Radiator Installation

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

Torque:

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

Install the No. 1 radiator hose to the radiator.

HINT:

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

Install the No. 2 water by-pass hose and No. 2 radiator hose to the radiator.

HINT:

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

w/ Air Conditioning System:
Install the cooler condenser to the fan shroud with cooling fan.

HINT:

Before installing the condenser, make sure that all 4 cooler condenser cushions are attached to the condenser.

Attach the 2 claws to install the No. 2 fan shroud.

Install the 2 bolts.

Torque:

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

Install the radiator together with the 2 lower radiator supports.

HINT:

Before installing the radiator, make sure that both lower radiator support are attached to the fan shroud.

Install the 2 upper radiator support brackets with the 2 bolts.

Torque:

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

Remove the attached vinyl tape from the pipe and the connecting part of the cooler condenser.

Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pipe joint.

Compressor oil:

ND-OIL 8 or equivalent

Install the O-ring on the liquid pipe sub-assembly.

Install the liquid pipe sub-assembly on the cooler condenser with the bolt.

Torque:

9.8 N*m{100 kgf*cm, 7 ft.*lbf}

Remove the attached vinyl tape from the hose and the connecting part of the cooler condenser.

Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint.

Compressor oil:

ND-OIL 8 or equivalent

Install the O-ring on the cooler refrigerant discharge hose.

Install the cooler refrigerant discharge hose on the cooler condenser with the bolt.

Torque:

9.8 N*m{100 kgf*cm, 7 ft.*lbf}

Install the reinforcement with the 2 bolts.

Torque:

13 N*m{133 kgf*cm, 10 ft.*lbf}

Install the stay with the 2 bolts.

Torque:

7.0 N*m{71 kgf*cm, 62 in.*lbf}

Connect the 2 horn connectors.

w/o Hood Courtesy Switch:

1. Attach the wire harness with the 4 clamps.
   





2. Connect the 2 fan motor connectors.
   
   

   
   
   
   

w/ Hood Courtesy Switch:

1. Attach the wire harness with the 5 clamps.
   

2. Connect the 2 fan motor connectors.
   





3. Connect the hood courtesy switch connector.
   
   

   
   
   
   

Connect the No. 2 water by-pass hose to the radiator reservoir.

HINT:

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

Install the No. 1 water by-pass pipe to the upper radiator support with the 2 bolts.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Install the by-pass hose to the radiator and No. 1 water by-pass pipe.

HINT:

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

Install the by-pass hose to the radiator reservoir and No. 1 water by-pass pipe.

HINT:

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

Connect the No. 2 radiator hose to the water inlet housing.

HINT:

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

Connect the 2 radiator hoses.

HINT:

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

Install the 2 bolts.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Attach the hook of the battery clamp to the front battery bracket.

Partially tighten the nut and temporarily install the bolt.

Adjust the battery clamp position.

Tighten the nut and bolt.

Torque:

for bolt:

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

for nut:

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

Install the generator (RAV4_ACA30 RM000003X0R000X.html).

w/ Hood Moulding:
Install the front bumper cover (RAV4_ACA30 RM0000015RH00PX.html).

w/ Under Guard:
Install the front bumper cover (RAV4_ACA30 RM000003PKD001X.html).

w/o Under Guard:
Install the front bumper cover (RAV4_ACA30 RM0000015RH00GX.html).

Tighten the radiator drain cock plug by hand.

Tighten the water drain cock plug.

Torque:

13 N*m{130 kgf*cm, 9 ft.*lbf}

Add TOYOTA Super Long Life Coolant (SLLC) to the radiator reservoir filler opening until it is filled to the B line at the base of the reservoir filler neck.

HINT:

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

Standard capacity:

Item	Specified Condition
for Manual Transaxle	5.8 liters (6.1 US qts, 5.1 Imp. qts)
for CVT	6.0 liters (6.3 US qts, 5.3 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 is 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.
   
   

   Measurement condition

   Item	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 (HOT) Air conditioning switch: Off

2. Maintain the engine speed at 2000 to 2500 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 coolant 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. 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 2000 rpm until the coolant level has stabilized.
      

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

CAUTION:

When pressing the radiator hoses:

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 lines. 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 lines.

Perform vacuum purging using a vacuum pump.

Charge refrigerant HFC-134a (R134a).

Standard:

430 +-30 g (15.2 +-1.1 oz.)

SST

09985-20010(09985-02130,09985-02150,09985-02090,09985-02110,09985-02010,09985-02050,09985-02060,09985-02070)

NOTICE:

1. Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.
   
2. Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.
   

Warm up the engine at less than 1,850 rpm for 2 minutes or more after charging the refrigerant.

NOTICE:

Be sure to warm up the compressor when turning the A/C switch ON after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

Perform the operation under these conditions:

1. Stop the engine.
   
2. Secure good ventilation (the gas leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).
   
3. Repeat the test 2 or 3 times.
   
4. Make sure that some refrigerant remains in the refrigeration system. When compressor is off: approximately 392 to 588 kPa (4 to 6 kgf/cm², 57 to 85 psi)
   

Using a gas leak detector, check the refrigerant line for leakage.

If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test.

Disconnect the connector and leave the pressure switch on for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test.

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.

Install the under cover with the 6 screws and 10 clips.

Attach the 4 clips to install the cover.

NOTICE:

1. Be sure to attach the clips securely.
   
2. Do not apply excessive force or do not hit the cover to attach the clips. This may cause the cover to break.