Originally Posted by RockHardRich
Thought these step by step instructions might be helpful to anyone planning on installing a serpentine belt on their Rav4 2004.
1) Remove the right front wheel (this makes the job much easier).
2) Remove enough of the hardware holding the splash guard in place to move it out of your way (I removed the three screws I needed to with a phillips head screwdriver, or you can use a 10mm socket and appropriate drive. I removed the two remaining push in fasteners with a small slotted screwdriver).
3) Using a long breaker bar (I used a 17” half inch drive Craftsman) and a 19mm half inch drive 6 point socket, (I used a Craftsman socket that was 1 1/2" deep) compress the tensioner (use a slow and steady pressure to achieve this compression). There’s only one 19mm bolt on the tensioner assembly, so you can’t make a mistake (I attacked it from the top side of the motor, pulling the breaker bar toward the front of the vehicle).
4) While keeping the tensioner compressed, have an assistant (in my case it was my beloved fiancée Ann) slip the belt off the small, smooth idler pulley. You will then be able to work the belt off the rest of the pulleys.
5) Install the new belt (its non directional, so you don’t have to worry about that) by wrapping around the power steering pulley first. Make sure you leave the small, smooth idler pulley for last. That’s the easiest pulley to finish the installation with.
6) After you’ve checked to see that the new belt is wrapped around all the pulleys correctly (not only the orientation, but that the belt’s grooves are mated to all the pulleys’ grooves properly), start the engine and make sure the belt turns smoothly.
7) Reinstall the splash guard, the wheel, and you’re good to go.
Just as insurance, I had a Chilton manual available to me, so that I could keep referring back to the serpentine belt installation diagram when needed.
My belt decided to leave my car on the dark wet evening of Friday in North Wales... Nice Mr AA Man came and rescued me by finding amongst his selection of random 7 rib belts in his van, one that fitted perfectly to cover the power steering pump, water pump and alternator so I could continue and steer, charge the lights and have cool water. Worked a treat and I drove home yesterday too. Only bypassed the aircon but that's no loss at all.
My main problem now is finding a correct part number. By a (long) process of elimination I think it's a 7PK1595 but can someone confirm this please? 1AZ-FE on a 2003, Auto box.
Also perhaps a supplier in the UK. Having watched the mechanic and held the brolly for him I'm quite happy to do the swap myself.
In the none-too-good Haynes manual it suggests changing this belt at 60,000 miles although I can't remember ever seeing/hearing warnings of drivers saying this belt (like the earlier timing belt on the 4.1) was a vital job to be done. My car has turned 65,000 miles so perhaps I was on borrowed time?
Thanks for the blow-by-blow above, it will surely assist me when I can find a new belt. I'll keep the shorter one for a spare!