2008 TOYOTA RAV4 Service Repair Manual

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This is the Highly Detailed factory service repair manual for the2008 TOYOTA RAV4 , this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.2008 TOYOTA RAV4 Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly. Service Repair Manual Covers: Airbags Auto Trans U140f Auto Trans U241e Axle Brake Control Brakes Charging 2az Charging 2gr differential Drive Shaft Electrical Component Locations Hvac Parking Brakes Power Steering Printing From Undefined Propeller Shaft Service Specs Starting 2az Starting 2gr Steering Column Suspension Transfer Case Wiring And more File Format: PDF Compatible: All Versions of Windows & Mac Language: English Requirements: Adobe PDF Reader NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to have2008 TOYOTA RAV4 Service Repair Workshop Manual. Looking for some other Service Repair Manual,please check: https://www.aservicemanualpdf.com/ Thanks for visiting!
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  • 1. INTRODUCTION – HOW TO USE THIS MANUAL IN–1 IN HOW TO USE THIS MANUAL GENERAL INFORMATION 1. GENERAL DESCRIPTION (a) This manual is written in accordance with SAE J2008. (1) Diagnosis (2) Removing / Installing, Replacing, Disassembling / Reassembling, Checking and Adjusting (3) Final Inspection (b) The following procedures are omitted from this manual. However, these procedures must be performed. (1) Use a jack or lift to perform operations. (2) Clean all removed parts. (3) Perform a visual check. 2. INDEX (a) An alphabetical INDEX section is provided at the end of the manual as a reference to help you find the item to be repaired. 3. PREPARATION (a) Use of Special Service Tools (SST) and Special Service Materials (SSM) may be required, depending on the repair procedure. Be sure to use SST and SSM when they are required and follow the working procedures properly. A list of SST and SSM is in the "Preparation" section of this manual. 4. REPAIR PROCEDURES (a) A component illustration is placed under the title where necessary.
  • 2. IN–2 INTRODUCTION – HOW TO USE THIS MANUAL IN (b) Non-reusable parts, grease application areas, precoated parts and torque specifications are noted in the component illustrations. The following illustration is an example. (c) Torque specifications, grease application areas and non-reusable parts are emphasized in the procedures. HINT: There are cases where such information can only be explained by using an illustration. In these cases, torque, oil and other information are described in the illustration. (d) Only items with key points are described in the text. What to do and other details are explained using illustrations next to the text. Both the text and illustrations are accompanied by standard values and notices. (e) Illustrations of similar vehicle models are sometimes used. In these cases, minor details may be different from the actual vehicle. (f) Procedures are presented in a step-by-step format. 5. SERVICE SPECIFICATIONS (a) SPECIFICATIONS are presented in boldface text throughout the manual. The specifications are also found in the "Service Specifications" section for reference. FILTER CAP FLOAT RESERVOIR TANK SLOTTED SPRING PIN CYLINDER PISTON PUSH ROD SNAP RING BOOT LOCK NUT CLEVIS CLIP CLEVIS PIN WASHER : Specified torqueN*m (kgf*cm, ft.*lbf) Non-reusable part GASKET GROMMET 12 (120, 9) 15 (155, 11) Example: D100720E02 Illustration What to do and where to do it Task heading What work will be performed Explanation text • How to perform the task • Information such as specifications and warnings, which are written in boldface text
  • 3. INTRODUCTION – HOW TO USE THIS MANUAL IN–3 IN 6. TERM DEFINITIONS 7. INTERNATIONAL SYSTEM OF UNITS (a) The units used in this manual comply with the International System of Units (SI) standard. Units from the metric system and English system are also provided. Example: Torque: 30 N*m (310 kgf*cm, 22 ft.*lbf) CAUTION Possibility of injury to you or other people. NOTICE Possibility of damage to components being repaired. HINT Provides additional information to help you perform repairs.
  • 4. IN–4 INTRODUCTION – IDENTIFICATION INFORMATION IN IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION AND SERIAL NUMBERS 1. VEHICLE IDENTIFICATION NUMBER (a) The vehicle identification number is stamped on the vehicle identification number plate and on the certification label, as shown in the illustrations. (1) Vehicle Identification Number Plate (2) Certification Label 2. ENGINE SERIAL NUMBER AND TRANSAXLE SERIAL NUMBER (a) The engine serial number is stamped on the cylinder block of the engine and the transaxle serial number is stamped on the housing as shown in the illustrations. (1) Engine Serial Number (2) Transaxle Serial Number D100910 D100911 2AZ-FE 2GR-FE D101077E01 D100928E01
  • 5. INTRODUCTION – REPAIR INSTRUCTION IN–5 IN REPAIR INSTRUCTION PRECAUTION 1. BASIC REPAIR HINT (a) HINTS ON OPERATIONS 1 Attire • Always wear a clean uniform. • A hat and safety shoes must be worn. 2 Vehicle protection Prepare a grille cover, fender cover, seat cover and floor mat before starting the operation. 3 Safe operation • When working with 2 or more persons, be sure to check safety for one another. • When working with the engine running, make sure to provide ventilation for exhaust fumes in the workshop. • If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others. • When jacking up the vehicle, be sure to support the specified location with a safety stand. • When lifting up the vehicle, use appropriate safety equipment. 4 Preparation of tools and measuring gauge Before starting the operation, prepare a tool stand, SST, gauge, oil and parts for replacement. 5 Removal and installation, disassembly and assembly operations • Diagnose with a thorough understanding of proper procedures and of the reported problem. • Before removing parts, check the general condition of the assembly and for deformation and damage. • When the assembly is complicated, take notes. For example, note the total number of electrical connections, bolts, or hoses removed. Add matchmarks to ensure reassembly of components to their original positions. Temporarily mark hoses and their fittings if needed. • Clean and wash the removed parts if necessary and assemble them after a thorough check. 1 2 4 6 3 5 3 D100912E01
  • 6. IN–6 INTRODUCTION – REPAIR INSTRUCTION IN (b) JACKING UP AND SUPPORTING VEHICLE (1) Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations. (c) PRECOATED PARTS (1) Precoated parts are bolts and nuts that are coated with a seal lock adhesive at the factory. (2) If a precoated part is retightened, loosened or moved in any way, it must be recoated with the specified adhesive. (3) When reusing a precoated part, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriate to that part. (4) Some seal lock agents harden slowly. You may have to wait for the seal lock adhesive to harden. (d) GASKETS (1) When necessary, use a sealer on gaskets to prevent leaks. (e) BOLTS, NUTS AND SCREWS (1) Carefully follow all the specifications for tightening torques. Always use a torque wrench. (f) FUSES (1) When inspecting a fuse, check that the wire of the fuse is not broken. (2) When replacing fuses, be sure that the new fuse has the correct amperage rating. Do not exceed the rating or use one with a lower rating. 6 Removed parts • Place removed parts in a separate box to avoid mixing them up with new parts or contaminating new parts. • For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them with new ones as instructed in this manual. • Retain the removed parts for customer inspection, if requested. Seal Lock Adhesive D100721E01 INCORRECT CORRECT D100722E01 Illustration Symbol Part Name Abbreviation FUSE FUSE MEDIUM CURRENT FUSE M-FUSE
  • 7. INTRODUCTION – REPAIR INSTRUCTION IN–7 IN (g) CLIPS (1) The removal and installation methods of typical clips used for vehicle body parts are shown in the table below. HINT: If clips are damaged during a procedure, always replace the clips with new clips. HIGH CURRENT FUSE H-FUSE FUSIBLE LINK FL CIRCUIT BREAKER CB Illustration Symbol Part Name Abbreviation Shape (Example) Illustration Procedures 1. Remove clips with a clip remover or pliers. 1. Remove clips with a clip remover or screwdriver.
  • 8. IN–8 INTRODUCTION – REPAIR INSTRUCTION IN (h) CLAWS (1) The removal and installation methods of typical claws used for vehicle body parts are shown in the table below. HINT: If claws of caps or covers are damaged during a procedure, always replace the caps or covers with new ones. 1. Remove clips with a wide scraper to prevent panel damage. 1. Remove clips by pushing the center pin through and prying out the shell. 1. Remove clips by unscrewing the center pin and prying out the shell. 1. Remove the clip by prying out the pin and then prying out the shell. Shape (Example) Illustration Procedures
  • 9. INTRODUCTION – REPAIR INSTRUCTION IN–9 IN (i) REMOVAL AND INSTALLATION OF VACUUM HOSES (1) To disconnect a vacuum hose, pull and twist from the end of the hose. Do not pull from the middle of the hose as this may cause damage. Shape (Example) Illustration Procedures 1. Using a screwdriver, detach the claws and remove the caps or cover. 1. Using a screwdriver, detach the claws and remove the caps or cover. 1. Using a screwdriver, detach the claws and remove the caps or cover. INCORRECT CORRECT D100723E01
  • 10. IN–10 INTRODUCTION – REPAIR INSTRUCTION IN (2) When disconnecting vacuum hoses, use tags to identify where they should be reconnected. (3) After completing any hose related repairs, double-check that the vacuum hoses are properly connected. The label under the hood shows the proper layout. (4) When using a vacuum gauge, never force the hose onto a connector that is too large. If a hose has been stretched, it may leak air. Use a step- down adapter if necessary. (j) TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL (1) Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with a torque wrench. Formula: T' = L2 / (L1 + L2) * T NOTICE: If an extension tool or SST is combined with a torque wrench and the wrench is used to tighten to a torque specification in this manual, the actual torque will be excessive and parts will be damaged. 2. FOR VEHICLES WITH SUPPLEMENTAL RESTRAINT SYSTEM The RAV4 is equipped with a Supplemental Restraint System (SRS). The SRS of this vehicle consists of the following: 1. Steering pad 2. Front passenger airbag assembly 3. Front seat side airbag assembly 4. Front seat outer belt assembly with pretensioner 5. Curtain shield 6. Center airbag sensor 7. Front airbag sensor 8. Side airbag sensor 9. Rear airbag sensor 10.Occupant Classification ECU D100724 L2L1 D100725E01 L1 L2 D100726E01 T' Reading of torque wrench {N*m (kgf*cm, ft.*lbf)} T Torque {N*m (kgf*cm, ft.*lbf)} L1 Length of SST or extension tool {cm (in.)} L2 Length of torque wrench {cm (in.)}
  • 11. INTRODUCTION – REPAIR INSTRUCTION IN–11 IN CAUTION: • Failure to carry out service procedures in the correct sequence could cause SRS parts to unexpectedly deploy and possibly lead to serious injuries. Furthermore, if a mistake is made when servicing SRS parts, they may fail to operate when required. Before performing servicing (including installation/removal, inspection and replacement of parts), be sure to read the following precautions. • Before starting work, wait at least 90 seconds after the ignition switch is turned OFF and after the cable of the negative (-) battery terminal is disconnected. (SRS parts are equipped with a backup power source. If work is started within 90 seconds of turning the ignition switch OFF and disconnecting the cable from the negative (-) battery terminal, SRS parts may deploy.) • Do not expose SRS parts directly to hot air or flames. NOTICE: • Malfunction symptoms of SRS parts are difficult to confirm. DTCs are the most important source of information when troubleshooting. During troubleshooting, always confirm DTCs before disconnecting the cable from the negative (-) battery terminal. • For minor collisions where SRS parts do not deploy, always inspect the SRS parts. • Before performing repairs, remove airbag sensors as necessary if any kind of impact is likely to occur to an airbag sensor during repairs. • Never use SRS parts from another vehicle. When replacing SRS parts, replace them with new ones. • Never disassemble or attempt to repair SRS parts. • If an SRS part has been dropped, or if there are any cracks, dents or other defects in the case, bracket or connector, replace the SRS part with a new one. • Use an ohmmeter/voltmeter with high impedance (10 kΩ/V minimum) for troubleshooting the electrical circuits. • Information labels are attached to the periphery of SRS parts. Follow the cautions and instructions on the labels. • After work on SRS parts is completed, perform the SRS warning light check.
  • 12. IN–12 INTRODUCTION – REPAIR INSTRUCTION IN • When the cable is disconnected from the negative (-) battery terminal, the memory settings of each system will be cleared. Because of this, be sure to write down the settings of each system before starting work. When work is finished, reset the settings of each system as before. Never use a backup power supply from outside the vehicle to avoid erasing the memory in a system. (a) SPIRAL CABLE (1) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, as cable disconnection and other problems may occur. Refer to the information about correct installation of the steering wheel. (b) AIRBAG ASSEMBLY (1) Airbag assembly with pad: Always place a removed or new airbag assembly with the pad surface facing upward. Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag inflates. Also, do not place anything on top of the airbag assembly. (2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause a serious injury. (3) Grease or detergents of any kind should not be applied to the airbag assembly. (4) Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise. (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring. (6) When disposing of the vehicle or the airbag assembly by itself, the airbag should be deployed using SST before disposal. Activate the airbag in a safe place away from electrical noise. (c) SEAT OUTER BELT ASSEMBLY WITH PRETENSIONER (1) Never measure the resistance of the seat outer belt. This may cause the pretensioner of the seat outer belt to activate, which could cause a serious injury. (2) Never install the seat outer belt on another vehicle.
  • 13. INTRODUCTION – REPAIR INSTRUCTION IN–13 IN (3) Store the seat outer belt in an area where the ambient temperature is below 80°C (176°F), the humidity is not high and there is no electrical noise. (4) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (2 pins). These connectors contain shorting springs. This feature reduces the possibility of the pretensioner deploying due to currents entering the squib wiring. (5) When disposing of a vehicle or the seat outer belt by itself, the pretensioner should be activated before disposal. Activate the pretensioner in a safe place away from electrical noise. (6) As the seat outer belt is hot after the pretensioner is activated, allow some time for it to cool down sufficiently before disposal. Never apply water to try to cool down the seat outer belt. (7) Grease, detergents, oil or water should not be applied to the seat outer belt. (d) AIRBAG SENSOR ASSEMBLY (1) Never reuse an airbag sensor assembly that has been involved in a collision where the SRS has deployed. (2) The connectors to the airbag sensor assembly should be connected or disconnected with the sensor placed on the floor. If the connectors are connected or disconnected while the airbag sensor assembly is not placed on the floor, the SRS may activate. (3) Work must be started at least 90 seconds after the ignition switch is turned OFF and the cable is disconnected from the negative (-) battery terminal, even if only loosening the set bolts of the airbag sensor assembly. (e) WIRE HARNESS AND CONNECTOR (1) The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are yellow. If the SRS wire harness becomes disconnected or the connector becomes broken, repair or replace it. 3. ELECTRONIC CONTROL (a) REMOVAL AND INSTALLATION OF BATTERY TERMINAL NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. (1) Before performing electronic work, disconnect the cable from the negative (-) battery terminal to prevent component and wire damage caused by accidental short circuits. Negative (-) Cable Negative (-) Battery Terminal D100727E01
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  • 15. IN–14 INTRODUCTION – REPAIR INSTRUCTION IN (2) When disconnecting the cable, turn the ignition switch OFF and headlight dimmer switch OFF and loosen the cable nut completely. Perform these operations without twisting or prying the cable. Then disconnect the cable. (3) Clock settings, radio settings, audio system memory, DTCs and other data are erased when the cable is disconnected from the negative (-) battery terminal. Write down any necessary data before disconnecting the cable. (b) HANDLING OF ELECTRONIC PARTS (1) Do not open the cover or case of the ECU unless absolutely necessary. If the IC terminals are touched, the IC may be rendered inoperative by static electricity. (2) Do not pull the wires when disconnecting electronic connectors. Pull the connector. (3) Be careful not to drop electronic components, such as sensors or relays. If they are dropped on a hard surface, they should be replaced. (4) When cleaning the engine with steam, protect the electronic components, air filter and emission-related components from water. (5) Never use an impact wrench to remove or install temperature switches or temperature sensors. (6) When measuring the resistance of a wire connector, insert the tester probe carefully to prevent terminals from bending. 4. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS (a) PLACE FOR REMOVING AND INSTALLING FUEL SYSTEM PARTS (1) Work in a location with good air ventilation that does not have welders, grinders, drills, electric motors, stoves, or any other ignition sources. (2) Never work in a pit or near a pit as vaporized fuel will collect in those places. (b) REMOVING AND INSTALLING FUEL SYSTEM PARTS (1) Prepare a fire extinguisher before starting the operation. (2) To prevent static electricity, install a ground wire to the fuel changer, vehicle and fuel tank, and do not spray the surrounding area with water. Be careful when performing work in this area, as the work surface will become slippery. Do not clean up gasoline spills with water, as this may cause the gasoline to spread, and possibly create a fire hazard. (3) Avoid using electric motors, working lights and other electric equipment that can cause sparks or high temperatures. (4) Avoid using iron hammers as they may create sparks. INCORRECT D100728E01
  • 16. INTRODUCTION – REPAIR INSTRUCTION IN–15 IN (5) Dispose of fuel-contaminated cloth separately using a fire resistant container. 5. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS (a) If any metal particles enter inlet system parts, they may damage the engine. (b) When removing and installing inlet system parts, cover the openings of the removed parts and engine openings. Use gummed tape or other suitable materials. (c) When installing inlet system parts, check that no metal particles have entered the engine or the installed parts. 6. HANDLING OF HOSE CLAMPS (a) Before removing the hose, check the clamp position so that it can be reinstalled in the same position. (b) Replace any deformed or dented clamps with new ones. (c) When reusing a hose, attach the clamp on the clamp track portion of the
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