key TOYOTA RAV4 2002 XA20 / 2.G Service Manual

’02 Rav4_U (L/O 0108)
1842002 MY RAV4_U (OM42503U)
Before making these checks, make sure
you have followed the correct starting
procedure given in “How to start the
engine” on page 170 in Section 3 and that
you have sufficient fuel. If your vehicle is
equipped with the engine immobiliser sys-
tem, also check whether the other keys
will start the engine. If they work, your
key may be broken. Have the key
checked at your Toyota dealer. If none of
your keys work, the system is possibly
broken. Call your Toyota dealer. (See
“Keys (with engine immobiliser system)”
on page 8 in Section 12.)
If the engine is not turning over or is
turning over too slowly—1. Check that the battery terminals are tight and clean.
2. If the battery terminals are O.K., switch on the interior light.
3. If the light is out, dim or goes out when the starter is cranked, the battery
is discharged. You may try jump start-
ing. See “(c) Jump starting” on page
185 for further instructions.
If the light is O.K., but the engine still will
not start, it needs adjustment or repair.
Call a Toyota dealer or qualified repair
shop.NOTICE
Do not pullor pushstart the vehicle.
It may damage the vehicle or cause
a collision when the engine starts.
Also the threeway catalytic converter
may overheat and become a fire haz-
ard.
If the engine turns over at its normal
speed but will not start— 1. Turn the ignition key to “ACC” or “LOCK” and try starting the engine
again.
2. If the engine will not start, the engine may be flooded because of repeated
cranking. See “(b) Starting a flooded
engine” on page 184 for further instruc-
tions.
3. If the engine still will not start, it needs adjustment or repair. Call a Toyota
dealer or qualified repair shop. If the engine will not start, your engine
may be flooded because of repeated
cranking.
If this happens, turn the key to “START”
with the accelerator pedal held down.
Keep the key and accelerator pedal these
positions for 15 seconds and release
them. Then try starting the engine with
your foot off the accelerator pedal.
If the engine does not start after 15 se-
conds of cranking, release the key, wait
a few minutes and try again.
If the engine still will not start, it needs
adjustment or repair. Call a Toyota dealer
or qualified repair shop for assistance.
NOTICE
Do not crank for more than 30 se-
conds at a time. This may overheat
the starter and wiring systems.
If your vehicle will not start—
(a) Simple checks
(b) Starting a flooded engine

’02 Rav4_U (L/O 0108)
1882002 MY RAV4_U (OM42503U)
If your engine stalls while driving...1. Reduce your speed gradually, keeping a straight line. Move cautiously off the
road to a safe place.
2. Turn on your emergency flashers.
3. Turn the ignition key to “ACC” or “LOCK”, and try starting the engine
again.
If the engine will not start, see “If your
vehicle will not start” on page 184 in this
section.
CAUTION
If the engine is not running, the pow-
er assist for the brakes and steering
will not work so steering and braking
will be much harder than usual.
If your engine coolant temperature
gauge indicates overheating, if you ex-
perience a loss of power, or if you hear
a loud knocking or pinging noise, the
engine has probably overheated. You
should follow this procedure... 1. Pull safely off the road, stop the ve- hicle and turn on your emergency
flashers. Put the transmission in “P”
(automatic) or neutral (manual) and ap-
ply the parking brake. Turn off the air
conditioning if it is being used.
2. If coolant or steam is boiling out of the radiator or reservoir, stop the engine.
Wait until the steam subsides before
opening the hood. If there is no coolant
boiling over or steam, leave the engine
running and make sure the electric
cooling fan is operating. If it is not,
turn the ignition off.
CAUTION
To help avoid personal injury, keep
the hood closed until there is no
steam. Escaping steam or coolant is
a sign of very high pressure.
3. Look for obvious coolant leaks from theradiator, hoses, and under the vehicle.
However, note that water draining from
the air conditioning is normal if it has
been used.
CAUTION
When the engine is running, keep
hands and clothing away from the
moving fan and engine drive belts.
4. If the coolant is leaking, stop the en-gine immediately. Call a Toyota dealer
for assistance.
5. If there are no obvious leaks, check the coolant reservoir. If it is dry, add
coolant to the reservoir while the en-
gine is running. Fill it about half full.
CAUTION
Do not attempt to remove the radiator
cap when the engine and radiator are
hot. Serious injury could result from
scalding hot fluid and steam blown
out under pressure.
If your engine stalls while
driving If your vehicle overheats

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TOWING PRECAUTIONS:
Use a safety chain system for all towing,
and abide by the state/provincial and local
laws. The wheels and axle on the ground
must be in good condition. If they are
damaged, use a towing dolly.
Twowheel drive models—
(a) Towing with wheel lift type truck
From front—Release the parking brake.
NOTICE
When lifting wheels, take care to en-
sure adequate ground clearance for
towing at the opposite end of the
raised vehicle. Otherwise, the bumper
and/or underbody of the towed vehicle
will be damaged during towing.
From rear—
Manual transmission:
We recommend using a towing dolly
under the front wheels. If you do not
use a towing dolly, place the ignition
key in the “ACC” position and put the
transmission in neutral.
NOTICE
Do not tow with the key removed or
in the “LOCK” position when towing
from the rear without a towing dolly.
The steering lock mechanism is not
strong enough to hold the front
wheels straight.
Automatic transmission:
Use a towing dolly under the front
wheels.
NOTICE
Never tow a vehicle with an automatic
transmission from the rear with the
front wheels on the ground, as this
may cause serious damage to the
transmission.
(b) Using flat bed truck
Fourwheel drive models—
(a) Towing with wheel lift type truck
Use a towing dolly under the wheels not
lifted by the truck.
(b) Using flat bed truck
(c) Towing with sling type
truck
All models—
(c) Towing with sling type truck
NOTICE
Do not tow with sling type truck, ei-
ther from the front or rear. This may
cause body damage.

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NOTICE
Use only a cable or chain specifically
intended for use in towing vehicles.
Securely fasten the cable or chain to
the towing eyelet provided.
Before towing, release the parking brake
and put the transmission in neutral (manu-
al) or “N” (automatic). The key must be
in “ACC” (engine off) or “ON” (engine run-
ning).
CAUTION
If the engine is not running, the pow-
er assist for the brakes and steering
will not work so steering and braking
will be much harder than usual.
Before emergency towing, check that
the eyelet is not broken or damaged
and that the installation bolts are not
loose.
Fasten the towing cable or chain se-
curely to the eyelet.
Do not jerk the eyelet. Apply steady
and even force.
To avoid damaging the eyelet, do not
pull from the side or at a vertical
angle. Always pull straight ahead.
CAUTION
If the emergency towing eyelet is
used to get out when your vehicle
becomes struck in mud, sand or oth-
er condition from which the vehicle
cannot be driven out under its own
power, make sure to observe the pre-
cautions mentioned below. Otherwise,
excessive stress will be put on the
eyelet and the towing cable or chain
may break, causing serious injury or
damage.
If the towing vehicle can hardly
move, do not forcibly continue the
towing. Contact your Toyota dealer
or a commercial tow truck service
for assistance.
Tow the vehicle as straight ahead
as possible.
Keep away from the vehicle during
towing.
—Emergency towing eyelet
precautions

’02 Rav4_U (L/O 0108)
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The following methods are effective to get
out when your vehicle is struck in mud,
sand or other condition from which the
vehicle cannot be driven out under its own
power. Use extreme caution when towing
vehicles. In addition, keep away from the
vehicles and towing cable or chain when
towing.
Remove the soil and sand in the front
and the back of the tires.
Place a stone or wood under the tires.
If you cannot shift the selector lever
out of “P” position to other positions
even though the brake pedal is de-
pressed, use the shift lock override but-
ton as follows:1. Turn the ignition key to “LOCK” position. Make sure the parking
brake is applied.
2. Pry up the cover with a flatbladed screwdriver or equivalent.3. Insert your finger into the hole topush down the shift lock override
button. You can shift out of “P”
position only while pushing the but-
ton.
4. Shift into “N” position.
5. Insert the cover.
6. Start the engine. For your safety, keep the brake pedal depressed.
Be sure to have the system checked by
your Toyota dealer as soon as possible.
—Tips for towing a stuck
vehicle If you cannot shift automatic
transmission selector lever

’02 Rav4_U (L/O 0108)
2032002 MY RAV4_U (OM42503U)
You can purchase a new key at your
Toyota dealer if you can give them the
key number. If your vehicle is equipped
with the engine immobiliser system, the
dealer will also need your master key.
Vehicles with engine immobiliser system—
Even if you lose only one key, contact
your Toyota dealer to make a new key. If
you lose all your master keys, you cannot
make new keys; the whole engine immobi-
liser system must be replaced.
See the suggestion given in “Keys” on
page 8 in Section 12.
If your keys are locked in the vehicle and
you cannot get a duplicate, many Toyota
dealers can still open the door for you,
using their special tools. If you must
break a window to get in, we suggest
breaking the smallest side window be-
cause it is the least expensive to replace.
Be extremely cautious to avoid cuts from
the glass.You can purchase a new wireless re-
mote control transmitter at your Toyota
dealer.
Have the registered identification numbers
of your transmitters deleted from your ve-
hicle by your Toyota dealer as soon as
possible to avoid the possibility of theft or
an accident. Then, have the identification
number of your new transmitter registered.
At the same time, you must bring all of
the remaining transmitters to have them
registered again as well.
You can use the wireless remote control
system with the new transmitter. Contact
your Toyota dealer for detailed information.
If you lose your keys
If you lose your wireless
remote control transmitter

’02 Rav4_U (L/O 0108)
2562002 MY RAV4_U (OM42503U)
BATTERY
Open voltage
∗ at 20 C (68 F):
12.6—12.8 V Fully charged
12.2—12.4 V Half charged
11.8—12.0 V Discharged
∗: Voltage that is checked 20 minutes af-
ter the key is removed with all the lights
turned off
Charging rates: 5 A max.
CLUTCH
Pedal free play, mm (in.): 5—15 (0.2—0.6)
Fluid type: SAE J1703 or FMVSS No.116 DOT 3
MANUAL TRANSAXLE
Oil capacity, L (qt., Imp. qt.): Twowheel drive models2.5 (2.6, 2.2)
Fourwheel drive models
3.4 (3.6, 3.0)
Oil type: Gear oil API GL4 or GL5
Recommended oil viscosity: SAE 75W90 AUTOMATIC TRANSAXLE
Fluid capacity (drain and ref
ill), L (qt.,
Imp. qt.):
Twowheel drive modelsUp to 3.3 (3.5, 2.9)
Fourwheel drive models Up to 3.9 (4.1, 3.4)
Fluid type: Automatic transmission fluid Type TIV
Change automatic transmission fluid only
as necessary.
Generally, it is necessary to change
automatic transmission fluid only if your
vehicle is driven under one of the Special
Operating Conditions listed in your
“Scheduled Maintenance Guide” or
“Owner ’s Manual Supplement”. When
changing the automatic transmission fluid,
use only Toyota Genuine ATF Type TIV
(ATF JWS3309 or NWS6500) to aid in
assuring optimum transaxle performance.
Notice: Using automatic transmission
fluid other than Toyota Genuine ATF
Type TIV may cause deterioration in
shift quality, locking up of your trans-
mission accompanied by vibration, and
ultimately damage the automatic trans-
mission of your vehicle. TRANSFER
(fourwheel drive models)
Oil capacity, L (qt., Imp. qt.):
0.9 (1.0, 0.8)
Oil type: Hypoid gear oil API GL5
Recommended oil viscosity: Above 18 C (0 F)
SAE 90 or 85W90
Below 18 C (0 F)
SAE 80W or 80W90
REAR DIFFERENTIAL
(fourwheel drive models)
Oil capacity, L (qt., Imp. qt.): 0.9 (1.0, 0.8)
Oil type: Hypoid gear oil API GL5
Recommended oil viscosity: Above 18 C (0 F)
SAE 90
Below 18 C (0 F)
SAE 80W or 80W90

’02 Rav4_U (L/O 0108)
2672002 MY RAV4_U (OM42503U)
Discharge warning light90
. . . . . . . . . . . . . . . .
Doityourself maintenance
Parts and tools 221
. . . . . . . . . . . . . . . . . . . . .
Service precautions 219
. . . . . . . . . . . . . . . .
Does your vehicle need repairing? 215 . . . . .
Doors
Side doors 12
. . . . . . . . . . . . . . . . . . . . . . . . .
Driver ’s seat belt reminder buzzer 90 . . . . . . .
Driver ’s seat belt reminder light 90
. . . . . . . . .
Driving
Automatic transmission 99
. . . . . . . . . . . . . .
Driving tips 170
. . . . . . . . . . . . . . . . . . . . . . . .
Manual transmission 103
. . . . . . . . . . . . . . .
Driving tips
Driving tips in various conditions 171 . . . . .
Driving with a manual transmission 103
. . . . . . . . . . . .
Driving with an automatic transmission 99
. . . . . . . . .
Economical driving 181
. . . . . . . . . . . . . . . . .
Good driving practice 99,103
. . . . . . . . . . . .
Winter driving tips 173
. . . . . . . . . . . . . . . . . .
During
Breakin 155
. . . . . . . . . . . . . . . . . . . . . . . . . .
E
Economical driving
Saving money on both fuel and repairs 181 . . . . . . . . . . . . . . . . . .
Electric moon roof 25 . . . . . . . . . . . . . . . . . . . . . Electrical system
Battery 240,241 . . . . . . . . . . . . . . . . . . . . . . . .
Fuse locations 219 . . . . . . . . . . . . . . . . . . . . .
Fuses 242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency flasher switch 81 . . . . . . . . . . . . . .
Emergency, In case of
Blown fuse 242 . . . . . . . . . . . . . . . . . . . . . . . .
Emergency flasher switch 81 . . . . . . . . . . . .
Flat tire 189 . . . . . . . . . . . . . . . . . . . . . . . . . . .
If you cannot shift automatic transmission selector lever 202 . . . . . . . .
If you lose your keys 203 . . . . . . . . . . . . . . . .
If you lose your wireless remote control transmitter 203 . . . . . . . . . . . . . . . .
If your engine stalls while driving 188 . . . . .
If your vehicle needs to be towed 198 . . . . .
If your vehicle will not start 184 . . . . . . . . . .
Jump starting 185 . . . . . . . . . . . . . . . . . . . . . .
Overheating 188 . . . . . . . . . . . . . . . . . . . . . . .
Towing 198 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emissions Inspection and Maintenance (I/M) programs 216 . . . . . . . . .
Engine
Air cleaner 230 . . . . . . . . . . . . . . . . . . . . . . . .
Before starting the engine 170 . . . . . . . . . . .
Checking the coolant level 227 . . . . . . . . . .
Emission control device 158 . . . . . . . . . . . . .
Engine compartment 218 . . . . . . . . . . . . . . .
Exhaust gas caution 159 . . . . . . . . . . . . . . . .
Hood release 22 . . . . . . . . . . . . . . . . . . . . . . .
Oil consumption 159 . . . . . . . . . . . . . . . . . . . .
Oil level 226 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overheating 188 . . . . . . . . . . . . . . . . . . . . . . . Starting procedure 170
. . . . . . . . . . . . . . . . .
Threeway catalytic converter 158 . . . . . . .
Engine coolant
Temperature gauge 88 . . . . . . . . . . . . . . . . . .
Winter driving tips 173 . . . . . . . . . . . . . . . . . .
Engine coolant temperature gauge 88 . . . . . .
Engine immobiliser system 11 . . . . . . . . . . . . .
Engine oil
Winter driving tips 173 . . . . . . . . . . . . . . . . . .
Exhaust gas caution 159 . . . . . . . . . . . . . . . . . .
F
Facts about engine oil consumption 159 . . . .
Flasher, Headlight 80 . . . . . . . . . . . . . . . . . . . . .
Flat tire
After changing wheels 197 . . . . . . . . . . . . . .
Changing tire 194 . . . . . . . . . . . . . . . . . . . . . .
If you have a flat tire 189 . . . . . . . . . . . . . . . .
Jack point 193 . . . . . . . . . . . . . . . . . . . . . . . . .
Jacking precautions 189 . . . . . . . . . . . . . . . .
Jacking up 193 . . . . . . . . . . . . . . . . . . . . . . . .
Loosening wheel nuts 193 . . . . . . . . . . . . . . .
Lowering vehicle 195 . . . . . . . . . . . . . . . . . . .
Stowing flat tire 196 . . . . . . . . . . . . . . . . . . . .
Wheel block 192 . . . . . . . . . . . . . . . . . . . . . . .
Wheel nuts 195 . . . . . . . . . . . . . . . . . . . . . . . .
Floor mat 151 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid level
Brake 229 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power steering 229 . . . . . . . . . . . . . . . . . . . . .
Washer fluid 243 . . . . . . . . . . . . . . . . . . . . . . .
Fog light switch, Front 82 . . . . . . . . . . . . . . . . .
Foreign countries, Operation in 157 . . . . . . . .

’02 Rav4_U (L/O 0108)
2682002 MY RAV4_U (OM42503U)
Front cup holder143
. . . . . . . . . . . . . . . . . . . . .
Front fog light switch 82
. . . . . . . . . . . . . . . . . .
Front passenger ’s seat belt reminder light 90
. . . . . . . . . . . . . . . . . . . . . . .
Front seat
Seatback flattening 38
. . . . . . . . . . . . . . . . . .
Front seats 28,29
. . . . . . . . . . . . . . . . . . . . . . . .
Fuel
Filler door o pener 24
. . . . . . . . . . . . . . . . . . .
Fuel economy 181
. . . . . . . . . . . . . . . . . . . . .
Fuel pump shut off system 157
. . . . . . . . . .
Gauge 88
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation in foreign countries 157 . . . . . . .
Tank cap 24
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel information 155
. . . . . . . . . . . . . . . . . . . . .
Fuel pump shut off system 157
. . . . . . . . . . . .
Fuse
Fuse box 242
. . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse locations 219
. . . . . . . . . . . . . . . . . . . . . . .
G
Garage door opener box 138
. . . . . . . . . . . . . .
Gauge
Engine coolant temperature 88
. . . . . . . . . .
Fuel 88
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glove box 138
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Good driving practice 99,103
. . . . . . . . . . . . . .
Grocery bag hooks 145
. . . . . . . . . . . . . . . . . . .
H
Hazard switch 81
. . . . . . . . . . . . . . . . . . . . . . . .
Head restraints 39
. . . . . . . . . . . . . . . . . . . . . . .
Headlight switch 80
. . . . . . . . . . . . . . . . . . . . . .
High speed operation
During breakin 155
. . . . . . . . . . . . . . . . . . . .
Hood release, Engine 22
. . . . . . . . . . . . . . . . . .
How to start the engine 170
. . . . . . . . . . . . . . .
I
I/M test 216
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification
Engine 166
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle 165
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition switch 98
. . . . . . . . . . . . . . . . . . . . . . . .
Indicator symbols 5
. . . . . . . . . . . . . . . . . . . . . .
Instrument panel
Brightness control 82
. . . . . . . . . . . . . . . . . . .
Cigarette lighter and ashtrays 136 . . . . . . .
Clock 136
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel gauge 88
. . . . . . . . . . . . . . . . . . . . . . . . .
Indicator symbols 5
. . . . . . . . . . . . . . . . . . . .
Odometer 89
. . . . . . . . . . . . . . . . . . . . . . . . . .
Tachometer 89
. . . . . . . . . . . . . . . . . . . . . . . . .
Trip meter 89
. . . . . . . . . . . . . . . . . . . . . . . . . .
Instrument panel light control 82
. . . . . . . . . . .
Instrument panel overview 2,4
. . . . . . . . . . . .
Interior light 82
. . . . . . . . . . . . . . . . . . . . . . . . . .
J
Jack
Location 190 . . . . . . . . . . . . . . . . . . . . . . . . . .
Jump starting 185 . . . . . . . . . . . . . . . . . . . . . . . .
K
Key reminder buzzer 90
. . . . . . . . . . . . . . . . . .
Keys 8,203
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
L
Light bulbs
Backup lights 249 . . . . . . . . . . . . . . . . . . . . .
Front fog lights 246 . . . . . . . . . . . . . . . . . . . . .
Front side marker lights 248 . . . . . . . . . . . . .
Front turn signal lights 248,249 . . . . . . . . . .
Headlights 245 . . . . . . . . . . . . . . . . . . . . . . . .
High mounted stoplight 250 . . . . . . . . . . . . .
License plate lights 251 . . . . . . . . . . . . . . . . .
Parking lights 248 . . . . . . . . . . . . . . . . . . . . . .
Rear side marker lights 249 . . . . . . . . . . . . .
Rear turn signal lights 249 . . . . . . . . . . . . . .
Stop/tail lights 249 . . . . . . . . . . . . . . . . . . . . .
Light bulbs, Replacing 244 . . . . . . . . . . . . . . . .
Light reminder buzzer 90 . . . . . . . . . . . . . . . . .
Limited slip differential 165 . . . . . . . . . . . . . . . .
Lock
Back door 21 . . . . . . . . . . . . . . . . . . . . . . . . . .
Side doors 12 . . . . . . . . . . . . . . . . . . . . . . . . .
Steering column 98 . . . . . . . . . . . . . . . . . . . .
Low engine oil pressure warning light 90 . . . .
Low fuel level warning light 90 . . . . . . . . . . . . .