2023 Toyota RAV4 PHV (Prime) OEM Service & Repair Manual

Last Modified: 11-15-2024 6.11:8.1.0 Doc ID: RM100000001O1H1 Model Year Start: 2021 Model: RAV4 Prime Prod Date Range: [06/2020 - ] Title: INTRODUCTION: HOW TO USE THIS MANUAL: GENERAL INFORMATION; 2021 - 2025 MY RAV4 PHV RAV4 Prime [06/2020 - ] GENERAL INFORMATION GENERAL DESCRIPTION (a) This manual is written in accordance with SAE J2008. (b) Repair operations can be separated mainly into the following 3 processes: (1) Diagnosis (2) Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting (3) Final Inspection (c) 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 before and after performing any work. 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 work procedure properly. A list of SST and SSM is in the "Preparation" section of this manual. REPAIR PROCEDURES (a) A component illustration is placed under the title where necessary. (b) Non-reusable parts, grease application areas, precoated parts and torque specifications are noted in the component illustrations. The following illustration is an example. SYMBOL CONTENTS Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf) N*m (kgf*cm, ft.*lbf): Specified torque ● Non-reusable part ★ Precoated part Apply Lubricant Here Do not apply lubricants to the threaded parts CAUTION:

"Major areas involving basic vehicle performance such as moving/turning/stopping" indicates areas that require a higher degree of precision when tightening. *A Example - - *1 CYLINDER BOOT *2 PISTON SEAL *3 FRONT DISC BRAKE PISTON *4 FRONT DISC BRAKE BLEEDER PLUG *5 FRONT DISC BRAKE BLEEDER PLUG CAP *6 SET RING *7 DISC BRAKE CYLINDER ASSEMBLY LH - - Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf) N*m (kgf*cm, ft.*lbf): Specified torque ● Non-reusable part Lithium soap base glycol grease (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.

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 (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. SERVICE SPECIFICATIONS (a) Specifications are presented in boldface text throughout the manual. The specifications are also found in the "Specifications" section for reference. TERM DEFINITIONS 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 INTERNATIONAL SYSTEM OF UNITS (a) The units used in this manual comply with the International System of Units (SI UNIT) standard. Other units from the metric system and the English system are also provided. Example: Torque: 30 N·m {306 kgf·cm, 22 ft·lbf}

Last Modified: 11-15-2024 6.11:8.1.0 Doc ID: RM100000001O1H2 Model Year Start: 2021 Model: RAV4 Prime Prod Date Range: [06/2020 - ] Title: INTRODUCTION: IDENTIFICATION INFORMATION: VEHICLE IDENTIFICATION AND SERIAL NUMBERS; 2021 - 2025 MY RAV4 PHV RAV4 Prime [06/2020 - ] VEHICLE IDENTIFICATION AND SERIAL NUMBERS VEHICLE IDENTIFICATION NUMBER (a) The vehicle identification number is stamped on the vehicle body and on the certification label or name label as shown in the illustration. *a Vehicle Identification Number *b Certification Label or Name Label ENGINE SERIAL NUMBER AND TRANSMISSION/TRANSAXLE CODE (a) The engine serial number is stamped on the area shown in the illustration. *A A25A-FXS *a Engine Serial Number (b) The transmission/transaxle serial number, transmission/transaxle code and transmission/transaxle type are stamped on or embossed onto the area shown in the illustration.

*A P810 *a Transmission/Transaxle Serial Number *b Transmission/Transaxle Code *c Transmission/Transaxle Type *A Q610 *a Transmission/Transaxle Code

Last Modified: 11-15-2024 6.11:8.1.0 Doc ID: RM100000001O1H4 Model Year Start: 2021 Model: RAV4 Prime Prod Date Range: [06/2020 - ] Title: INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION; 2021 - 2025 MY RAV4 PHV RAV4 Prime [06/2020 - ] PRECAUTION 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 work. 3 Safety procedures When working with 2 or more persons, be sure to check the safety of 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 vehicle at the specified locations with safety stands. When lifting up the vehicle, use appropriate safety equipment. 4 Preparation of tools and measuring equipment Before starting work, prepare a tool stand, SST, measuring equipment, oil, and any replacement parts required.

5 Removal and installation, disassembly and assembly operations Diagnose with a thorough understanding of proper procedures and of the reported problem. Before removing any parts, check the general condition of the assembly and for deformation and damage. If the procedure is complicated, take notes. For example, note the total number of electrical connections, bolts or hoses removed. Add matchmarks to ensure reassembly of components in the 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. 6 Removed parts Place the removed parts in a separate box to avoid mixing them up with new parts or contaminating the 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. 7* Checks to perform after work is finished Make sure that removed and installed parts (oil filler cap, level dipstick, floor mat, etc.) are properly installed/tightened. Make sure that none of the cloths or tools that were used have been left in the engine compartment or within the vehicle. Check that there are no oil leaks. CAUTION: *: Be sure to perform these checks properly, not performing these checks properly after finishing work can lead to a serious accident or injury. (b) JACKING UP AND SUPPORTING THE 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 *a Seal Lock Adhesive (1) Precoated parts are bolts and nuts that are coated with 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 appropriately to that part. (4) Some seal lock agents harden slowly. You may have to wait for the seal lock adhesive to harden. (d) SMALL-HEAD BOLTS (1) Small-head bolts are bolts with a smaller bolt head than standard bolts with the same thread diameter and flange diameter.

*A Example: M6 Bolt *a Ring Mark *b Black (2) Although the size of the bolt head is smaller than a standard bolt, the tightening torque remains unchanged as the thread diameter and flange diameter are not different. Make sure to tighten all small-head bolts to the correct torque indicated in the repair manual. (3) As the force applied to the sides of the head of a small-head bolt is higher than that of a standard bolt when the same tightening torque is used, the height of the bolt head has been increased to ensure its strength. (4) For identification purposes, small-head bolts are black and the bolt head is marked with a ring. (e) GASKETS (1) When necessary, use a sealant on gaskets to prevent leaks. (f) BOLTS, NUTS AND SCREWS (1) Carefully follow all of the specifications for tightening torque. Always use a torque wrench. (2) Make sure that no foreign matter (burrs, paint, etc.) gets trapped under the heads of the bolts and nuts when tightening them. (g) FUSES

*a NG *b OK (1) When inspecting a fuse, check that the wire of the fuse is not broken. (2) If the wire of a fuse is broken, confirm that there are no shorts in its circuit. (3) When a fuse is replaced, a fuse with the same amperage rating must be used. ILLUSTRATION SYMBOL PART NAME ABBREVIATION FUSE FUSE MEDIUM CURRENT FUSE M-FUSE HIGH CURRENT FUSE H-FUSE FUSIBLE LINK FL CIRCUIT BREAKER CB FUSIBLE LINK FL (h) 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 damaged clips with new ones. SHAPE (EXAMPLE) REMOVAL/INSTALLATION Remove the clips with a clip remover or pliers. Remove the clips using a clip remover or a screwdriver with its tip wrapped with protective tape. Remove the clips with a wide scraper to prevent panel damage.

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2023 Toyota RAV4 PHV (Prime) OEM Service & Repair Manual

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2023 Toyota RAV4 PHV (Prime) OEM Service & Repair Manual

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What's Inside the RAV4 PHV (Prime) Factory Repair Manual

General Information, Maintenance and High-Voltage Safety Reference

2.5L A25A-FXS Dynamic Force Engine Mechanical

Hybrid Powertrain and High-Voltage Battery Control

Fuel, Intake, Exhaust and Emission Control Systems

Cooling, Lubrication and Hybrid Start-Stop Systems

P810 and Q610 Hybrid Transaxle Service

E-Four All-Wheel Drive System and Driveline Components

Chassis, Suspension and Electronic Power Steering

Electronically Controlled Braking (ECB) System

Infotainment, Telematics and Driver Assist Calibration

Power Distribution, Network Communication and Lighting

Interior Cabin and Exterior Equipment Procedures

Collision and Structural Body Repair

Why This RAV4 Prime Manual Works for Pros and DIYers

Format and Compatibility

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