OEM 2002 Toyota RAV4 Radiator

2002 Toyota RAV4 Parts Questions & Experts Answers

• Q: How to remove and reinstall a radiator on 2002 Toyota RAV4?

  A: Start by draining engine coolant before you remove the radiator grille by unscrewing four screws along with unclipping two components. Begin by removing 4 screws that secure the front end panel and disconnect the hood lock through removing 3 bolts and unclipping its wire from the clamp. Disconnecting the upper radiator hose requires you to remove the upper radiator support through 5 bolt unscrewing and remove the LH engine under cover. Begin the radiator service by removing both the radiator reservoir and the cooling fans designated as No.1 and No.2. Automatic transmission needs installation of two plastic tubes from the radiator followed by removal of the ECT switch connector and the lower radiator hose before taking out the radiator unit. The support brackets found on the radiator's upper and lower components need to be detached from their position. To perform disassembly begin by removing drain plug and O-ring followed by assembly of Special Service Tool 09230-01010 using an overhaul handle that includes a claw along with adjustable stopper bolts set to dimension "B" of 0.2 - 0.3 mm (0.008 - 0.012 inch). Using the same tool you can unfasten lock plates before you tap the radiator bracket lightly to extract the tanks with their O-rings. The automatic transmission oil cooler pipes should be disconnected by unfastening two nuts followed by removing the pipes as well as their O-rings. New O-rings must be installed to the oil cooler before securing its pipes with two nuts to 12 Nm (120 kgf-cm, 10 ft. lbs.) torque. Then install the LH and RH cooler pipes to 14.7 Nm (150 kgf-cm, 11 ft. lbs.). Examining the lock plate must include checking for damage that would stop the device from reconnecting successfully. The installation procedure should involve new O-rings and tanks as well as a specific check for foreign objects in the lockplate groove before using a soft-faced hammer to eliminate gaps. The installation of Special Service Tools 09230-01010 and 09231-14010 requires adjustment of the stopper bolt to reach a 8.4 mm (0.331 inch) measurement for dimension "B". Press the tool onto the lock plate for caulking before checking the lock plate dimension between 8.45 - 8.85 mm (0.3327 - 0.3484 inch). First install a new drain plug O-ring before securing it in place by checking for water leaks through a plug-test operation using Special Service Tool: 09230-01010. The test procedure involves tightening the drain plug while using the tool to block inlet and outlet pipes under 177kPa (1.8 kgf/cm2, 26 psi) radiator cap pressure with the radiator immersed in water. The installation process involves mounting lower and upper radiator supports onto the radiator before radiator installation followed by attaching the lower radiator hose while automatic transmission installation requires connection of two oil cooler hoses to the radiator. Join the ECT switch connector while you install the radiator reservoir with both No. 1 and No. 2 fans and the RH engine under cover. Fix the upper radiator support using 5 bolts followed by attaching the upper radiator hose and completing the hood lock installation with 3 bolts and clamps wires. The repair process culminates in adding the front end panel through 4 screws then the radiator grille locked by 4 screws plus 2 clips followed by engine coolant addition before starting the vehicle to inspect for coolant leakage.