDS FAN, CIG, SRS-ACC, WIPER, ECU-IG, TURN & GAUGE, DEFOG, TAIL, STOP, HORN, OBD, SRS-B, PWR OUTLET, PWR, & AM1 Fuses
  37. 37 - HTR 50 Amp Air Conditioning System, A/C Fuse