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Engine Cooling System (2GR-FE): Removal & Installation Toyota RAV4 III

Cooling Fan 33 illustrations ~1659 words

REMOVAL

  1. REMOVE RADIATOR ASSEMBLY Remove the radiator (see «REMOVAL»(ref-265076-S18573382132007092000000) ).

Scheme 129

Scheme 129: DISASSEMBLY
Scheme 129: DISASSEMBLY

Scheme 130

Scheme 130
Scheme 130
  1. REMOVE FAN Remove the 2 nuts and 2 fans.
  2. REMOVE NO. 1 COOLING FAN MOTOR Remove the 3 screws and fan motor. (Scheme 130)
  3. REMOVE NO. 2 COOLING FAN MOTOR Remove the 3 screws and fan motor.

Scheme 131

Scheme 131: REASSEMBLY
Scheme 131: REASSEMBLY

Scheme 132

Scheme 132
Scheme 132
  1. INSTALL NO. 2 COOLING FAN MOTOR Install the fan motor with the 3 screws. Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
  2. INSTALL NO. 1 COOLING FAN MOTOR Install the fan motor with the 3 screws. Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
  3. INSTALL FAN Install the 2 fans with the 2 nuts. Torque: 6.3 N*m (64 kgf*cm, 55 in.*lbf) Check the fan motor operation.

INSTALLATION

  1. INSTALL RADIATOR ASSEMBLY Install the radiator (see «INSTALLATION»(ref-265076-S41914176972007092000000) ).

Scheme 133

Scheme 133: ON-VEHICLE INSPECTION
Scheme 133: ON-VEHICLE INSPECTION

Scheme 134

Scheme 134
Scheme 134
  1. CHECK COOLING FAN ECU (w/o Trailer Towing System) Disconnect the B12 ECU connector. Measure the voltage and resistance of the wire harness side connector. Standard voltage TESTER CONNECTION SPECIFIED CONDITION CHART Tester Connection Condition Specified Condition B12-3 (+B) - Body ground Ignition switch ON 9 to 14 V Standard resistance TESTER CONNECTION SPECIFIED CONDITION CHART Tester Connection Condition Specified Condition B12-1 (E1) - Body ground Always Below 1 ohms If the result is not as specified, inspect the power source system (fusible link, fuse, wire harness and relay). Connect the B12 ECU connector.
  2. CHECK COOLING FAN ECU (w/Trailer Towing System) Disconnect the B10 and B11 ECU connector. Measure the voltage and resistance of the wire harness side connector. Standard voltage STANDARD VOLTAGE CONDITION CHART Tester Connection Condition Specified Condition B10-1 (+B1) - Body ground Ignition switch ON 9 to 14 V B11-1 (+B2) - Body ground Ignition switch ON 9 to 14 V Standard resistance TESTER CONNECTION RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition B10-3 (E1) - Body ground Always Below 1 ohms B11-3 (E2) - Body ground Always Below 1 ohms If the result is not as specified, inspect the power source system (fusible link, fuse, wire harness and relay). Connect the B10 and B11 ECU connector.

Scheme 135

Scheme 135: ON-VEHICLE INSPECTION
Scheme 135: ON-VEHICLE INSPECTION

Scheme 136

Scheme 136
Scheme 136
  1. 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.
  2. REMOVE ENGINE ROOM NO. 2 RELAY BLOCK COVER
  3. INSPECT NO. 1 FAN RELAY (Marking: FAN NO. 1) Remove the relay from the engine room No. 2 relay block. Measure the resistance of the relay. Standard resistance TESTER CONNECTION RESISTANCE SPECIFICATION Tester Connection Specified Condition 3 - 5 10 ohms or higher 3 - 5 Below 1 ohms (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay. Install the relay.
  4. INSPECT NO. 2 FAN RELAY (Marking: FAN NO. 2) Remove the relay from the engine room No. 2 relay block. Measure the resistance of the relay. Standard resistance TESTER CONNECTION RESISTANCE SPECIFICATION Tester Connection Specified Condition 3 - 5 10 ohms or higher 3 - 5 Below 1 ohms (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay. Install the relay.
  5. INSTALL ENGINE ROOM NO. 2 RELAY BLOCK COVER
  6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Scheme 137

Scheme 137: COMPONENTS
Scheme 137: COMPONENTS

Scheme 138

Scheme 138
Scheme 138

Scheme 139

Scheme 139
Scheme 139

Scheme 140

Scheme 140: ON-VEHICLE INSPECTION
Scheme 140: ON-VEHICLE INSPECTION

Scheme 141

Scheme 141
Scheme 141
  1. CHECK RADIATOR RESERVOIR CAP SUB-ASSEMBLY Measure the valve opening pressure. If there are water stains or foreign matter on O-ring 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°. 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 ITEM SPECIFIED CONDITION CHART Item Specified Condition Standard value (for brand-new cap) 93.3 to 122.7 kPa (0.95 to 1.25 kgf/cm 2 , 13.5 to 17.8 psi) Minimum standard value (after using cap) 78.5 kPa (0.8 kgf/cm 2 , 11.4 psi) If the maximum pressure is less than the minimum standard value, replace the radiator reservoir cap sub-assembly.

Scheme 142

Scheme 142: ON-VEHICLE CLEANING
Scheme 142: ON-VEHICLE CLEANING
  1. 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. NOTE: 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 INJECTION PRESSURE SPECIFIED CONDITION CHART Injection Pressure Specified Condition 2,942 to 4,903 kPa (30 to 50 kgf/cm 2 , 427 to 711 psi) 300 mm (11.81 in.) 4,903 to 7,845 kPa (50 to 80 kgf/cm 2 , 711 to 1,138 psi) 500 mm (19.69 in.) 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.

Scheme 143

Scheme 143: REMOVAL
Scheme 143: REMOVAL

Scheme 144

Scheme 144
Scheme 144

Scheme 145

Scheme 145
Scheme 145

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Scheme 146

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Scheme 147

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Scheme 148

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Scheme 149

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Scheme 150

Scheme 151

Scheme 151
Scheme 151
  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag activation.
  2. REMOVE BATTERY CLAMP SUB-ASSEMBLY (See appropriate step(s) under «REMOVAL»(ref-265089-S37099865802007092000000) )
  3. REMOVE BATTERY INSULATOR
  4. REMOVE BATTERY
  5. REMOVE NO. 1 ENGINE UNDER COVER (See appropriate step(s) under «REMOVAL»(ref-265059-S01631031182007092000000) )
  6. DRAIN ENGINE COOLANT (See «REPLACEMENT»(ref-265076-S03413639462007092000000) )
  7. REMOVE V-BANK COVER SUB-ASSEMBLY (See appropriate step(s) under «REMOVAL»(ref-265059-S01631031182007092000000) )
  8. REMOVE RADIATOR SUPPORT OPENING COVER (See appropriate step(s) under «REMOVAL»(ref-265059-S01631031182007092000000) )
  9. REMOVE RADIATOR GRILLE SUB-ASSEMBLY (See appropriate step(s) under REMOVAL and «DISASSEMBLY»(ref-265092-S30453618192007092000000) )
  10. DISCONNECT HOOD LOCK SWITCH CONNECTOR
  11. DISCONNECT NO. 1 WATER BY-PASS HOSE Disconnect the hose from the radiator reservoir. (Scheme 144)
  12. DISCONNECT NO. 5 WATER BY-PASS HOSE Disconnect the hose from the radiator.
  13. REMOVE NO. 1 WATER BY-PASS PIPE Disconnect the pipe from the No. 1 radiator hose. Remove the 2 bolts and pipe.
  14. DISCONNECT COOLING FAN ECU HARNESS (w/o Trailer Towing System) Disconnect the fan ECU connector. Detach the 3 harness clamps from the fan shroud and upper radiator support.
  15. DISCONNECT COOLING FAN ECU HARNESS (w/Trailer Towing System) Disconnect the 2 fan ECU connectors. Detach the 3 harness clamps from the fan shroud and upper radiator support.
  16. DISCONNECT HORN CONNECTOR Disconnect the 2 horn connectors.
  17. REMOVE UPPER RADIATOR SUPPORT BRACKET Remove the 2 bolts and 2 upper radiator support brackets.
  18. REMOVE NO. 2 FAN SHROUD Remove the 2 bolts. Detach the 2 claws and No. 2 shroud.
  19. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY Remove the 4 bolts and upper radiator support with hood lock.
  20. DISCONNECT OIL COOLER INLET HOSE
  21. DISCONNECT OIL COOLER OUTLET HOSE
  22. DISCONNECT NO. 1 RADIATOR HOSE
  23. DISCONNECT NO. 2 RADIATOR HOSE
  24. DISCONNECT NO. 2 WATER BY-PASS HOSE Disconnect the by-pass hose from the radiator reservoir and radiator.
  25. REMOVE RADIATOR ASSEMBLY Detach 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 lower cushions. HINT: After detaching the radiator, make sure that all 2 radiator support lowers are present.
  26. REMOVE FAN SHROUD WITH COOLING FAN Remove the 2 bolts and fan shroud with cooling fan from the radiator.

Scheme 152

Scheme 152: INSTALLATION
Scheme 152: INSTALLATION

Scheme 153

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Scheme 153

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Scheme 157

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Scheme 159

Scheme 160

Scheme 160
Scheme 160

Scheme 161

Scheme 161
Scheme 161
  1. INSTALL FAN SHROUD WITH COOLING FAN 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)
  2. INSTALL RADIATOR ASSEMBLY Install the 4 fan shroud cushions to the cooler condenser. Set the cooler condenser into 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 lowers.
  3. INSTALL UPPER RADIATOR SUPPORT SUBASSEMBLY Install the upper radiator support with the 4 bolts. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf)
  4. 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)
  5. INSTALL UPPER RADIATOR SUPPORT BRACKET Install the brackets with the 2 bolts. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
  6. CONNECT HORN CONNECTOR Connect the 2 horn connectors.
  7. 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.
  8. CONNECT NO. 2 RADIATOR HOSE HINT: The direction of the hose clamp is indicated in the illustration. (Scheme 157)
  9. CONNECT NO. 1 RADIATOR HOSE HINT: The direction of the hose clamp is indicated in the illustration. (Scheme 157)
  10. CONNECT OIL COOLER OUTLET HOSE
  11. CONNECT OIL COOLER INLET HOSE
  12. CONNECT COOLING FAN ECU HARNESS (w/Trailer Towing System) Attach the harness with the 3 clamps. Connect the 2 fan ECU connectors.
  13. CONNECT COOLING FAN ECU HARNESS (w/o Trailer Towing System) Attach the harness with the 3 clamps. Connect the fan ECU connector.
  14. INSTALL NO. 1 WATER BY-PASS PIPE Install the by-pass pipe with the 2 bolts to the upper radiator support. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) Connect the No. 1 radiator hose to the pipe.
  15. CONNECT NO. 5 WATER BY-PASS HOSE Connect the by-pass hose to the radiator. (Scheme 160)
  16. CONNECT NO. 1 WATER BY-PASS HOSE Connect the by-pass hose to the radiator reservoir.
  17. CONNECT HOOD LOCK SWITCH CONNECTOR
  18. INSTALL RADIATOR GRILLE SUB-ASSEMBLY (See appropriate step(s) under «REASSEMBLY»(ref-265092-S12383463612007092000000) )
  19. INSTALL BATTERY
  20. INSTALL BATTERY INSULATOR
  21. INSTALL BATTERY CLAMP SUB-ASSEMBLY (See appropriate step(s) under «INSTALLATION»(ref-265089-S03487941332007092000000) )
  22. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
  23. INSTALL RADIATOR SUPPORT OPENING COVER (See appropriate step(s) under «INSTALLATION»(ref-265059-S19240684252007092000000) )
  24. INSTALL V-BANK COVER SUB-ASSEMBLY (See appropriate step(s) under «INSTALLATION»(ref-265059-S19240684252007092000000) )
  25. ADD ENGINE COOLANT (See «REPLACEMENT»(ref-265076-S03413639462007092000000) )
  26. CHECK FOR ENGINE COOLANT LEAKS (See «ON-VEHICLE INSPECTION»(ref-265076-S22677065082007092000000) )
  27. INSTALL NO. 1 ENGINE UNDER COVER (See appropriate step(s) under «INSTALLATION»(ref-265059-S19240684252007092000000) )

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