1995–1998 Toyota RAV4 2.0L, 2.4L, 3.0L, 3.4L Service & Repair Manual (P/N RM057U)

• Covers 1997–1998 and 1999–2000 Toyota RAV4 3S-FE 2.0L engine repair, including valve-clearance and timing-belt work, camshafts, cylinder head and valve train, cylinder block, crankshaft seals, water and oil pumps, oil pan, oil cooler, and lubrication-system procedures.
• Documents 1996 RAV4 A241E/A540H fluid service and linkage adjustments, A540H 4WD automatic transaxle and transfer-case overhaul, and E250/E250F 5-speed manual transaxle disassembly, inspection, preload selection, and reassembly.
• Includes brake and ABS diagnosis, axle and differential repair, front and FWD rear-suspension service, power-steering pump and rack overhaul, SRS fault isolation, manual A/C and heater testing, starting/charging, cooling-fan, and body-electrical procedures.
• Provides 1999 RAV4 system wiring diagrams and Toyota’s May 2000 RAV4 Electrical Wiring Diagram for ACA20/ACA21 and ZCA25/ZCA26, with relay locations, harness routing, ground points, power-source flow charts, connector data, and overall circuit layouts.
• Adds limited 1995–1996 4Runner automatic-transmission service, a 1996 4Runner SRS article, and two 1998 RAV4 EV bulletins; these are supplemental sections rather than full 4Runner or RAV4 EV repair manuals.

Coverage and Document Structure

This 49-PDF set totals 1,808 pages and combines year-specific RAV4 articles with shared Toyota/Lexus service sections. Most chassis, drivetrain, HVAC, electrical, and body material is identified as 1999 or 1999–2000 coverage. Earlier content includes a 1997–98 3S-FE engine article, 1996 RAV4 automatic-transmission service data, and a 1997–98 multi-model transmission removal and installation section.

Only the 2.0L 3S-FE receives internal engine repair coverage. The 2.4L, 3.0L, and 3.4L references occur in shared automatic-transmission application and service tables; they are not engine-overhaul chapters. RAV4 automatic-overhaul coverage centers on the A540H. A340E, A340F, and A340H data appear in the limited 4Runner transmission material, not as a complete A340 internal overhaul manual.

The 2000 EWD is electrical-only coverage for the ACA20/21 and ZCA25/26 series. Its foreword directs chassis/body and 1ZZ-FE or 1AZ-FE engine repair to separate publications RM777E, RM773E, RM774E, and NCF185E; those manuals are outside this PDF set. The RAV4 EV files are supplements: EV002-01 covers DTC 2846/22 and traction-battery terminal contamination, while EV003-99 supplies correction pages associated with RM600-U. The referenced full EV manuals RM845U and RM600-U are not included.

Engine and Transaxle Specifications

The paired 3S-FE articles cover cold valve-clearance inspection and shim selection, engine removal and installation, cylinder-head and manifold work, timing-belt installation, camshaft and valve-lifter service, crankshaft seals, water-pump and oil-pan service, and internal inspection of the valve train, pistons, rods, crankshaft, bearings, and cylinder block. Lubrication coverage includes the oil pump and oil cooler, with related inspection limits and assembly data.

A540H material includes symptom diagnosis, clutch-and-brake application charts, time-lag and road tests, shift and lockup checks, stall and hydraulic-pressure testing, torque-converter checks, and internal disassembly. Exploded views and inspection procedures cover the oil pump, clutches, planetary gearsets, brakes, valve body, overdrive unit, differential, final drive, thrust components, check balls, springs, and clutch-pack clearances. The E250/E250F section covers input and output shafts, oil pump, shift mechanism, forks, synchronizers, differential assemblies, bearing preload, shim selection, and reassembly.

Related drivetrain chapters cover front and rear axle shafts, the rear integral differential, drive shaft, center differential lock, and A540H transfer case control-solenoid testing and overhaul.

Shop Workflow and Safety Requirements

ABS coverage includes DTC retrieval and clearing, relay and actuator tests, wheel-speed and 4WD deceleration-sensor circuits, pump-motor faults, bleeding, actuator removal, and pedal or booster adjustments. Power-steering sections include bleeding, pressure testing, pump repair, rack removal, seal and bushing inspection, control-valve setup, and assembly-preload checks. Manual A/C material covers performance testing, amplifier circuits, thermistor and pressure-switch diagnosis, compressor controls, and major refrigerant-system components.

SRS material covers the 1999 RAV4 modules, front sensors, seat-belt pretensioners, spiral cable, sensor assembly, post-collision inspection, code retrieval and clearing, and circuit-specific diagnosis. Airbag and steering-column work requires system deactivation and the specified backup-power waiting period. The RAV4 EV bulletin carries separate high-voltage isolation, insulated-glove, and voltage-verification requirements.

Several manual-specific repair traps are called out. An incorrectly indexed SRS spiral cable can be severed and disable the restraint system. On the A540H valve body, changing the retainer-to-plunger-sleeve position can alter line pressure. The E250/E250F major housings use liquid gasket rather than conventional cut gaskets, so incorrect joint preparation can cause sealing failure.

Torque Values and Diagnostic Data

The set provides component-specific torque tables, fluid capacities and approved-fluid references, transaxle pressure and shift specifications, clutch-pack and end-play measurements, bearing-preload and shim-selection data, engine wear limits, brake and steering test values, and electrical pin-voltage, resistance, continuity, and amperage checks. Tool references include valve-clearance adjuster 09248-55040, A/T tool set 09350-32014, SRS diagnosis check wire 09843-18020, and airbag deployment equipment 09082-00700/09082-00740.

Diagram examples include the 2.0L engine-performance circuits, anti-lock brake circuits, supplemental-restraint circuit, A/T circuit, center-differential-lock circuit, and power/ground distribution diagrams. The 2000 EWD adds relay-location views, harness and splice routing, current-flow charts, connector lists and part numbers, ground-point maps, and the overall electrical wiring diagram. Exploded views include the A540H valve body and check-ball layouts, automatic-transaxle clutch and planetary assemblies, E250/E250F transmission and differential assemblies, ABS actuator, and RAV4 power-steering rack and pump.