Toyota RAV4 (XA40) 2013-2018 Service Manual: Radiator
Components
![Toyota RAV4. Radiator](images/books/256/21/1.htm22.jpg)
![Toyota RAV4. Radiator](images/books/256/21/1.htm23.jpg)
![Toyota RAV4. Radiator](images/books/256/21/1.htm24.jpg)
On-vehicle inspection
- Check radiator reservoir cap subassembly
![Toyota RAV4. Check radiator reservoir cap subassembly](images/books/256/21/1.htm25.jpg)
- Measure the valve opening pressure.
![Toyota RAV4. Check radiator reservoir cap subassembly](images/books/256/21/1.htm26.jpg)
- 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 ![](images/books/256/21/1.htm27.jpg)
If the maximum pressure is less than the
minimum standard value, replace the radiator
reservoir cap sub-assembly.
On-vehicle cleaning
- Inspect radiator assembly
![Toyota RAV4. Inspect radiator assembly](images/books/256/21/1.htm28.jpg)
- 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 ![](images/books/256/21/1.htm29.jpg)
- 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.
![Toyota RAV4. Remove no. 1 Water by-pass pipe](images/books/256/21/1.htm30.jpg)
![Toyota RAV4. Remove no. 1 Water by-pass pipe](images/books/256/21/1.htm31.jpg)
- 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.
![Toyota RAV4. Disconnect cooling fan motor harness](images/books/256/21/1.htm32.jpg)
- Disconnect horn connector
- Disconnect the 2 horn connectors.
- Remove upper radiator support bracket
- Remove the 2 bolts and the 2 upper radiator support
brackets.
![Toyota RAV4. Remove upper radiator support bracket](images/books/256/21/1.htm33.jpg)
- Remove no. 2 Fan shroud
![Toyota RAV4. Remove no. 2 Fan shroud](images/books/256/21/1.htm34.jpg)
- Remove the 2 bolts.
- Detach the 2 claws and no. 2 Shroud.
- Remove upper radiator support subassembly
![Toyota RAV4. Remove upper radiator support subassembly](images/books/256/21/1.htm35.jpg)
- 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.
![Toyota RAV4. Disconnect no. 2 Water by-pass hose](images/books/256/21/1.htm36.jpg)
- Remove radiator assembly
![Toyota RAV4. Remove radiator assembly](images/books/256/21/1.htm37.jpg)
- 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
![Toyota RAV4. Remove fan shroud with cooling fan](images/books/256/21/1.htm38.jpg)
- Remove the 2 bolts and radiator from the fan
shroud.
Installation
- Install fan shroud with cooling fan
![Toyota RAV4. Install fan shroud with cooling fan](images/books/256/21/1.htm39.jpg)
- 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.
![Toyota RAV4. Install radiator assembly](images/books/256/21/1.htm40.jpg)
- Install upper radiator support subassembly
![Toyota RAV4. Install upper radiator support subassembly](images/books/256/21/1.htm41.jpg)
- Install the upper radiator support with the 4 bolts.
Torque: 19 n*m (194 kgf*cm, 14 ft.*Lbf)
- Install no. 2 Fan shroud
![Toyota RAV4. Install no. 2 Fan shroud](images/books/256/21/1.htm42.jpg)
- 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)
![Toyota RAV4. Install upper radiator support bracket](images/books/256/21/1.htm43.jpg)
- 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.
![Toyota RAV4. Connect no. 1 Radiator hose](images/books/256/21/1.htm44.jpg)
- Connect cooling fan motor harness
- Attach the harness with the 5 clamps.
- Connect the 2 fan motor connectors.
![Toyota RAV4. Connect cooling fan motor harness](images/books/256/21/1.htm45.jpg)
- 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.
![Toyota RAV4. Connect no. 1 Water by-pass hose](images/books/256/21/1.htm46.jpg)
- Connect hood lock switch connector
![Toyota RAV4. Connect hood lock switch connector](images/books/256/21/1.htm47.jpg)
- 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:
Exhaust pipe
Installation
Install front exhaust pipe assembly
Using a vernier caliper, measure the free length of
the compression spring.
Minimum length:
41.5 Mm (1.634 In.)
If the length is less than the minimum, replace the
compression spring.
Install a new gasket by hand so that its ...
Removal
Discharge fuel system pressure (see page
fu-9)
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 op ...
Tire information
Typical tire symbols
Full-size tire
Compact spare tire
Tire size
Dot and tire identification number (tin)
Location of treadwear indicators
Tire ply composition and materials
Plies are layers of rubber-coated parallel cords. Cords are the strands
which form the plies in a tire ...