TOYOTA RAV4 2006 Service Repair Manual

2GR-FE COOLING – THERMOSTATCO–21
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INSTALLATION
1. INSTALL THERMOSTAT
(a) Install a new gasket to the thermostat.
(b) Install the thermostat with the jiggle valve facing
upward.
HINT:
The jiggle valve can be set to within 10
of either
side of the upward position.
2. INSTALL WATER INLET
(a) Install the water inlet with the 2 nuts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
3. CONNECT NO. 2 RADIATOR HOSE
4. 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)
5. INSTALL FRONT NO. 1 ENGINE MOUNTING
BRACKET LH (See page CO-15)
6. INSTALL ENGINE MOUNTING INSULATOR RH
(a) Install the engine mounting insulator RH with the 2
nuts and 5 bolts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) for bolt
95 N*m (969 kgf*cm, 70 ft.*lbf) for nut A
52 N*m (530 kgf*cm, 38 ft.*lbf) for nut B
7. INSTALL FAN AND GENERATOR V BELT (See page
EM-8)
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CO–222GR-FE COOLING – THERMOSTAT
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8. INSTALL RADIATOR RESERVOIR TANK
(a) Install the radiator reservoir with the 2 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
9. INSTALL RADIATOR SUPPORT OPENING COVER
(See page EM-42)
10. INSTALL V-BANK COVER SUB-ASSEMBLY (See
page EM-42)
11. ADD ENGINE COOLANT (See page CO-8)
12. CHECK FOR ENGINE COOLANT LEAKAGE (See
page CO-1)
13. INSTALL FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-9)
14. INSTALL ENGINE UNDER COVER REAR RH (See
page EM-41)
15. INSTALL NO. 1 ENGINE UNDER COVER (See page
EM-41)
16. INSTALL FRONT WHEEL RH
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2GR-FE COOLING – COOLING FAN MOTORCO–29
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REMOVAL
1. REMOVE RADIATOR ASSEMBLY
(a) Remove the radiator (see page CO-36).
DISASSEMBLY
1. REMOVE FAN
(a) Remove the 2 nuts and 2 fans.
2. REMOVE NO. 1 COOLING FAN MOTOR
(a) Remove the 3 screws and fan motor.
3. REMOVE NO. 2 COOLING FAN MOTOR
(a) Remove the 3 screws and fan motor.
REASSEMBLY
1. INSTALL NO. 2 COOLING FAN MOTOR
(a) 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
(a) Install the fan motor with the 3 screws.
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
3. INSTALL FAN
(a) Install the 2 fans with the 2 nuts.
Torque: 6.3 N*m (64 kgf*cm, 55 in.*lbf)
(b) Check the fan motor operation.
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CO–302GR-FE COOLING – COOLING FAN MOTOR
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INSTALLATION
1. INSTALL RADIATOR ASSEMBLY
(a) Install the radiator (see page CO-40).

CO–362GR-FE COOLING – RADIATOR
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REMOVAL
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
page ST-6)
3. REMOVE BATTERY INSULATOR
4. REMOVE BATTERY
5. REMOVE NO. 1 ENGINE UNDER COVER (See page
EM-21)
6. DRAIN ENGINE COOLANT (See page CO-8)
7. REMOVE V-BANK COVER SUB-ASSEMBLY (See
page EM-21)
8. REMOVE RADIATOR SUPPORT OPENING COVER
(See page EM-22)
9. REMOVE RADIATOR GRILLE SUB-ASSEMBLY (See
page ET-6)
10. DISCONNECT HOOD LOCK SWITCH CONNECTOR
11. DISCONNECT NO. 1 WATER BY-PASS HOSE
(a) Disconnect the hose from the radiator reservoir.
12. DISCONNECT NO. 5 WATER BY-PASS HOSE
(a) Disconnect the hose from the radiator.
13. REMOVE NO. 1 WATER BY-PASS PIPE
(a) Disconnect the pipe from the No. 1 radiator hose.
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2GR-FE COOLING – RADIATORCO–37
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(b) Remove the 2 bolts and pipe.
14. DISCONNECT COOLING FAN ECU HARNESS (w/o
Trailer Towing System)
(a) Disconnect the fan ECU connector.
(b) Detach the 3 harness clamps from the fan shroud
and upper radiator support.
15. DISCONNECT COOLING FAN ECU HARNESS (w/
Trailer Towing System)
(a) Disconnect the 2 fan ECU connectors.
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CO–382GR-FE COOLING – RADIATOR
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(b) Detach the 3 harness clamps from the fan shroud
and upper radiator support.
16. DISCONNECT HORN CONNECTOR
(a) Disconnect the 2 horn connectors.
17. REMOVE UPPER RADIATOR SUPPORT BRACKET
(a) Remove the 2 bolts and 2 upper radiator support
brackets.
18. REMOVE NO. 2 FAN SHROUD
(a) Remove the 2 bolts.
(b) Detach the 2 claws and No. 2 shroud.
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2GR-FE COOLING – RADIATORCO–39
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19. REMOVE UPPER RADIATOR SUPPORT SUB-
ASSEMBLY
(a) 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
(a) Disconnect the by-pass hose from the radiator
reservoir and radiator.
25. REMOVE RADIATOR ASSEMBLY
(a) Detach the cooler condenser from the radiator.
HINT:
After detaching the condenser, make sure that all 4
fan shroud cushions are present.
(b) 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.
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CO–402GR-FE COOLING – RADIATOR
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26. REMOVE FAN SHROUD WITH COOLING FAN
(a) Remove the 2 bolts and fan shroud with cooling fan
from the radiator.
INSTALLATION
1. INSTALL FAN SHROUD WITH COOLING FAN
(a) 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
(a) Install the 4 fan shroud cushions to the cooler
condenser.
(b) Set the cooler condenser into the fan shroud.
(c) Install the 2 radiator support lower cushions to the
fan shroud.
(d) Install the radiator with cooler condenser and fan
shroud to the radiator support lowers.
3. INSTALL UPPER RADIATOR SUPPORT SUB-
ASSEMBLY
(a) 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
(a) 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)
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2GR-FE COOLING – RADIATORCO–41
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5. INSTALL UPPER RADIATOR SUPPORT BRACKET
(a) Install the brackets 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 OIL COOLER OUTLET HOSE
11. CONNECT OIL COOLER INLET HOSE
12. CONNECT COOLING FAN ECU HARNESS (w/ Trailer
Towing System)
(a) Attach the harness with the 3 clamps.
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