This procedure covers the removal and replacement of the serpentine belt on the 2019-2024 Toyota RAV4 with the 2.5L I4 gasoline engine, including tensioner operation and belt routing verification.

Warnings

Tools required

Parts

• Serpentine belt × 1 — Use OEM specification for 2.5L I4 RAV4

Preparation

1. Ensure engine is completely cool to the touch
2. Park vehicle on level surface and engage parking brake
3. Open hood and secure with prop rod
4. Photograph or diagram the existing belt routing path for reference before removal

Procedure

1. 1

   Locate belt routing diagram
   Locate the belt routing diagram on the underside of the hood or on the radiator support. If the diagram is missing or illegible, take a clear photo of the current belt routing around all pulleys before removal. The 2.5L I4 RAV4 routes the belt around the crankshaft, water pump, alternator, A/C compressor, and idler pulleys.
2. 2

   Access the belt tensioner
   Identify the automatic belt tensioner assembly located on the front right side of the engine (passenger side when viewed from driver's seat). The tensioner has a 14mm hex drive point in the center of the tensioner arm.
3. 3

   Inspect belt condition
   Before removal, inspect the existing belt for cracks, glazing, fraying, or excessive wear. Check all pulleys for smooth rotation and listen for bearing noise. Any rough or noisy pulleys should be addressed before installing the new belt.
4. 4

   Release belt tension
   Insert a 3/8" breaker bar or serpentine belt tool into the 14mm square hole in the belt tensioner arm. Rotate the tensioner clockwise (toward the passenger side fender) to release tension on the belt. The tensioner will move approximately 45 degrees to provide slack.
   ⚠Maintain firm control of the breaker bar. The tensioner spring is strong and will forcefully return to position if released suddenly.
5. 5

   Remove old belt
   While holding the tensioner in the released position, slip the belt off the alternator pulley or any other accessible pulley. Slowly release the tensioner back to its resting position. Remove the belt from all remaining pulleys and extract it from the engine bay.
6. 6

   Inspect tensioner and pulleys
   With the belt removed, manually spin each pulley to check for rough bearings or excessive play. Inspect the tensioner arm for full range of motion and proper spring tension. Check all pulley surfaces for damage, wear, or contamination from oil or coolant.
7. 7

   Route new belt
   Following the belt routing diagram or reference photo, route the new belt around all pulleys EXCEPT the alternator pulley or another easily accessible pulley that will be used for final installation. Ensure the ribbed side of the belt contacts all pulleys except any smooth idler pulleys. The belt should sit centered in each pulley groove.
8. 8

   Install belt on final pulley
   Using the breaker bar, rotate the tensioner clockwise again to release tension. Guide the belt onto the final pulley (typically the alternator), ensuring proper seating in all pulley grooves. Verify the ribbed side contacts the pulley correctly.
9. 9

   Release tensioner and verify installation
   Slowly and carefully release the tensioner, allowing it to apply proper tension to the belt. Remove the tool from the tensioner. Visually verify the belt is properly seated in all pulley grooves and follows the correct routing path.
10. 10

    Perform final checks
    Manually rotate the crankshaft pulley clockwise 2-3 full revolutions using a socket on the crankshaft bolt. Observe the belt tracking on all pulleys to ensure it remains centered and does not slip off. Check that the belt does not contact any engine covers, brackets, or other components.

Reassembly

1. No disassembly was required for this procedure
2. Ensure no tools or materials are left in the engine compartment
3. Close and secure the hood

Verification

• Start the engine and allow it to idle while observing belt operation from the side
• Listen for any squealing, chirping, or unusual noises that would indicate improper tension or misalignment
• Observe belt tracking on all pulleys during idle - the belt should run smoothly without slipping or wobbling
• Turn on electrical loads (headlights, A/C) to verify alternator pulley operation under load
• Shut off engine and perform a final visual inspection to confirm belt remains properly seated
• Test drive the vehicle and verify no belt-related noises occur during acceleration or at various engine speeds

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