OEM 2004 Toyota RAV4 Radiator

2004 Toyota RAV4 Parts Questions & Experts Answers

• Q: How to service and repair the radiator on 2004 Toyota RAV4?

  A: A repair or service of the radiator begins with drain plug removal and O-ring extraction. To protect the radiator from damagearness Special Service Tool 09230-01010 should be assembled by fixing the claw to the overhaul handle and adjusting the stopper bolt until dimension "B" measures 0.2 to 0.3 mm (0.008 to 0.012 inch). Assemble Special Service Tool 09230-01010 by installing the claw to the overhaul handle while holding the stopper bolt as it reaches its stopping position. A soft-faced hammer can gently hit the radiator bracket to detach tanks along with O-rings while the oil cooler pipes from the lower tank must be removed by unfastening the nuts and O-rings. Assemble two new O-rings to the oil cooler before fastening nuts to 12 Nm (122 kgf-cm, 9 ft. lbs.) torque and attach the LH and RH cooler pipes at a torque of 14.7 Nm (150 kgf-cm, 11 ft. lbs.). The recaulking process is limited to two instances and the replacement of the radiator is necessary after the second recaulking. Inspect the lock plate for damage then correct any needed reassembly steps since the radiator will need replacement following two recaulkings. Secure new O-rings and replace tanks by checking for any foreign objects and complete the operation by tapping the lock plate to avoid gaps. Use Assemble Special Service Tool: 09230-01010 and 09231-14010 to adjust the stopper bolt toward dimension "B" of 8.4 mm (0.331 inch). Caulk the lock plate through tool pressure while keeping away from pipes and brackets and verify the lock plate height falls between 8.45 to 8.85 mm (0.3327 to 0.3484 inch). Place the new drain plug O-ring then fasten it before testing for water leaks by tightening the drain plug followed by plugging the inlet and outlet pipes using Special Service Tool: 09230-01010 under 177 kPa (1.8 kgf/cm2, 26 psi) radiator cap pressure testing while submerging the radiator in water to check for leaks before swishing it to eliminate trapped air.