brake TOYOTA RAV4 2004 XA20 / 2.G Workshop Manual

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1. Battery
2. Power steering fluid reservoir
3. Engine oil filler cap
4. Brake fluid reservoir
5. Fuse block
6. Engine coolant reservoir
7. Radiator
8. Condenser
9. Electric cooling fans
10. Engine oil level dipstick
11. Windshield and rear window washer fluid tank
Engine compartment overview

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Do not allow dirt or anything else
to fall through the spark plug holes.
 Use only spark plugs of the speci-
fied type. Using other types will
cause engine damage, loss of per-
formance or radio noise.
 Do not reuse iridiumtipped spark
plugs by cleaning or regapping.
 Do not overfill automatic transmis-
sion fluid, or the transmission
could be damaged.
 Do not drive with the air cleaner
filter removed, or excessive engine
wear could result. Also backfiring
could cause a fire in the engine
compartment.
 Be careful not to scratch the glass
surface with the wiper frame.
 When closing the engine hood,
check to see that you have not for-
gotten any tools, rags, etc.Here is a list of parts and tools you will
need to perform do− it−yourself mainte-
nance. Remember all Toyota parts are de-
signed in metric sizes, so your tools must
be metric.
CHECKING THE ENGINE OIL LEVEL
Parts (if level is low):
“Toyota Genuine Motor Oil” or equiva-
lent
See page 284 in Section 7 −2 for de-
tails about engine oil selection.
Tools:
Rag or paper towel
Funnel (only for adding oil)
CHECKING THE ENGINE COOLANT
LEVEL
Parts (if level is low):
“Toyota Super Long Life Coolant” or
similar high quality ethylene glycol
based non −silicate, non −amine, non− ni-
trite, and non −borate coolant with long −
life hybrid organic acid technology.
“Toyota Super Long Life Coolant” is a
mixture of 50% coolant and 50% deion-
ized water.
Tools:
Funnel (only for adding coolant) CHECKING BRAKE FLUID
Parts (if level is low):
SAE J1703 or FMVSS No.116 DOT 3
brake fluid
Tools:
Rag or paper towel
Funnel (only for adding fluid)
CHECKING POWER STEERING FLUID
Parts (if level is low):
Automatic transmission fluid DEXRON II
or III
Tools:
Rag or paper towel
Funnel (only for adding fluid)
CHECKING BATTERY CONDITION
Tools:
Warm water
Baking soda
Grease
Conventional wrench (for terminal
clamp bolts)
CHECKING AND REPLACING FUSES
Parts (if replacement is necessary):
Fuse with same amperage rating as
original
Parts and tools

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When jacking up your vehicle with the
jack, position the jack correctly as
shown in the illustrations.
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 wheels on the opposite
side of the jack up point 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 vehicle support stands.
Do not raise the vehicle with some-
one in the vehicle.
When raising the vehicle, do not
place any objects on top of or un-
derneath the jack.
NOTICE
Make sure to place the jack correctly,
or your vehicle may be damaged.

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DOITYOURSELF MAINTENANCE
Engine and Chassis
Checking the engine oil level284
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the engine coolant level 286
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the radiator and condenser 287
. . . . . . . . . . . . . . . . . . . . . . . . .
Checking brake fluid 288
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. . . .
Checking power steering fluid 288
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking and replacing the air conditioning filter 289
. . . . . . . . . . . . . . .
Checking tire inflation pressure 291
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking and replacing tires 293
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotating tires 295
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. . . . . . . . . . .
Installing snow tires and chains 296
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing wheels 298
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Aluminum wheel precautions 298
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 2

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To check the fluid level, simply look at
the seethrough reservoir. The level
should be between the “MAX” and
“MIN” lines on the reservoir.
It is normal for the brake fluid level to go
down slightly as the brake pads wear. So
be sure to keep the reservoir filled.
If the reservoir needs frequent refilling, it
may indicate a serious mechanical prob-
lem.
If the level is low, add SAE J1703 or
FMVSS No.116 DOT 3 brake fluid to the
brake reservoir.Remove and replace the reservoir cap by
hand. Fill the brake fluid to the dotted
line. This brings the fluid to the correct
level when you put the cap back on.
Use only newly opened brake fluid. Once
opened, brake fluid absorbs moisture from
the air, and excess moisture can cause a
dangerous loss of braking.
CAUTION
Take care when filling the r
eservoir
because brake fluid can harm your
eyes and damage painted surfaces. If
fluid gets in your eyes, flush your
eyes with clean water immediately. If
you still feel uncomfortable with your
eyes, go to the doctor.
NOTICE
If you spill some of the fluid, be sure
to wash it off with water to prevent
it from damaging the parts or paint.
Close Open
If cold add If cold O.K.
If hot add
If hot O.K.
Check the fluid level through the reser-
voir. If necessary, add automatic trans-
mission fluid DEXRON
II or III.
If the vehicle has been driven around 80
km/h (50 mph) for 20 minutes (a little
more in frigid temperatures), the fluid is
hot (80 C or 175 F). You may also check
the level when the fluid is cold (about
room temperature, 10 C—30 C or
50 F—85 F) if the engine has not been
run for about five hours.
Checking brake fluid Checking power steering fluid

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WHEN TO REPLACE YOUR WHEELS
If you have wheel damage such as
bending, cracks or heavy corrosion, the
wheel should be replaced.
If you fail to replace a damaged wheel,
the tire may slip off the wheel or cause
loss of handling control.
WHEEL SELECTION
When replacing wheels, care should be
taken to ensure that the wheels are re-
placed by ones with the same load ca-
pacity, diameter, rim width, and offset.
Correct replacement wheels are available
at your Toyota dealer.
A wheel of a different size or type may
adversely affect handling, wheel and bear-
ing life, brake cooling, speedometer/odom-
eter calibration, stopping ability, headlight
aim, bumper height, vehicle ground clear-
ance, and tire or snow chain clearance to
the body and chassis.Replacement with used wheels is not rec-
ommended as they may have been sub-
jected to rough treatment or high mileage
and could fail without warning. Also, bent
wheels which have been straightened may
have structural damage and therefore
should not be used. Never use an inner
tube in a leaking wheel which is designed
for a tubeless tire.
CAUTION
Observe the following instructions.
Otherwise, an accident may occur re-
sulting in death or serious injuries.
Do not use wheels other than the
manufacturer ’s recommended size,
as this may cause dangerous han-
dling characteristics resulting in
loss of control.
Fourwheel drive models:
Do not use wheels of different
brands, sizes and types, as this
may cause dangerous handling
characteristics resulting in loss of
control.
When installing aluminum wheels,
check that the wheel nuts are tight
after driving your vehicle the first 1600
km (1000 miles).
If you have rotated, repaired, or
changed your tires, check that the
wheel nuts are still tight after driving
1600 km (1000 miles).
When using tire chains, be careful not
to damage the aluminum wheels.
Use only Toyota wheel nuts and
wrench designed for your aluminum
wheels.
When balancing your wheels, use only
Toyota balance weights or equivalent
and a plastic or rubber hammer.
As with any wheel, periodically check
your aluminum wheels for damage. If
damaged, replace immediately.
Replacing wheels
Aluminum wheel precautions

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AUTOMATIC TRANSAXLE
Fluid capacity (drain and refill), L (qt.,
Imp. qt.):Up to 3.5 (3.7, 3.0)
Fluid type: Toyota Genuine ATF Type T −IV
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 T −IV”
(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.
Please contact your Toyota dealer for fur-
ther details. TRANSFER
(fourwheel drive models)
Oil capacity, L (qt., Imp. qt.):
0.9 (1.0, 0.8)
Oil type: Hypoid gear oil API GL −5
Recommended oil viscosity: Above −18 C (0 F)
SAE 90
Below −18 C (0 F)
SAE 80W or 80W −90
REAR DIFFERENTIAL
(fourwheel drive models)
Oil capacity, L (qt., Imp. qt.): 0.9 (1.0, 0.8)
Oil type: Hypoid gear oil API GL −5
Recommended oil viscosity: Above −18 C (0 F)
SAE 90
Below −18 C (0 F)
SAE 80W or 80W −90 BRAKES
Minimum pedal clearance when depressed
with the force of 490 N (50 kgf, 110 lbf)
with the engine running, mm (in.):
118 (4.6)
Pedal free play, mm (in.): 1—6 (0.04—0.24)
Pad wear limit, mm (in.): 1.0 (0.04)
Lining wear limit, mm (in.): 1.0 (0.04)
Parking brake adjustment when pulled with
the force of 196 N (20 kgf, 44 lbf): 6—8 clicks
Fluid type: SAE J1703 or FMVSS No.116 DOT 3
STEERING
Wheel free play: Less than 30 mm (1.2 in.)
Power steering fluid type: Automatic transmission fluid DEXRON II
or
III

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7. ALTS 5 A: Charging system
8. IGN 15 A: Starting system, multiport
fuel injection system/sequential multi-
port fuel injection system
9. EFI3 10 A: Multiport fuel injection sys-
tem/sequential multiport fuel injection
system, emission control system
10. EFI2 5 A: Multiport fuel injection sys-
tem/sequential multiport fuel injection
system
11. RADIO NO.2 30 A: Car audio system
12. ABS 2 30 A: Anti−lock brake system,
vehicle stability control system, traction
control system, brake assist system
13. EFI1 20 A: Multiport fuel injection sys-
tem/sequential multiport fuel injection
system, automatic transmission fluid
temperature sensor, “EFI2” and “EFI3”
fuses
14. HLP RH 15 A: Right−hand headlight
15. HLP LH 15 A: Left−hand headlight
16. ETCS 10 A: Electronic throttle control
system
17. ST 5 A: Starting system 18. STOP 10 A:
Stop lights, high− mounted
stoplight, anti −lock brake system, shift
lock control system, multiport fuel in-
jection system/sequential multiport fuel
injection system, cruise control system
19. CIG 15 A: Cigarette lighter
20. POWER OUTLET 15 A: Power outlets
21. SHTR 10 A: Seat heaters
22. PANEL 7.5 A: Instrument panel lights,
gauges and meters, front fog lights,
instrument panel light control, outside
rear view mirror defoggers, air condi-
tioning system
23. FR FOG 15 A: Front fog lights
24. HORN 10 A: Horn
25. TAIL 7.5 A: Tail lights, license plate
lights, instrument cluster lights
26. TAIL&PANEL 15 A: “PANEL” and
“TAIL” fuses
27. ACC 7.5 A: Car audio system, shift
lock control system, clock, power rear
view mirrors
28. DEF 20 A: Rear window defogger
29. GAUGE 10 A: Back−up lights, electric
cooling fans, air conditioning system,
automatic transmission indicator lights,
charging system 30. OBD 7.5 A:
On−board diagnosis sys-
tem
31. IG2 10 A: Discharge warning light,
multiport fuel injection system/sequen-
tial multiport fuel injection system,
starting system, gauges and meters,
SRS airbag system
32. DOOR 20 A: Power door lock system
33. MIR HTR 10 A: Outside rear view mir-
ror defoggers
34. RR WIP 15 A: Rear window wiper and
washer
35. WIP 25 A: Windshield wipers and
was

her
36. ECU IG 10 A: Emergency flashers,
gauges and meters, anti −lock brake
system, vehicle stability control system,
traction control system, brake assist
system, SRS airbag system, shift lock
control system, cruise control system
Fuses (type B)
37. RDI 30 A: Electric cooling fan
38. CDS 30 A: Electric cooling fan
39. AM2 30 A: Discharge warning light,
multiport fuel injection system/sequen-
tial multiport fuel injection system,
starting system, SRS airbag system,
“IG2” fuse

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40. ABS 1 50 A: Anti−lock brake system
41. HTR 40 A: Air conditioning system
42. FHTR or HLP CLN 30 A: No circuit
43. PWR 30 A: Electric moon roof, power
windows
44. AM1 40 A: Power outlets, rear window
defogger, “ACC”, “CIG”, “ECU IG”,
“GAUGE”, “RR WIP”, “S −HTR” and
“WIP” fuses