2004 Toyota RAV4 Base, FWD, StandardFACTORY OEM SERVICE PROCEDURE

Basic Repair Hint

  1. Prevent damage and maintain vehicle cleanliness by protective covering on the fender, seat and floor.
  2. During disassembly, line up parts in the order they were removed to facilitate reassembly.
  3. Installation and removal of battery terminal:
    1. Before performing electrical work, disconnect the negative (-) terminal cable from the battery.
    2. If it is necessary to disconnect the battery for inspection or repair, first disconnect the negative (-) terminal cable.
    3. To prevent damage to the battery terminal when disconnecting the terminal cable, loosen the cable nut and raise the cable straight up. Do not twist or pry the cable off.
    4. Clean the battery terminals and cable ends with a clean shop rag. Do not scrape them with a file or other abrasive objects.
    5. Install the cable ends to the battery terminals after loosening the nut, and tighten the nut after installation. Do not use a hammer to tap the cable ends onto the terminals.
    6. Be sure the cover for the positive (+) terminal is properly in place.
      7. Fig 1: Installation & Removal Of Battery Terminal
      G02912267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Check hose and wiring connectors to make sure that they are connected securely and correctly.
  5. Non-reusable parts:
    1. Always replace cotter pins, gaskets, O-rings, oil seals, etc. with new ones.
    2. Non-reusable parts are indicated in component illustrations by the "diamond" symbols.
  6. Precoated parts

    Precoated parts are bolts, nuts, etc. that are coated with a seal lock adhesive at the factory.

    1. If a precoated part is retightened, loosened or move caused to in any way, it must be recoated with the specified adhesive.
    2. When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply new seal lock adhesive to the bolt, nut or threads.
      3. Fig 2: Applying Seal Lock Adhesive Over Bolts
      G02912268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Precoated parts are indicated in component illustrations by the "*" symbols.
  7. When necessary, use a sealer on gaskets to prevent leaks.
  8. Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.
  9. Use of special service tools (SST) and special service materials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure. A list of SST and SSM can be found in Preparation in this information.
  10. When replacing fuses, be sure the new fuse has the correct amperage rating. DO NOT exceed the rating or use one with a lower rating.
    Fig 3: Identifying Fuses
    G02912269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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