OEM 2003 Toyota RAV4 Radiator

2003 Toyota RAV4 Parts Questions & Experts Answers

• Q: How to remove and reassemble a radiator on 2003 Toyota RAV4?

  A: The radiator removal begins with draining engine coolant before proceeding with taking out 4 screws and 2 clips to detach the radiator grille. Start by unscrewing four screws from the front end panel followed by disconnecting the hood lock through bolt removal while separating the wire clamp. Start by disconnecting the upper radiator hose followed by removing the upper radiator support through the removal of 5 bolts. The LH engine under cover and radiator reservoir along with both No.1 and No.2 cooling fans must be detached. To replace a radiator with automatic transmission the system requires unhooking two oil cooler hoses from the radiator followed by disconnecting the ECT switch connector and lower radiator hose before separate the radiator from its position. Start disassembly by removing first the drain plug followed by the O-ring after which assemble SST 09230-01010 by mounting the claw onto the overhaul handle while adjusting the stopper bolts to create dimension "B" of 0.2 - 0.3 mm (0.008 - 0.012 inch). Use SST to remove radiator lock plate caulking after which tanks and O-rings can be removed through soft-faced hammer taps against the radiator bracket. When replacing automatic transmission oil cooler pipes the technician needs to remove the lower tank pipes by unscrewing two nuts before taking out both components and their O-rings. Place two new O-rings onto the oil cooler before tightening 2 nuts to 12 Nm (120 kgf-cm, 10 ft. lbs.). Then install the LH and RH cooler pipes with 14.7 Nm (150 kgf-cm, 11 ft. lbs.). Rewind the inspection of the lock plate to check for any damaged areas that may limit reassembly. The lock plate procedure calls for new O-rings and tanks while minimizing the presence of foreign objects within the lock plate groove before using a soft-faced hammer to close any openings. SST 09230-01010 and 09231-14010 require assembly while adjusting the stopper bolt to produce dimension "B" at 8.4 mm (0.331 inch). To properly caulk the lock plate use SST while pressing which helps check that H dimension measures between 8.45 - 8.85 mm (0.3327 - 0.3484 inch). Position a new drain plug O-ring then secure the drain plug while using SST 09230-01010 to seal the inlet pipe and outlet pipe which needs a radiator cap tester to run a leak check at 177 kPa (1.8 kgf/cm2, 26 psi) of test pressure. Check the radiator for leakage by submerging it in water and thoroughly mixing the water to get rid of bubbles before testing. The installation process begins with attaching radiator supports before radiator placement and lower hose connection as well as automatic transmission operations that require two oil cooler hose connections to the radiator. The ECT switch connector must be reconnected along with the installation of No. 1 and No. 2 cooling fans, radiator reservoir and RH engine under cover. Presentation of installation requires securing the 5 upper radiator support bolts while connecting the upper radiator hose and reinstalling the hood lock with 3 bolts in addition to hooking up the clamps. The service ends with installing 4 screws on the front end panel followed by screwing and clipping the radiator grille into place. Then add engine coolant before starting the engine to verify for any coolant leakage.