engine TOYOTA RAV4 2002 XA20 / 2.G Workshop Manual

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Slow down and downshift before
descending steep or long downhill
grades. Do not make sudden down-
shifts.
Avoid holding the brake pedal down
too long or too frequently. This
could cause the brakes to overheat
and result in reduced braking effi-
ciency.
Improving fuel economy is easy—just take
it easy. It will help make your vehicle last
longer, too. Here are some specific tips
on how to save money on both fuel and
repairs:
Keep your tires inflated at the cor-
rect pressure. Underinflation causes
tire wear and wastes fuel. See page
231 in Section 72 for instructions.
Do not carry unneeded weight in
your vehicle. Excess weight puts a
heavier load on the engine, causing
greater fuel consumption.
Avoid lengthy warmup idling. Once
the engine is running smoothly, begin
driving—but gently. Remember, howev-
er, that on cold winter days this may
take a little longer.
Keep the automatic transmission
overdrive turned on when engine
braking is not required. Driving with
the overdrive off will reduce the fuel
economy. (For details, see “Automatic
transmission” on page 99 in Section
16.)
Accelerate slowly and smoothly.
Avoid jackrabbit starts. Get into high
gear as quickly as possible.
Avoid long engine idling. If you have
a long wait and you are not in traffic,
it is better to turn off the engine and
start again later.
Avoid engine lugging or overrev-
ving. Use a gear position suitable for
the road on which you are travelling.
Avoid continuous speeding up and
slowing down. Stopandgo driving
wastes fuel.
Avoid unnecessary stopping and
braking. Maintain a steady pace. Try
to time the traffic signals so you only
need to stop as little as possible or
take advantage of through streets to
avoid traffic lights. Keep a proper dis-
tance from other vehicles to avoid sud-
den braking. This will also reduce wear
on your brakes.
Avoid heavy traffic or traffic jams
whenever possible.
Do not rest your foot on the clutch
or brake pedal. This causes premature
wear, overheating and poor fuel econo-
my.
Maintain a moderate speed on high-
ways. The faster you drive, the greater
the fuel consumption. By reducing your
speed, you will cut down on fuel con-
sumption.
How to save fuel and make
your vehicle last longer

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Keep the front wheels in proper
alignment. Avoid hitting the curb and
slow down on rough roads. Improper
alignment not only causes faster tire
wear but also puts an extra load on
the engine, which, in turn, wastes fuel.
Keep the bottom of your vehicle free
from mud, etc. This not only lessens
weight but also helps prevent corro-
sion.
Keep your vehicle tunedup and in
top shape. A dirty air cleaner, improp-
er valve clearance, dirty plugs, dirty oil
and grease,brakes not adjusted, etc. all
lower engine performance and contrib-
ute to poor fuel economy. For longer
life of all parts and lower operating
costs, keep all maintenance work on
schedule, and if you often drive under
severe conditions, see that your vehicle
receives more frequent maintenance.
(For scheduled maintenance informa-
tion, please refer to the “Scheduled
Maintenance Guide” or “Owner ’s Manu-
al Supplement”).
CAUTION
Never turn off the engine to coast
down hills. Your power steering and
brake booster will not function with-
out the engine running. Also, the
emission control system operates
properly only when the engine is run-
ning.

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IN CASE OF AN EMERGENCY
If your vehicle will not start184
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
If your engine stalls while driving 188
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
If your vehicle overheats 188
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
If you have a flat tire 189
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . .
If your vehicle needs to be towed 198
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
If you cannot shift automatic transmission selector lever 202 . . . . . . . .
If you lose your keys 203
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . .
If you lose your wireless remote control transmitter 203
. . . . . . . . . . . . .
SECTION 4

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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

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JUMP STARTING PROCEDURE1. If the booster battery is installed in another vehicle, make sure the vehicles
are not touching. Turn off all unneces-
sary lights and accessories.
2. If required, remove all the vent plugs from the booster and discharged batter-
ies. Lay a cloth over the open vents
on the batteries. (This helps reduce the
explosion hazard, personal injuries and
burns.)
3. If the engine in the vehicle with the booster battery is not running, start it
and let it run for a few minutes. During
jump starting, run the engine at about
2000 rpm with the accelerator pedal
lightly depressed.Jumper cable
Discharged
battery Positive
terminal
(“+” mark)
Booster battery Positive
terminal
(“+” mark)
4. Make the cable connections in the or-
der a, b, c, d.
a. Connect the clamp of the positive
(red) jumper cable to the positive (+)
terminal on the discharged battery.
b. Connect the clamp at the other end
of the positive (red) jumper cable to
the positive (+) terminal on the booster
battery.
Discharged
battery Jumper
cable
Negative terminal
(“” mark) Booster
battery
c. Connect the clamp of the negative
(black) cable to the negative () termi-
nal on the booster battery.
d. Connect the clamp at the other end
of the negative (black) jumper cable to
a solid, stationary, unpainted, metallic
point of the vehicle with the discharged
battery.
The recommended connecting point is
shown in the following illustration:

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Connecting point
Do not connect it to or near any part
that moves when the engine is
cranked.
CAUTION
When making the connections, to
avoid serious injury, do not lean over
the battery or accidentally let the
jumper cables or clamps touch any-
thing except the correct battery termi-
nals or the ground.
5. Start your engine in the normal way.After starting, run it at about 2000 rpm
for several minutes with the accelerator
pedal lightly depressed.
6. Carefully disconnect the cables in the exact reverse order: the negative cable
and then the positive cable.
7. Carefully dispose of the battery cover cloths—they may now contain sulfuric
acid.
8. If removed, replace all the battery vent plugs.
If the cause of your battery discharging is
not apparent (for example, lights left on),
you should have it checked.
AFTER JUMP STARTING
Insert the 6 removed clips and press
down their heads to fix the battery cover.
NOTICE
After installed the battery cover, make
sure the battery cover is securely in
its original position. If it is not se-
cured, it may be damaged to your
vehicle.

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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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6. After the engine coolant temperaturehas cooled to normal, again check the
coolant level in the reservoir. If neces-
sary, bring it up to half full again. Seri-
ous coolant loss indicates a leak in the
system. You s hould have it checked as
soon as possible at your Toyota dealer. 1. Reduce your speed gradually, keeping
a straight line. Move cautiously off the
road to a safe place well away from
the traffic. Avoid stopping on the center
divider of a highway. Park on a level
spot with firm ground.
2. Stop the engine and turn on your emergency flashers.
3. Firmly set the parking brake and put the transmission in “P” (automatic) or
reverse (manual).
4. Have everyone get out of the vehicle on the side away from traffic.
5. Read the following instructions thor- oughly.
CAUTION
When jacking, be sure to observe the
following to reduce the possibility of
personal injury:
Follow jacking instructions.
Do not put any part of your body
under the vehicle supported by the
jack. Personal injury may occur.
Do not start or run the engine while
your vehicle is supported by the
jack.
Stop the vehicle on a level firm
ground, firmly set the parking brake
and put the transmission in “P”
(automatic) or reverse (manual).
Block the wheel diagonally opposite
to the one being changed if neces-
sary.
Make sure to set the jack properly
in the jack point. Raising the ve-
hicle with jack improperly posi-
tioned will damage the vehicle or
may allow the vehicle to fall off the
jack and cause personal injury.
Never get under the vehicle when
the vehicle is supported by the jack
alone.
Use the jack only for lifting your
vehicle during wheel changing.
Do not raise the vehicle with some-
one in the vehicle.
When raising the vehicle, do not
put an object on or under the jack.
Raise the vehicle only high enough
to remove and change the tire.
If you have a flat tire—

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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

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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