TOYOTA RAV4 2006 Service Repair Manual

2AZ-FE COOLING – WATER PUMPCO–11
CO
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 and seat belt pretensioner activation.
2. REMOVE NO. 1 ENGINE UNDER COVER
3. REMOVE FRONT FENDER APRON RH
4. REMOVE RADIATOR SUPPORT OPENING COVER
5. DRAIN ENGINE COOLANT (See page CO-6)
6. REMOVE FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-6)
7. REMOVE FAN AND GENERATOR V BELT (See page
EM-6)
8. REMOVE GENERATOR ASSEMBLY (See page CH-9)
9. REMOVE WATER PUMP PULLEY
(a) Using SST, remove the 4 bolts and water pump
pulley.
SST 09960-10010 (09962-01000, 09963-00700)
10. REMOVE WATER PUMP ASSEMBLY
(a) Remove the clamp of the crankshaft position sensor
from the water pump.
(b) Disconnect the wire of the crankshaft position
sensor from the clamp bracket.
(c) Remove the 4 bolts, 2 nuts and clamp bracket.
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CO–122AZ-FE COOLING – WATER PUMP
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(d) Using a screwdriver, pry between the water pump
and cylinder block, and then remove the water
pump.
NOTICE:
Be careful not to damage the contact surfaces of
the water pump and cylinder block.
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 "click"
noise.
If it does not move smoothly, replace the water
pump assembly.
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2AZ-FE COOLING – WATER PUMPCO–13
CO
INSTALLATION
1. INSTALL WATER PUMP ASSEMBLY
(a) Remove any old seal packing material from the
contact surface.
(b) Apply a continuous line of seal packing as shown in
the illustration.
Seal packing:
Toyota Genuine Seal Parking Black, Three
Bond 1207B or equivalent
Standard seal diameter:
2.2 to 2.5 mm (0.09 to 0.10 in.)
NOTICE:
• Remove any oil from the contact surface.
• The parts must be set within 3 minutes after
applying seal packing. Otherwise, the
material must be removed and reapplied.
(c) Install the water pump and clamp bracket with the 4
bolts and 2 nuts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
(d) Install the wire of the crankshaft position sensor
onto the clamp bracket.
(e) Install the clamp of the crankshaft position sensor
onto the water pump.
2. INSTALL WATER PUMP PULLEY
(a) Using SST, install the water pump pulley with the 4
bolts.
SST 09960-10010 (09962-01000, 09963-00700)
Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)
3. INSTALL GENERATOR ASSEMBLY (See page CH-15)
4. INSTALL FAN AND GENERATOR V BELT (See page
EM-7)
5. INSTALL FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-7)
6. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
7. ADD ENGINE COOLANT (See page CO-6)
8. CHECK FOR ENGINE COOLANT LEAKS (See page
CO-1)
9. INSTALL RADIATOR SUPPORT OPENING COVER
10. INSTALL FRONT FENDER APRON RH
11. INSTALL NO. 1 ENGINE UNDER COVER
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CO–162AZ-FE COOLING – THERMOSTAT
CO
INSTALLATION
1. INSTALL THERMOSTAT
(a) Install a new gasket onto the thermostat.
(b) Install the thermostat with the jiggle valve upward.
HINT:
The jiggle valve may be set to within 10
on either
side of the prescribed position.
2. INSTALL WATER INLET
(a) Install the water inlet with the 2 nuts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
3. CONNECT NO. 2 RADIATOR HOSE
4. ADD ENGINE COOLANT (See page CO-6)
5. CHECK FOR ENGINE COOLANT LEAKS (See page
CO-1)
6. INSTALL RADIATOR SUPPORT OPENING COVER
7. INSTALL NO. 1 ENGINE UNDER COVER
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CO–222AZ-FE COOLING – COOLING FAN MOTOR
CO
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 and seat belt pretensioner activation.
2. REMOVE RADIATOR ASSEMBLY
(a) Remove the radiator (see page CO-29).
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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2AZ-FE COOLING – COOLING FAN MOTORCO–23
CO
INSTALLATION
1. INSTALL RADIATOR ASSEMBLY
(a) Install the radiator (see page CO-32).
2. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
3. ADD ENGINE COOLANT (See page CO-6)
4. CHECK FOR ENGINE COOLANT LEAKS (See page
CO-1)

2AZ-FE COOLING – RADIATORCO–29
CO
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 and seat belt pretensioner activation.
2. REMOVE RADIATOR SUPPORT OPENING COVER
3. REMOVE BATTERY CLAMP
(a) Remove the bolt, nut and clamp.
4. REMOVE BATTERY
5. REMOVE NO. 1 ENGINE UNDER COVER
6. DRAIN ENGINE COOLANT (See page CO-6)
7. REMOVE RADIATOR GRILLE SUB-ASSEMBLY (See
page ET-6)
8. DISCONNECT HOOD LOCK SWITCH CONNECTOR
9. DISCONNECT NO. 1 WATER BY-PASS HOSE
(a) Disconnect the hose from the radiator reservoir.
10. DISCONNECT NO. 5 WATER BY-PASS HOSE
(a) Disconnect the hose from the radiator.
11. REMOVE NO. 1 WATER BY-PASS PIPE
(a) Disconnect the pipe from the No. 1 radiator hose.
(b) Remove the 2 bolts and the pipe.
12. DISCONNECT COOLING FAN MOTOR HARNESS
(a) Disconnect the 2 fan motor connectors from the 2
fan motors.
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CO–302AZ-FE COOLING – RADIATOR
CO
(b) Detach the 5 harness clamps from the fan shroud
and upper radiator support.
13. DISCONNECT HORN CONNECTOR
(a) Disconnect the 2 horn connectors.
14. REMOVE UPPER RADIATOR SUPPORT BRACKET
(a) Remove the 2 bolts and the 2 upper radiator support
brackets.
15. REMOVE NO. 2 FAN SHROUD
(a) Remove the 2 bolts.
(b) Detach the 2 claws and No. 2 shroud.
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2AZ-FE COOLING – RADIATORCO–31
CO
16. REMOVE UPPER RADIATOR SUPPORT SUB-
ASSEMBLY
(a) Remove the 4 bolts and upper radiator support with
hood lock.
17. DISCONNECT NO. 1 RADIATOR HOSE
18. DISCONNECT NO. 2 RADIATOR HOSE
19. DISCONNECT NO. 2 WATER BY-PASS HOSE
Disconnect the by-pass hose from the radiator reservoir
and radiator.
20. REMOVE RADIATOR ASSEMBLY
(a) Separate 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
lowers.
HINT:
After detaching the radiator, make sure that both
radiator support lowers are present.
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CO–322AZ-FE COOLING – RADIATOR
CO
21. REMOVE FAN SHROUD WITH COOLING FAN
(a) Remove the 2 bolts and radiator from the fan
shroud.
INSTALLATION
1. INSTALL FAN SHROUD WITH COOLING FAN
(a) Install the fan shroud with cooling fan with the 2
bolts to the radiator.
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 to 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 lower.
3. INSTALL UPPER RADIATOR SUPPORT SUB-
ASSEMBLY
(a) Install the upper radiator support with the 4 bolts.
Torque: 19 N*m (194 kgf*cm, 14 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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