This procedure covers the complete state safety inspection process for a 2019-2024 Toyota RAV4 with 2.5L I4 gas engine, including all required safety systems, lighting, emissions, and mechanical component checks.

Warnings

Tools required

Preparation

1. Park vehicle on level surface and apply parking brake
2. Ensure engine is cold or sufficiently cooled for safe undercarriage inspection
3. Have vehicle registration and previous inspection documents available
4. Verify VIN matches registration documents
5. Place wheel chocks behind rear wheels before lifting

Procedure

1. 1

   OBD-II System and Emissions Check
   Connect OBD-II scanner to diagnostic port located below steering column on driver side. Turn ignition to ON position without starting engine. Check for stored diagnostic trouble codes (DTCs). Verify all emissions monitors are in 'Ready' status except EVAP which may show 'Not Ready'. Check that Malfunction Indicator Lamp (MIL/Check Engine Light) illuminates during bulb check and extinguishes after engine start. Record any DTCs found - any active emissions-related codes will result in inspection failure.
2. 2

   Exterior Lighting Inspection
   Verify operation of all exterior lights: headlights (low and high beam), front turn signals, front side markers, taillights, brake lights, reverse lights, rear turn signals, license plate light, and hazard flashers. Check that headlight aim is properly adjusted - low beams should not blind oncoming traffic. Inspect all lenses for cracks, excessive cloudiness, or damage. Verify correct color of all lenses (amber for front turn signals, red for rear). Test daytime running lights if equipped.
3. 3

   Horn and Windshield Wiper System Check
   Test horn operation - should produce adequate sound. Operate windshield wipers at all speeds (intermittent, low, high) and verify proper blade contact across entire windshield. Test windshield washer spray pattern and fluid level. Inspect wiper blades for tears, hardening, or separation from frame. Check windshield for cracks or chips in driver's primary vision area - damage larger than 3/4 inch in swept area typically fails inspection.
4. 4

   Interior Safety Equipment Inspection
   Check all seatbelts (driver, passenger, and rear seats) for proper retraction, locking mechanism function, and webbing condition with no fraying or cuts. Verify airbag system warning light illuminates briefly during startup and then extinguishes - constant illumination indicates system fault. Test parking brake operation and holding ability. Verify rear view mirror and side mirrors are securely mounted. Check steering wheel for excessive freeplay (should not exceed 2 inches before wheels begin to turn).
5. 5

   Tire and Wheel Inspection
   Check tire pressure on all four tires against door placard specification (typically 35 PSI front and rear for RAV4). Measure tread depth at multiple points across each tire - minimum legal depth is typically 2/32 inch, but 4/32 inch or greater is recommended. Inspect tires for uneven wear, bulges, exposed cords, or sidewall damage. Verify all lug nuts are present and properly torqued. Check for proper tire size matching vehicle specifications. Inspect wheels for cracks or significant damage.
6. 6

   Brake System Inspection
   With assistant or brake pedal depressor, verify brake lights illuminate when pedal is pressed. Start engine and test brake pedal feel - should be firm with approximately 1-2 inches of travel before resistance. Pedal should not sink to floor under sustained pressure. Listen for unusual noises during brake application. Check brake fluid level in reservoir - should be between MIN and MAX marks. Fluid should be clear to light amber, not dark or contaminated.
7. 7

   Front Suspension and Steering Inspection
   Safely raise front of vehicle using floor jack at designated lift points (front subframe reinforcements) and support on jack stands at pinch weld locations. Inspect front struts for leaks or damage. Check ball joints and tie rod ends for excessive play by grasping tire at 12 and 6 o'clock positions and checking for vertical movement. Check for horizontal play at 3 and 9 o'clock positions. Inspect CV axle boots for tears or grease leakage. Check for loose or damaged steering components.
   ⚠Never work under vehicle supported only by floor jack. Always use properly rated jack stands
8. 8

   Undercarriage and Exhaust System Inspection
   From under vehicle, inspect exhaust system for leaks, excessive rust, or damage. Pay special attention to flex pipe section and catalytic converter mounting. Check for proper exhaust hangers with no broken or missing components. Inspect fuel lines for leaks, damage, or excessive corrosion. Check brake lines and hoses for leaks, cracks, or damage. Examine frame and subframe for excessive rust or structural damage. Verify splash shields and under-trays are present and properly secured.
9. 9

   Rear Suspension and Brake Inspection
   Lower front of vehicle and raise rear using floor jack at rear axle beam center. Support on jack stands at rear pinch weld locations. Inspect rear struts for leaks. Check rear brake rotors for excessive wear, scoring, or minimum thickness. On models with rear drum brakes, verify adjustment is adequate. Inspect parking brake cables for fraying or binding. Check rear suspension bushings for deterioration or damage. Inspect trailing arms and lateral links for damage or excessive corrosion.
10. 10

    Body and Glass Final Inspection
    Lower vehicle completely. Inspect all glass (windshield, side windows, rear window) for cracks or damage. Check all doors including rear hatch for proper operation and latching. Verify hood and hood latch function properly. Check for sharp or protruding edges on body panels that could pose safety hazard. Verify license plates are properly mounted and illuminated. Check fuel door and fuel cap for proper sealing. Inspect for any fluid leaks under vehicle after running engine briefly.

Reassembly

1. Ensure all wheels are properly torqued to 140 Nm (103 lb-ft) in star pattern if removed
2. Remove jack stands and lower vehicle completely
3. Remove wheel chocks
4. Verify all inspection equipment has been removed from vehicle

Verification

• Start engine and verify no warning lights remain illuminated on instrument cluster
• Test drive vehicle briefly to verify brakes, steering, and handling feel normal
• Re-check for any fluid leaks after test drive
• Document all findings on official state inspection form
• Issue inspection certificate if all systems pass, or provide detailed failure report with specific items requiring correction

More procedures for this vehicle