light TOYOTA RAV4 2002 XA20 / 2.G Repair Manual

’02 Rav4_U (L/O 0108)
1782002 MY RAV4_U (OM42503U)
HITCHES
Use only a weight carrying hitch
designed for the total trailer weight.
Toyota does not recommend using a
weight distribution (load equalizing)
hitch.
The hitch must be bolted securely to
the vehicle frame and installed accord-
ing to the hitch manufacturer ’s instruc-
tions.
The hitch ball should have a light coat
of grease.
Toyota recommends that the trailer
hitch be removed when not towing to
prevent injury and/or damage by the
hitch in event of a rear end collision.
After removing the hitch, the installa-
tion area should be sealed to prevent
entry of exhaust fumes and mud.
NOTICE
Do not use an axlemounting hitch as
it may cause damage to the axle
housing, wheel bearings, wheels and/
or tires.
BRAKES AND SAFETY CHAINS
Toyota recommends trailers with brakes
that conform to any applicable federal
and state/provincial regulations.
A safety chain must always be used
between the towing vehicle and the
trailer. Leave sufficient slack in the
chain for turns. The chain should cross
under the trailer tongue to prevent the
tongue from dropping to the ground in
case it becomes damaged or sepa-
rated. For correct safety chain proce-
dures, follow the hitch or trailer
manufacturer ’s recommendations.
CAUTION
If the total trailer weight exceeds
272 kg (600 lb.), trailer brakes are
required.
Never tap into your vehicle’s hy-
draulic system as it would lower its
braking effectiveness.
Never tow a trailer without using a
safety chain securely attached to
both the trailer and the vehicle. If
damage occurs to the coupling unit
or hitch ball, there is danger of the
trailer wandering over into another
lane.
TIRES
Ensure that your vehicle’s tires are
properly inflated. See page 231 Section
72 for instructions.
The trailer tires should be inflated to
the pressure recommended by the trail-
er manufacturer in respect to the total
trailer weight.
TRAILER LIGHTS
Trailer lights must comply with federal,
state/provincial and local regulations.
See your local recreational vehicle
dealer or rental agency for the correct
type of wiring and relays for your trail-
er. Check for correct operation of the
turn signals and stop lights each time
you hitch up. Direct splicing may dam-
age your vehicle’s electrical system
and cause a malfunction of your lights.

’02 Rav4_U (L/O 0108)
1792002 MY RAV4_U (OM42503U)
BREAKIN SCHEDULE
Toyota recommends that you do not
tow a trailer with a new vehicle or a
vehicle with any new power train com-
ponent (engine, transmission, differen-
tial, wheel bearing, etc.) for the first
800 km (500 miles) of driving.
MAINTENANCE
If you tow a trailer, your vehicle will
require more frequent maintenance due
to the additional load. For this informa-
tion, please refer to the scheduled
maintenance information in the “Sched-
uled Maintenance Guide” or “Owner ’s
Manual Supplement”.
Retighten all fixing bolts of the towing
ball and bracket after approximately
1000 km (600 miles) of trailer driving.
PRETOWING SAFETY CHECK
Check that your vehicle remains level
when a loaded or unloaded trailer is
hitched. Do not drive if the vehicle has
an abnormal noseup or nosedown
condition, and check for improper
tongue load, overload, worn suspension
or other possible causes.
Make sure the trailer cargo is securely
loaded so that it cannot shift.
Check that your rear view mirrors con-
form to any applicable federal, state/
provincial or local regulations. If not,
install the rear view mirrors required
for towing purpose.
TRAILER TOWING TIPS
When towing a trailer, your vehicle will
handle differently than when not tow-
ing. The three main causes of vehicle
trailer accidents are driver error, exces-
sive speed and improper trailer loading.
Keep these in mind when towing:
Before starting out, check operation of
the lights and all vehicletrailer connec-
tions. After driving a short distance,
stop and recheck the lights and con-
nections. Before actually towing a trail-
er, practice turning, stopping and back-
ing with a trailer in an area away from
traffic until you learn the feel.
Because stopping distance may be in-
creased, vehicletovehicle distance
should be increased when towing a
trailer. For each 16 km/h (10 mph) of
speed, allow at least one vehicle and
trailer length between you and the ve-
hicle ahead. Avoid sudden braking as
you may skid, resulting in jackknifing
and loss of control. This is especially
true on wet or slippery surfaces.
Avoid jerky starts or sudden accelera-
tion. If your vehicle has a manual
transmission, prevent excessive clutch
slippage by keeping engine rpm low
and not racing the engine. Always start
out in first gear.
Avoid jerky steering and sharp turns.
The trailer could hit your vehicle in a
tight turn. Slow down before making a
turn to avoid the necessity of sudden
braking.
Backing with a trailer is difficult and
requires practice. Grip the bottom of
the steering wheel and move your hand
to the left to move the trailer to the
left. Move your hand to the right to
move the trailer to the right. (This pro-
cedure is generally opposite to that
when backing without a trailer). Also,
just turn the steering wheel a little at
a time, avoiding sharp or prolonged
turning. Have someone guide you when
backing to reduce the risk of an acci-
dent.
Remember that when making a turn,
the trailer wheels will be closer than
the vehicle wheels to the inside of the
turn. Therefore, compensate for this by
making a larger than normal turning
radius with your vehicle.

’02 Rav4_U (L/O 0108)
1812002 MY RAV4_U (OM42503U)
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

’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)
1852002 MY RAV4_U (OM42503U)
To avoid serious personal injury and
damage to your vehicle which might re-
sult from battery explosion, acid burns,
electrical burns, or damaged electronic
components, these instructions must be
followed precisely.
If you are unsure about how to follow this
procedure, we strongly recommend that
you seek the help of a competent me-
chanic or towing service.
CAUTION
Batteries contain sulfuric acid
which is poisonous and corrosive.
Wear protective safety glasses when
jump starting, and avoid spilling
acid on your skin, clothing, or ve-
hicle.
If you should accidentally get acid
on yourself or in your eyes, remove
any contaminated clothing and flush
the affected area with water im-
mediately. Then get immediate medi-
cal attention. If possible, continue
to apply water with a sponge or
cloth while en route to the medical
office.
The gas normally produced by a
battery will explode if a flame or
spark is brought near. Use only
standardized jumper cables and do
not smoke or light a match while
jump starting.
Warning: Battery posts, terminals
and related accessories contain lead
and lead compounds, chemicals
known to the State of California to
cause cancer and reproductive
harm. Wash hands after handling.
NOTICE
The battery used for boosting must
be 12 V. Do not jump start unless you
are sure that the booster battery is
correct.
BEFORE JUMP STARTING
Remove the 6 cover clips using a coin
and then take off the cover.
(c) Jump starting

’02 Rav4_U (L/O 0108)
1862002 MY RAV4_U (OM42503U)
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:

’02 Rav4_U (L/O 0108)
1872002 MY RAV4_U (OM42503U)
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.

’02 Rav4_U (L/O 0108)
2092002 MY RAV4_U (OM42503U)
CAUTION
Do not wash the vehicle floor with
water, or allow water to get onto the
floor when cleaning the vehicle interi-
or or exterior. Water may get into
audio components or other electrical
components above or under the floor
carpet (or mat) and cause a malfunc-
tion; and it may cause body corro-
sion.
Vinyl interior
The vinyl upholstery may be easily
cleaned with a mild soap or detergent
and water.
First vacuum over the upholstery to re-
move loose dirt. Then, using a sponge or
soft cloth, apply the soap solution to the
vinyl. After allowing it to soak in for a few
minutes to loosen the dirt, remove the dirt
and wipe off the soap with a clean damp
cloth. If all the dirt do not come off, re-
peat the procedure. Commercial foaming
type vinyl cleaners are also available
which work well. Follow the manufacturer ’s
instructions.
NOTICE
Do not use solvent, thinner, gasoline
or window cleaner on the interior.
Carpets
Use a good foamtype shampoo to
clean the carpets.
Begin by vacuuming thoroughly to remove
as much dirt as possible. Several types of
foam cleaners are available; some are in
aerosol cans and others are powders or
liquids which you mix with water to pro-
duce a foam. To shampoo the carpets,
use a sponge or brush to apply the foam.
Rub in overlapping circles.
Do not apply water—the best results are
obtained by keeping the carpet as dry as
possible. Read the shampoo instructions
and follow them closely.
Seat belts
The seat belts may be cleaned with
mild soap and water or with lukewarm
water.
Use a cloth or sponge. As you are clean-
ing, check the belts for excessive wear,
fraying, or cuts.
NOTICE
Do not use dye or bleach on the
belts —it may weaken them.
 Do not use the belts until they be-
come dry.
Windows
The windows may be cleaned with any
household window cleaner.
NOTICE
When cleaning the inside of the rear
window, be careful not to scratch or
damage the heater wires or connec-
tors.
Air conditioning control panel, car au-
dio, instrument panel, console panel,
and switches
Use a soft damp cloth for cleaning.
Soak a clean soft cloth in water or luke-
warm water then lightly wipe off dirt.
Cleaning the interior

’02 Rav4_U (L/O 0108)
2102002 MY RAV4_U (OM42503U)
NOTICE
Do not use organic substances (sol-
vents, kerosene, alcohol, gasoline,
etc.) or alkaline or acidic solutions.
These chemicals can cause discol-
oring, staining or peeling of the
surface.
 If you use cleaners or polishing
agents, make sure their ingredients
do not include the substances men-
tioned above.
 If you use a liquid car freshener, do
not apply the liquid onto the ve-
hicle’s interior surfaces. It may con-
tain the ingredients mentioned
above. Immediately clean any spill
using the method mentioned above.
Leather Interior
The leather upholstery may be cleaned
with neutral detergent for wool.
Remove dirt using a soft cloth dampened
with 5% solution of neutral detergent for
wool. Then thoroughly wipe off all traces
of detergent with a clean damp cloth. After cleaning or whenever any part of the
leather gets wet, dry with a soft clean
cloth. Allow the leather to dry in a venti-
lated shaded area.
NOTICE

If a stain should fail to come out
with a neutral detergent, apply a
cleaner that does not contain an
organic solvent.
 Never use organic substances such
as benzine, alcohol or gasoline, or
alkaline or acid solutions for clean-
ing the leather as these could
cause discoloring.
 Use of a nylon brush or synthetic
fiber cloth, etc. may scratch the
fine grained surface of the leather.
 Mildew may develop on soiled leath-
er upholstery. Be especially careful
to avoid oil spots. Try to keep your
upholstery always clean.
 Long exposure to direct sunlight
may cause the leather surface to
harden and shrink. Keep your ve-
hicle in a shaded area, especially in
the summer.
The interior of your vehicle is apt
to heat up on hot summer days, so
avoid placing on the upholstery
items made of vinyl or plastic or
containing wax as these tend to
stick to leather when warm .
 Improper cleaning of the leather up-
holstery could result in discolor-
ation or staining.
If you have any questions about the
cleaning of your Toyota, your local
Toyota dealer will be pleased to answer
them.

’02 Rav4_U (L/O 0108)
2142002 MY RAV4_U (OM42503U)
INSIDE THE VEHICLE
Items listed below should be checked
regularly, e.g. while performing periodic
services, cleaning the vehicle, etc.
Lights
Make sure the headlights, stop lights, tail
lights, turn signal lights, and other lights
are all working.
Service reminder indicators and warning
buzzers
Check that all service reminder indicators
and warning buzzers function properly.
Steering wheel
Check that it has the specified free play.
Be alert for changes in steering condition,
such as hard steering or strange noise.
Seats
Check that all seat controls such as seat
adjusters, seatback recliner, etc. operate
smoothly and that all latches lock securely
in any position. For foldingup rear seat-
backs, check that the latches lock secure-
ly.Seat belts
Check that the seat belt system such as
buckles, retractors and anchors operate
properly and smoothly. Make sure the belt
webbing is not cut, frayed, worn or dam-
aged.
Accelerator pedal
Check the pedal for smooth operation and
uneven pedal effort or catching.
Clutch pedal
Check the pedal for smooth operation.
Brake pedal
Check the pedal for smooth operation and
that the pedal has the proper clearance.
Check the brake booster function.
Brakes
At a safe place, check that the brakes do
not pull to one side when applied.
Parking brake
Check that the lever has the proper travel
and that, on a safe incline, your vehicle
is held securely with only the parking
brake applied.Automatic transmission “Park” mecha-
nism
Check the lock release button of the se-
lector lever for proper and smooth opera-
tion. On a safe incline, check that your
vehicle is held securely with the selector
lever in “P” position and all brakes re-
leased.
IN THE ENGINE COMPARTMENT
Items listed below should be checked
from time to time, e.g. each time when
refueling.
Washer fluid
Make sure there is sufficient fluid in the
tank. See page 243 in Section 73 for
additional information.
Engine coolant level
Make sure the coolant level is between
the “FULL” and “LOW” lines on the see
through reservoir when the engine is cold.
See page 227 in Section 72 for addition-
al information.
Radiator, condenser and hoses
Check that the front of the radiator and
condenser are clean and not blocked with
leaves, dirt, or insects. See page 228 in
Section 72 for additional information.