Toyota RAV4 2000-05

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Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the engine coolant reservoir.
  4.  
  5. Remove the air cleaner cap assembly, as follows:
    1. Disconnect the following:
    2.  



    Skid control relay connectors
     
    High tension cord from the air cleaner hose and resonator
     
    Intake Air Temperature (IAT) sensor connector
     
    Positive Crankcase Ventilation (PCV) hose from the air cleaner hose
     
    Air hose from the air cleaner cap assembly
     
    The air cleaner cap assembly from the air cleaner case assembly by removing the 4 clamps.
     
    Loosen the hose clamp and disconnect the air cleaner hose from the throttle body.
     
    Remove the air cleaner cap assembly.
     

  6.  
  7. Remove or disconnect the following:
    1. Vacuum Switching Valve (VSV) from the air cleaner case assembly
    2.  
    3. 3 bolts and the air cleaner case assembly
    4.  
    5. Starter electrical connectors
    6.  
    7. Both bolts and the starter
    8.  

  8.  

To install:



Install or connect the following:
  1. Starter. Tighten the bolts to 29 ft. lbs. (38 Nm).
  2.  
  3. Starter electrical connectors
  4.  
  5. Air cleaner case assembly
  6.  
  7. VSV to the air cleaner case assembly
  8.  

 
Install or connect the air cleaner cap assembly, as follows:

Install the air cleaner cap assembly.
 
Connect the air cleaner hose to the throttle body and tighten the hose clamp.
 
Install the air cleaner cap assembly to the air cleaner case assembly by installing the 4 clamps.
 
Connect the following:
 

  1. Air hose to the air cleaner cap assembly
  2.  
  3. PCV hose to the air cleaner hose
  4.  
  5. IAT sensor connector
  6.  
  7. High tension cord to the air cleaner hose and resonator
  8.  
  9. Skid control relay connectors
  10.  

 
Install the engine coolant reservoir.
 

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove the engine coolant reservoir.
  4.  
  5. Remove the air cleaner cap assembly, as follows:
    1. Disconnect the following:

      Skid control relay connectors
       
      High tension cord from the air cleaner hose and resonator
       
      Intake Air Temperature (IAT) sensor connector
       
      Positive Crankcase Ventilation (PCV) hose from the air cleaner hose
       
      Air hose from the air cleaner cap assembly
       

    2.  
    3. The air cleaner cap assembly from the air cleaner case assembly by removing the 4 clamps.
    4.  
    5. Loosen the hose clamp and disconnect the air cleaner hose from the throttle body.
    6.  
    7. Remove the air cleaner cap assembly.
    8.  

  6.  
  7. Remove or disconnect the following:

    Vacuum Switching Valve (VSV) from the air cleaner case assembly
     
    3 bolts and the air cleaner case assembly
     
    Starter electrical connectors
     
    Both bolts and the starter
     

  8.  

To install:

  1. Install or connect the following:

    Starter. Tighten the bolts to 29 ft. lbs. (38 Nm).
     
    Starter electrical connectors
     
    Air cleaner case assembly
     
    VSV to the air cleaner case assembly
     

  2.  
  3. Install or connect the air cleaner cap assembly, as follows:
    1. Install the air cleaner cap assembly.
    2.  
    3. Connect the air cleaner hose to the throttle body and tighten the hose clamp.
    4.  
    5. Install the air cleaner cap assembly to the air cleaner case assembly by installing the 4 clamps.
    6.  
    7. Connect the following:

      Air hose to the air cleaner cap assembly
       
      PCV hose to the air cleaner hose
       
      IAT sensor connector
       
      High tension cord to the air cleaner hose and resonator
       
      Skid control relay connectors
       

    8.  

  4.  
  5. Install the engine coolant reservoir.
  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine coolant reservoir.
  6.  
  7. Remove the air cleaner cap assembly, as follows:
    1. Disconnect the following:

      Skid control relay connectors
       
      High tension cord from the air cleaner hose and resonator
       
      Intake Air Temperature (IAT) sensor connector
       
      Positive Crankcase Ventilation (PCV) hose from the air cleaner hose
       
      Air hose from the air cleaner cap assembly
       

    2.  
    3. The air cleaner cap assembly from the air cleaner case assembly by removing the 4 clamps.
    4.  
    5. Loosen the hose clamp and disconnect the air cleaner hose from the throttle body.
    6.  
    7. Remove the air cleaner cap assembly.
    8.  

  8.  
  9. Remove or disconnect the following:

    Vacuum Switching Valve (VSV) from the air cleaner case assembly
     
    3 bolts and the air cleaner case assembly
     
    Starter electrical connectors
     
    Both bolts and the starter
     

  10.  

To install:

  1. Install or connect the following:

    Starter. Tighten the bolts to 29 ft. lbs. (38 Nm).
     
    Starter electrical connectors
     
    Air cleaner case assembly
     
    VSV to the air cleaner case assembly
     

  2.  
  3. Install or connect the air cleaner cap assembly, as follows:
    1. Install the air cleaner cap assembly.
    2.  
    3. Connect the air cleaner hose to the throttle body and tighten the hose clamp.
    4.  
    5. Install the air cleaner cap assembly to the air cleaner case assembly by installing the 4 clamps.
    6.  
    7. Connect the following:

      Air hose to the air cleaner cap assembly
       
      PCV hose to the air cleaner hose
       
      IAT sensor connector
       
      High tension cord to the air cleaner hose and resonator
       
      Skid control relay connectors
       

    8.  

  4.  
  5. Install the engine coolant reservoir.
  6.  

2.4L Engine


Before servicing the vehicle, refer to the Precautions section.
 
Disconnect the hose from the transmission level gauge.
 
Disconnect the wires from the starter.
 
Remove the 2 bolts and lift out the starter.
 
Installation is the reverse of removal. Torque the bolts to 27 ft. lbs. (37 Nm).
 

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect the hose from the transaxle level gauge.
  6.  
  7. Disconnect the wires from the starter.
  8.  
  9. Remove the 2 bolts and lift out the starter.
  10.  
  11. Installation is the reverse of removal. Torque the bolts to 27 ft. lbs. (37 Nm).
  12.  

Testing & Troubleshooting



Voltage Drop Test

NOTE
The battery must be in good condition and fully charged prior to performing this test.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disable the ignition system by unplugging the coil pack. Verify that the vehicle will not start.
  4.  
  5. Connect a voltmeter between the positive terminal of the battery and the starter B+ circuit.
  6.  
  7. Turn the ignition key to the START position and note the voltage on the meter.
  8.  
  9. If voltage reads 0.5 volts or more, there is high resistance in the starter cables or the cable ground, repair as necessary. If the voltage reading is ok proceed to the next step.
  10.  
  11. Connect a voltmeter between the positive terminal of the battery and the starter M circuit.
  12.  
  13. Turn the ignition key to the START position and note the voltage on the meter.
  14.  
  15. If voltage reads 0.5 volts or more, there is high resistance in the starter. Repair or replace the starter as necessary.
    NOTE
    Many automotive parts stores have starter bench testers available for use by customers. A starter bench test is the most definitive way to determine the condition of your starter.

  16.  

 
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