TOYOTA RAV4 2006 Service Repair Manual

2AZ-FE COOLING – RADIATORCO–33
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5. INSTALL UPPER RADIATOR SUPPORT BRACKET
(a) Install the bracket with the 2 bolts.
Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
6. CONNECT HORN CONNECTOR
(a) Connect the 2 horn connectors.
7. CONNECT NO. 2 WATER BY-PASS HOSE
(a) 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.
9. CONNECT NO. 1 RADIATOR HOSE
HINT:
The direction of the hose clamp is indicated in the
illustration.
10. CONNECT COOLING FAN MOTOR HARNESS
(a) Attach the harness with the 5 clamps.
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(b) Connect the 2 fan motor connectors.
11. INSTALL NO. 1 WATER BY-PASS PIPE
(a) Install the by-pass pipe with the 2 bolts to the upper
radiator support.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
(b) Connect the No. 1 radiator hose to the pipe.
HINT:
The direction of the hose clamp is indicated in the
lustration.
12. CONNECT NO. 5 WATER BY-PASS HOSE
(a) Connect the by-pass hose to the radiator.
HINT:
The direction of the hose clamp is indicated in the
lustration.
13. CONNECT NO. 1 WATER BY-PASS HOSE
(a) Connect the by-pass hose to the radiator and
radiator reservoir.
HINT:
The direction of the hose clamp is indicated in the
illustration.
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2AZ-FE COOLING – RADIATORCO–35
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14. CONNECT HOOD LOCK SWITCH CONNECTOR
15. INSTALL RADIATOR GRILLE SUB-ASSEMBLY (See
page ET-10)
16. INSTALL BATTERY
17. INSTALL BATTERY CLAMP
(a) Attach the hook of the battery clamp to the battery
bracket.
(b) Temporarily tighten the nut and install the bolt.
(c) Adjust the battery clamp's position.
(d) Fully tighten the bolt and nut.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) for bolt
5.0 N*m (51 kgf*cm, 44 in.*lbf) for nut
18. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
19. ADD ENGINE COOLANT (See page CO-6)
20. CHECK FOR ENGINE COOLANT LEAKS (See page
CO-1)
21. INSTALL RADIATOR SUPPORT OPENING COVER
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CO–62GR-FE COOLING – COOLING FAN SYSTEM
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ON-VEHICLE INSPECTION
HINT:
It is normal for the cooling fan to sometimes rotate when the
ignition switch is turned from ACC to ON.
1. CHECK COOLING FAN OPERATION AT LOW
TEMPERATURES (Below 94
C (201F))
(a) Turn the ignition switch ON with the A/C switch OFF.
(b) Check that the cooling fan stops.
If it does not, check the cooling fan relays and
engine coolant temperature sensor, and then check
for disconnection of the connector or wire breaks
between the cooling fan relay and engine coolant
temperature sensor.
(c) Disconnect the engine coolant temperature sensor
connector.
(d) Check that the cooling fan rotates.
If it does not, check the fuses, cooling fan relays,
ECM and cooling fan, and then check for an open
circuit between the cooling fan relay and engine
coolant temperature sensor.
(e) Reconnect the engine coolant temperature sensor
connector.
2. CHECK COOLING FAN OPERATION AT HIGH
TEMPERATURES (Above 96
C (205F))
(a) Start the engine, and then raise the coolant
temperature to above 96
C (205F).
HINT:
Coolant temperature is the value detected by the
engine coolant temperature sensor on the cylinder
head.
(b) Check that the A/C switch is OFF.
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2GR-FE COOLING – COOLING FAN SYSTEMCO–7
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(c) Check that the cooling fan rotates.
If it does not, check the engine coolant temperature
sensor, cooling fan, harness or connector.
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2GR-FE COOLING – WATER PUMPCO–13
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6. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Remove the bolt, No. 2 idler pulley cover plate and
No. 2 idler pulley.
7. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(a) Remove the 5 bolts and V-ribbed belt tensioner
assembly.
8. REMOVE WATER PUMP ASSEMBLY
(a) Remove the 16 bolts, water pump and water pump
gasket.
INSPECTION
1. INSPECT WATER PUMP ASSEMBLY
(a) Visually check the drain hole for coolant leakage.
If leakage is found, replace the water pump
assembly.
(b) Turn the pulley, and then check that the water pump
bearing moves smoothly without making a clicking
noise.
If it does not move smoothly, replace the water
pump assembly.
INSTALLATION
1. INSTALL WATER PUMP ASSEMBLY
(a) Install a new water pump gasket and the water
pump with the 16 bolts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt A
9.1 N*m (93 kgf*cm, 81 in.*lbf) for bolt B
and C
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NOTICE:
• Be sure to replace the 2 C bolts with new
ones or reuse them after applying adhesive.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond
1344 or Equivalent
• Make sure that there is no oil on the threads
of the A bolts.
2. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Temporarily install the V-ribbed belt tensioner with
the 5 bolts.
HINT:
Each bolt length is as follows:
A: 70 mm (2.76 in.)
B: 30 mm (1.30 in.)
(b) Install the V-ribbed belt tensioner by tightening the
bolt 1 and bolt 2 in the order shown in the
illustration.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
(c) Tighten the other bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
3. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Install the No. 2 idler pulley cover plate and No. 2
idler pulley with the bolt.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
4. INSTALL WATER PUMP PULLEY
(a) Temporarily install the water pump pulley with the 4
bolts.
(b) Using SST, hold the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00700)
(c) Tighten the 4 bolts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
5. INSTALL CRANKSHAFT PULLEY (See page EM-126)
6. INSTALL WATER INLET HOUSING
(a) Install a new water inlet housing No. 1 gasket and
water outlet pipe O-ring.
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2GR-FE COOLING – WATER PUMPCO–15
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(b) Install the water inlet with the 2 bolts and nut.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
NOTICE:
Be careful not to allow the O-ring to get caught
between the parts.
(c) Connect the water hose.
7. INSTALL FRONT NO. 1 ENGINE MOUNTING
BRACKET LH
(a) Install the front No. 1 engine mounting bracket LH
with the 6 bolts.
Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
NOTICE:
• Install the water inlet and mounting bracket
within 15 minutes after installing the chain
cover.
• Do not start the engine for at least 2 hours
after installation.
8. INSTALL ENGINE ASSEMBLY
(a) Install the engine (see page EM-31).
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2GR-FE COOLING – THERMOSTATCO–19
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REMOVAL
1. REMOVE FRONT WHEEL RH
2. REMOVE NO. 1 ENGINE UNDER COVER (See page
EM-21)
3. REMOVE ENGINE UNDER COVER REAR RH (See
page EM-21)
4. REMOVE FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-7)
5. DRAIN ENGINE COOLANT (See page CO-8)
6. REMOVE V-BANK COVER SUB-ASSEMBLY (See
page EM-21)
7. REMOVE RADIATOR SUPPORT OPENING COVER
(See page EM-22)
8. REMOVE RADIATOR RESERVOIR TANK
(a) Remove the 2 bolts and radiator reservoir.
9. REMOVE FAN AND GENERATOR V BELT (See page
EM-8)
10. REMOVE ENGINE MOUNTING INSULATOR RH
(a) Remove the 5 bolts, 2 nuts and engine mounting
insulator RH.
11. REMOVE FRONT NO. 1 ENGINE MOUNTING
BRACKET LH (See page CO-12)
12. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Remove the bolt, No. 2 idler pulley cover plate and
No. 2 idler pulley.
13. DISCONNECT NO. 2 RADIATOR HOSE
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CO–202GR-FE COOLING – THERMOSTAT
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14. REMOVE WATER INLET
(a) Remove the 2 nuts and remove the water inlet from
the water inlet housing.
15. REMOVE THERMOSTAT
INSPECTION
1. INSPECT THERMOSTAT
HINT:
The valve opening temperature is inscribed on the
thermostat.
(a) Immerse the thermostat in water, and then gradually
heat the water.
(b) Check the valve opening temperature of the
thermostat.
Standard valve opening temperature:
80 to 84
C (176 to 183F)
If the valve opening temperature is not as specified,
replace the thermostat.
(c) Check the valve lift.
Standard valve lift:
10 mm (0.39 in.) or more at 95
C (203F)
If the valve lift is not as specified, replace the
thermostat.
(d) Check that the valve is fully closed when the
thermostat is at low temperatures (below 77
C
(171
F)).
If not fully closed, replace the thermostat.
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