Radiator Removal

Engine. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35
3Zr-Fae Cooling. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (w/ Air Conditioning System)

  2. REMOVE NO. 2 CYLINDER HEAD COVER

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  4. REMOVE NO. 1 ENGINE UNDER COVER

  5. DRAIN ENGINE COOLANT

  6. REMOVE FRONT BUMPER COVER

  7. REMOVE BATTERY CLAMP

  8. REMOVE BATTERY

  9. REMOVE GENERATOR ASSEMBLY

  10. DISCONNECT NO. 1 RADIATOR HOSE

  11. DISCONNECT NO. 2 RADIATOR HOSE

  12. REMOVE NO. 1 WATER BY-PASS HOSE

  13. REMOVE NO. 5 WATER BY-PASS HOSE

  14. REMOVE NO. 1 WATER BY-PASS PIPE

  15. DISCONNECT NO. 2 WATER BY-PASS HOSE

  16. DISCONNECT WIRE HARNESS

  17. DISCONNECT HORN CONNECTOR

  18. REMOVE FRONT BUMPER CENTER STAY SUB-ASSEMBLY

  19. REMOVE FRONT BUMPER UPPER REINFORCEMENT SUB-ASSEMBLY

  20. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (w/ Air Conditioning System)

  21. DISCONNECT COOLER REFRIGERANT LIQUID PIPE (w/ Air Conditioning System)

  22. REMOVE UPPER RADIATOR SUPPORT BRACKET

  23. REMOVE RADIATOR ASSEMBLY

Radiator -- Removal



1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (w/ Air Conditioning System)

  1. Start the engine.

  1. Turn the A/C switch on.

  1. Operate the cooler compressor while the engine speed is approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compressor.

  1. Stop the engine.

  1. Recover the refrigerant from the A/C system using a refrigerant recovery unit.

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


2. REMOVE NO. 2 CYLINDER HEAD COVER


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Hold the rear of the cover and raise it to detach the 2 clips on the rear of the cover. Continue to raise the cover to detach the 2 clips on the front of the cover and remove the cover.

    NOTICE:
    Attempting to detach both front and rear clips at the same time may cause the cover to break.


3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
NOTICE:
w/ Navigation System (for HDD):
After the ignition switch is turned off, the HDD navigation system requires approximately a minute to record various types of memory and settings. As a result, after turning the ignition switch off, wait a minute or more before disconnecting the cable from the negative (-) battery terminal.


4. REMOVE NO. 1 ENGINE UNDER COVER


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 6 screws, 10 clips and under cover.



5. DRAIN ENGINE COOLANT


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.3Zr-Fae Cooling.Cooling System.Radiator Removal

  1. Install a vinyl hose to the drain cock plug on the radiator side.



  1. Loosen the radiator drain cock plug.


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.3Zr-Fae Cooling.Cooling System.Radiator Removal

    HINT:
    Collect the coolant in a container and dispose of it according to the regulations in your area.

  1. Remove the radiator reservoir cap.

    CAUTION:
    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


6. REMOVE FRONT BUMPER COVER

  1. w/ Hood Moulding:
    Remove the front bumper cover (RAV4_ACA30 RM000003PKF007X.html).

  1. w/ Under Guard:
    Remove the front bumper cover (RAV4_ACA30 RM000003PKF001X.html).

  1. w/o Under Guard:
    Remove the front bumper cover (RAV4_ACA30 RM0000015RJ00HX.html).



7. REMOVE BATTERY CLAMP


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the bolt and loosen the nut.

  1. Detach the hook of the battery clamp from the front battery bracket, and then remove the battery clamp.



8. REMOVE BATTERY


9. REMOVE GENERATOR ASSEMBLY

  1. Remove the generator (RAV4_ACA30 RM000003X0U000X.html).



10. DISCONNECT NO. 1 RADIATOR HOSE


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 2 bolts.

  1. Disconnect the 2 radiator hoses.



11. DISCONNECT NO. 2 RADIATOR HOSE


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Disconnect the hose from the water inlet housing.



12. REMOVE NO. 1 WATER BY-PASS HOSE

  1. Remove the No. 1 water by-pass hose from the radiator reservoir and No. 1 water by-pass pipe.



13. REMOVE NO. 5 WATER BY-PASS HOSE

  1. Remove the No. 5 water by-pass hose from the radiator and No. 1 water by-pass pipe.



14. REMOVE NO. 1 WATER BY-PASS PIPE


  1. Remove the 2 bolts and pipe.


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.3Zr-Fae Cooling.Cooling System.Radiator Removal



15. DISCONNECT NO. 2 WATER BY-PASS HOSE


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Disconnect the No. 2 water by-pass hose from the radiator reservoir.



16. DISCONNECT WIRE HARNESS


  1. w/o Hood Courtesy Switch:

    1. Disconnect the 2 fan motor connectors from the 2 fan motors.



    2. Detach the 4 wire harness clamps and disconnect the wire harness.


      Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.3Zr-Fae Cooling.Cooling System.Radiator Removal



  1. w/ Hood Courtesy Switch:

    1. Disconnect the hood courtesy switch connector.

    2. Disconnect the 2 fan motor connectors from the 2 fan motors.



    3. Detach the 5 wire harness clamps and disconnect the wire harness.


      Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.3Zr-Fae Cooling.Cooling System.Radiator Removal



17. DISCONNECT HORN CONNECTOR


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Disconnect the 2 horn connectors.



18. REMOVE FRONT BUMPER CENTER STAY SUB-ASSEMBLY


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 2 bolts and stay.



19. REMOVE FRONT BUMPER UPPER REINFORCEMENT SUB-ASSEMBLY


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 2 bolts and reinforcement.



20. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (w/ Air Conditioning System)


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the bolt and disconnect the cooler refrigerant discharge hose from the cooler condenser.

  1. Remove the O-ring from the cooler refrigerant discharge hose.

    NOTICE:
    Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.


21. DISCONNECT COOLER REFRIGERANT LIQUID PIPE (w/ Air Conditioning System)


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the bolt and disconnect the liquid pipe sub-assembly from the cooler condenser.

  1. Remove the O-ring from the liquid pipe sub-assembly.

    NOTICE:
    Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.


22. REMOVE UPPER RADIATOR SUPPORT BRACKET


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 2 bolts and 2 upper radiator support brackets.



23. REMOVE RADIATOR ASSEMBLY


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the radiator together with the 2 lower radiator supports.

    HINT:
    After removing the radiator, make sure that both lower radiator supports are attached to the fan shroud.


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 2 bolts.

  1. Detach the 2 claws and remove the No. 2 fan shroud.



    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. w/ Air Conditioning System:
    Remove the cooler condenser from the fan shroud with cooling fan.

    HINT:
    After removing the condenser, make sure that all 4 cooler condenser cushions are attached to the condenser.


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the No. 2 water by-pass hose and No. 2 radiator hose from the radiator.



    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the No. 1 radiator hose from the radiator.



    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 2 bolts and radiator from the fan shroud with cooling fan.