2009–2010 Toyota RAV4 Service Manual • (P/N 01-051014-00)

• Coverage note: These publications identify the 2006 North American Toyota RAV4, not a 2009–2010 model-year edition. They cover ACA33/ACA38 models with the 2AZ-FE four-cylinder and GSA33/GSA38 models with the 2GR-FE V6 in the 5-door body configuration. The U.S. lineup includes 2WD and 4WD models, while the Canadian entries are 4WD; Standard, Limited, and Sport grades are distinguished in the model tables.
• Model and production differences are explicit: ACA38 uses the U241E 2WD transaxle, ACA33 uses the U140F 4WD transaxle, GSA38 uses the U151E 2WD transaxle, and GSA33 uses the U151F 4WD transaxle. Affected repair chapters also separate 2005/11–2006/01 and 2006/01-onward production versions.
• Three bookmarked PDFs total 6,883 pages: New Car Features, 570 pages; Repair Manual, 5,885 pages, Pub. No. RM01M1U; and Electrical Wiring Diagram, 428 pages, Pub. No. EM01M1U. The New Car Features volume is marked First Printing Oct. 14, 2005, print code 01-051014-00.
• Engine sections cover SFI diagnosis, ETCS-i, VVT-i, returnless fuel and EVAP controls, air-fuel ratio and heated oxygen sensors, ignition, charging, starting, cooling, and lubrication, plus engine removal, timing-chain, valve-clearance, cylinder-head, and engine-unit repair as applicable to each engine.
• Drivetrain coverage includes DTC diagnosis and internal repair of all four automatic transaxles—fluid service, speed sensors, valve bodies, torque converters, oil pumps, clutch, brake, planetary-gear, and differential-case assemblies—along with A/T reset-memory routines, the GF1A transfer, active torque control 4WD, propeller and drive shafts, and the rear differential.
• Chassis and safety chapters document hydraulic brake repair, ABS, TRAC, enhanced VSC, Brake Assist, downhill and hill-start assist, Auto LSD, tester-assisted brake-actuator bleeding, yaw/deceleration-sensor zero-point calibration, EPS, wheel alignment, SRS and occupant-classification calibration, and tire-pressure transmitter registration.
• Cabin, body, and electrical coverage includes manual and power front seats, rear No. 1 and optional rear No. 2 seat assemblies, stow, walk-in, and remote-operation mechanisms, seat heaters and lumbar components, power and wireless door locks, windows, automatic and manual A/C, lighting, mirrors, sliding roof, standard and JBL audio, relay locations, wire routing, connector views, ground points, current-flow charts, and overall wiring diagrams.

Factory Repair and Diagnostic Coverage

The 570-page New Car Features volume is the architecture book. It explains construction and operation through system diagrams, section views, control charts, component layouts, and major technical specifications. It does not replace the detailed repair procedures in the 5,885-page Repair Manual, which carries the removal, installation, replacement, disassembly, reassembly, inspection, adjustment, and final-check information.

ECU-controlled sections follow a consistent workshop format: parts locations, system diagrams, troubleshooting flow, DTC charts, freeze-frame and Data List information, Active Tests, problem-symptom tables, ECU terminal checks, and circuit inspection. Tester-based routines are written around the Toyota intelligent tester with CAN VIM. Module or assembly replacement is followed by the required reset, registration, or calibration work rather than ending with mechanical installation.

Preparation chapters identify Toyota Special Service Tools and Special Service Materials by system. One example is SST 09387-00020, specified for clutch return-spring compression during automatic-transaxle repair. The manual also captures repair traps that are easy to miss without factory information: removing cylinder-head bolts in the wrong order can warp or crack the head, and allowing vehicle weight to load a hub while a drive shaft is removed can damage the hub bearing. SRS, fuel, brake, and refrigerant procedures carry their own isolation and handling cautions.

Wiring Diagrams and Technical Data

The 428-page Electrical Wiring Diagram is organized into relay locations, electrical wiring routing, individual system circuits, ground points, power-source current-flow charts, connector lists, connector part numbers, and the overall electrical wiring diagram. Representative circuits include Multiplex Communication System–CAN, Engine Control for 2AZ-FE and 2GR-FE, 4WD, ABS/TRAC/VSC/Downhill Assist/Hill-Start Assist/Auto LSD, SRS, and the JBL audio system.

The New Car Features appendix supplies the model-code matrix, drivetrain assignments, dimensions and vehicle weights, engine and performance data, automatic-transaxle gear and final-drive ratios, and brake, suspension, steering, generator, and speaker specifications. The Repair Manual’s Service Specifications section adds component-specific torque tables, approved fluids and capacities, clearances, wear and inspection limits, adjustment data, and electrical test values. Confirming the model code, production date, and transaxle before selecting a procedure is especially important because the 2WD/4WD and four-cylinder/V6 combinations use different driveline hardware and control strategies.