Radiator Installation

Install the fan shroud with cooling fan to the radiator with the 2 bolts.

Torque:

10.5 N*m{107 kgf*cm, 8 ft.*lbf}

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 the upper radiator support with the 4 bolts.

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

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 the bracket with the 2 bolts.

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

Connect the 2 horn connectors.

Connect the by-pass hose to the radiator and radiator reservoir.

HINT:

The direction of the hose clamp is indicated in the illustration.

Connect the oil cooler hose for U241E (2WD) (RAV4_ACA30 RM0000024P800JX_01_0004.html).

Connect the oil cooler hose for U140F (4WD) (RAV4_ACA30 RM0000024P800HX_01_0004.html).

Connect the oil cooler hose for U241E (2WD) (RAV4_ACA30 RM0000024P800JX_01_0004.html).

Connect the oil cooler hose for U140F (4WD) (RAV4_ACA30 RM0000024P800HX_01_0004.html).

Attach the harness with the 5 clamps.

Connect the 2 fan motor connectors.

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}

HINT:

The direction of the hose clamp is indicated in the illustration.

Connect the No. 1 radiator hose to the pipe.

Connect the by-pass hose to the radiator.

HINT:

The direction of the hose clamp is indicated in the illustration.

Connect the by-pass hose to the radiator and radiator reservoir.

HINT:

The direction of the hose clamp is indicated in the illustration.

Attach the 7 claws and guide to install the radiator grille.

Install the 3 bolts and 3 nuts.

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:

17 N*m{168 kgf*cm, 12 ft.*lbf} for bolt.

4.9 N*m{50 kgf*cm, 43 in.*lbf} for nut

Tighten the radiator drain cock plug by hand.

Tighten the cylinder block drain cock plug.

Torque:

12.7 N*m{130 kgf*cm, 10 ft.*lbf}

Add TOYOTA Super Long Life Coolant (SLLC) to the radiator reservoir filler opening.

Continue adding TOYOTA SLLC until it is filled to the B line at the base of the reservoir's filler neck.

HINT:

The B line is the lower edge of the inner wall of the filler neck.

Standard capacity:

Item	Specified Condition
A/T	6.5 liters (6.9 US qts, 5.7 Imp. qts)
M/T	6.6 liters (7.0 US qts, 5.9 Imp. qts)

HINT:

TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).

NOTICE:

Never use water as a substitute for engine coolant.

Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the coolant. If the coolant level drops below the B line, add TOYOTA SLLC to the B line.

Install the radiator reservoir cap.

Start the engine and warm it up until the cooling fan operates.

1. Set the air conditioning as follows while warming up the engine.
   

   Item	Specified Condition
   Manual Air Conditioning System	Fan speed: Any setting except OFF Temperature: Toward WARM Air conditioning switch: OFF
   Automatic Air Conditioning System	Temperature: Toward MAX Air conditioning switch: OFF

2. Maintain the engine speed at 2,000 to 2,500 rpm and warm up the engine until the cooling fan operates.
   

   NOTICE:

   1. Make sure that the radiator reservoir still has some coolant in it.
      
   2. Pay attention to the needle of the water temperature meter. Make sure that the needle does not show an abnormally high temperature.
      
   3. If there is not enough coolant, the engine may burn out or overheat.
      
   4. Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the B line.
      
   5. Run the engine at 2,000 rpm until the coolant level has stabilized.
      

Press the No. 1 and No. 2 radiator hoses several times by hand to bleed air.

CAUTION:

1. Wear protective gloves.
   
2. Be careful as the radiator hoses are hot.
   
3. Keep your hands away from the radiator fan.
   

Stop the engine and wait until the coolant cools down to ambient temperature.

Check that the coolant level is between the FULL and LOW line.
If the coolant level is below the LOW line, repeat all of the procedures above.
If the coolant level is above the FULL line, drain coolant so that the coolant level is between the FULL and LOW line.

Remove the radiator reservoir cap.

CAUTION:

To avoid the danger of being burned, do not remove the radiator reservoir cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator reservoir.

Fill the radiator and reservoir with coolant, and then attach a radiator cap tester.

Warm up the engine.

Pump the radiator cap tester to 118 kPa (1.2 kgf/cm², 17.1 psi), and then check that the pressure does not drop.
If the pressure drops, check the hoses, radiator and water pump for leakage.
If there are no signs of external coolant leaks, check the heater core, cylinder block and head.

Reinstall the radiator reservoir cap.