Toyota RAV4 (XA40) 2013-2018 Service Manual: Radiator
Components



On-vehicle inspection
- Check radiator reservoir cap subassembly

- Measure the valve opening pressure.

- If there are water stains or foreign matter on oring
1, clean it with water and finger scouring.
- Check that o-ring 1 is not deformed, cracked or
swollen.
- Apply engine coolant to o-ring 1 and rubber
packing 2 before using a radiator cap tester.
- When using the cap tester, tilt it more than 30
degrees.
- Pump the cap tester several times, and check
the maximum pressure*.
Pump speed:
1 pump per second
*: Even if the cap cannot maintain the
maximum pressure, it is not a defect.
Judgment criterion 
If the maximum pressure is less than the
minimum standard value, replace the radiator
reservoir cap sub-assembly.
On-vehicle cleaning
- Inspect radiator assembly

- Check that the radiator and condenser are not
blocked with leaves, dirt, or insects. Clean the hose
connections.
If the fins are blocked, wash them with water or a
steam cleaner.
Notice:
- If the distance between the steam cleaner and
core is too close, the fins may be damaged.
- Keep the following injection distance.
Standard injection distance 
- If the fins are bent, straighten them with a
screwdriver or pliers.
- Never apply water directly onto the electronic
components.
- Dry the fins with compressed air.
Removal
- Disconnect cable from negative battery
terminal
Caution:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
- Remove radiator support opening cover
- Remove battery clamp
- Remove the bolt, nut and clamp.
- Remove battery
- Remove no. 1 Engine under cover
- Drain engine coolant (see page co-6)
- Remove radiator grille sub-assembly (see
page et-6)
- Disconnect hood lock switch connector
- Disconnect no. 1 Water by-pass hose
- Disconnect the hose from the radiator reservoir.
- Disconnect no. 5 Water by-pass hose
- Disconnect the hose from the radiator.
- Remove no. 1 Water by-pass pipe
- Disconnect the pipe from the no. 1 Radiator hose.
- Remove the 2 bolts and the pipe.


- Disconnect cooling fan motor harness
- Disconnect the 2 fan motor connectors from the 2
fan motors.
- Detach the 5 harness clamps from the fan shroud
and upper radiator support.

- Disconnect horn connector
- Disconnect the 2 horn connectors.
- Remove upper radiator support bracket
- Remove the 2 bolts and the 2 upper radiator support
brackets.

- Remove no. 2 Fan shroud

- Remove the 2 bolts.
- Detach the 2 claws and no. 2 Shroud.
- Remove upper radiator support subassembly

- Remove the 4 bolts and upper radiator support with
hood lock.
- Disconnect no. 1 Radiator hose
- Disconnect no. 2 Radiator hose
- Disconnect no. 2 Water by-pass hose
Disconnect the by-pass hose from the radiator reservoir
and radiator.

- Remove radiator assembly

- Separate the cooler condenser from the radiator.
Hint:
After detaching the condenser, make sure that all 4
fan shroud cushions are present
- Remove the radiator with the 2 radiator support
lowers.
Hint:
After detaching the radiator, make sure that both
radiator support lowers are present.
- Remove fan shroud with cooling fan

- Remove the 2 bolts and radiator from the fan
shroud.
Installation
- Install fan shroud with cooling fan

- Install the fan shroud with cooling fan with the 2
bolts to the radiator.
Torque: 10.5 N*m (107 kgf*cm, 8 ft.*Lbf)
- Install radiator assembly
- Install the 4 fan shroud cushions to the cooler
condenser.
- Set the cooler condenser to the fan shroud.
- Install the 2 radiator support lower cushions to the
fan shroud.
- Install the radiator with cooler condenser and fan
shroud to the radiator support lower.

- Install upper radiator support subassembly

- Install the upper radiator support with the 4 bolts.
Torque: 19 n*m (194 kgf*cm, 14 ft.*Lbf)
- Install no. 2 Fan shroud

- Attach the 2 claws to install the no. 2 Fan shroud
and install the 2 bolts.
Torque: 10.5 N*m (107 kgf*cm, 8 ft.*Lbf)
- Install upper radiator support bracket
- Install the bracket with the 2 bolts.
Torque: 19 n*m (194 kgf*cm, 14 ft.*Lbf)

- Connect horn connector
- Connect the 2 horn connectors.
- Connect no. 2 Water by-pass hose
- Connect the by-pass hose to the radiator and
radiator reservoir.
Hint:
The direction of the hose clamp is indicated in the
illustration.
- Connect no. 2 Radiator hose
Hint:
The direction of the hose clamp is indicated in the
illustration.
- Connect no. 1 Radiator hose
Hint:
The direction of the hose clamp is indicated in the
illustration.

- Connect cooling fan motor harness
- Attach the harness with the 5 clamps.
- Connect the 2 fan motor connectors.

- Install no. 1 Water by-pass pipe
- Install the by-pass pipe with the 2 bolts to the upper
radiator support.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*Lbf)
- Connect the no. 1 Radiator hose to the pipe.
Hint:
The direction of the hose clamp is indicated in the
lustration.
- Connect no. 5 Water by-pass hose
- Connect the by-pass hose to the radiator.
Hint:
The direction of the hose clamp is indicated in the
lustration.
- Connect no. 1 Water by-pass hose
- Connect the by-pass hose to the radiator and
radiator reservoir.
Hint:
The direction of the hose clamp is indicated in the
illustration.

- Connect hood lock switch connector

- Install radiator grille sub-assembly (see
page et-10)
- Install battery
- Install battery clamp
- Attach the hook of the battery clamp to the battery
bracket.
- Temporarily tighten the nut and install the bolt.
- Adjust the battery clamp's position.
- Fully tighten the bolt and nut.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*Lbf) for bolt
5.0 N*m (51 kgf*cm, 44 in.*Lbf) for nut
- Connect cable to negative battery
terminal
- Add engine coolant (see page co-6)
- Check for engine coolant leaks (see page
co-1)
- Install radiator support opening cover
On-vehicle inspection
Disconnect cable from negative battery
terminal
Caution:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airb ...
Other materials:
Rear axle hub and bearing
Components
On-vehicle inspection
Remove rear wheel
Disconnect rear drive shaft assembly lh
(for 4wd)
Disconnect the drive shaft (see page ds-69).
Remove rear disc brake cylinder assembly
lh (see page br-55)
Remove rear disc (see page br-57)
Check bearing backlash a ...
Inspection
Inspect oil pump assembly
Turn the drive gear with 2 screwdrivers and make
sure it rotates smoothly.
Notice:
Be careful not to damage the oil seal lip.
Inspect clearance of oil pump assembly
Push the driven gear to one side of the body. Using
a feeler gauge, measur ...
Fog light switch
The fog lights offer
improved visibility in difficult
driving conditions,
such as in rain and fog.
Operating procedure
*1 or
*2 Turns the
fog lights off
Turns the fog lights on
*1:For the U.S.A.
*2:For Canada
â– Fog lights can be used when
The headlights are on in low beam. ...