Remove and replace the cooling fan assembly on a 2019-2024 Toyota RAV4 2.5L I4 FWD, including disconnecting electrical connectors and removing mounting hardware.

Warnings

Tools required

Parts

• Cooling fan assembly × 1 — Use OEM specification
• Upper radiator mounting clips (if damaged) × 2 — Use OEM specification

Fluids

• Toyota Super Long Life Coolant (Pink) — 0.5 qt

Preparation

1. Ensure engine is completely cold to the touch
2. Park vehicle on level ground and engage parking brake
3. Open hood and secure with hood prop
4. Disconnect negative battery terminal and wait 2 minutes for system discharge
5. Remove engine cover by pulling upward on four corner clips

Procedure

1. 1

   Access the cooling fan assembly
   Locate the cooling fan assembly mounted on the engine side of the radiator. Identify the two upper radiator mounting clips that also secure the fan shroud. Note the electrical connector location on the driver side of the fan motor.
2. 2

   Disconnect the fan motor electrical connector
   Press the locking tab on the fan motor electrical connector and pull straight back to disconnect. The connector is located on the driver side of the fan shroud near the top. Move the wiring harness aside to provide clearance for fan removal.
3. 3

   Remove upper radiator mounting clips
   Remove the two upper radiator mounting clips that pass through the fan shroud. These are plastic clips with 10mm heads. Pull upward firmly to release them from the radiator support. These clips secure both the radiator and fan shroud in place.
4. 4

   Remove lower fan shroud mounting bolts
   Using a 10mm socket with extension, remove the two lower fan shroud mounting bolts located at the bottom of the assembly. These bolts thread into the lower radiator support. Keep these bolts organized for reinstallation.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
5. 5

   Carefully lift fan assembly from radiator
   Grasp the fan shroud firmly with both hands at the top corners. Lift straight up approximately 2 inches to clear the lower mounting tabs, then tilt the top of the assembly toward the engine while lifting. Carefully maneuver the fan assembly up and out, being extremely careful not to contact the radiator fins or coolant hoses. The assembly may require angling to clear the upper radiator hose.
6. 6

   Inspect radiator and mounting points
   With the fan removed, inspect the radiator fins for damage. Check the upper and lower mounting points for cracks or damage. Inspect the radiator surface where the fan shroud seals for debris or damage. Clean any debris from the radiator face and mounting surfaces.
7. 7

   Position new fan assembly
   Carefully lower the new fan assembly into position, reversing the removal process. Angle the top of the assembly toward the engine first, then tilt upright while guiding it down over the radiator. Ensure the lower mounting tabs engage properly with the radiator support brackets. The shroud should sit flush against the radiator mounting surface.
8. 8

   Install lower mounting bolts
   Thread in the two lower fan shroud mounting bolts by hand first to ensure proper thread engagement. Once both bolts are started, torque them to specification in a cross pattern to ensure even seating of the shroud.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
9. 9

   Install upper radiator mounting clips
   Insert the two upper radiator mounting clips through the holes in the fan shroud and into the radiator support. Press down firmly until they click into place. Verify both clips are fully seated and the fan shroud is secure at all four mounting points.
10. 10

    Reconnect electrical connector
    Reconnect the fan motor electrical connector by aligning the connector and pushing firmly until the locking tab clicks into place. Tug gently on the connector to verify it is locked. Route the wiring harness back to its original position and ensure it has adequate clearance from moving parts.
11. 11

    Reinstall engine cover and reconnect battery
    Reinstall the engine cover by aligning the four corner mounting points and pressing down until all clips engage. Reconnect the negative battery terminal. Check coolant level and top off if necessary with Toyota Super Long Life Coolant (Pink) to maintain proper level.

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify all mounting hardware is torqued to specification
3. Confirm fan blades have adequate clearance and do not contact the shroud
4. Check coolant level and top off if needed

Verification

• Start the engine and allow it to reach operating temperature
• Verify the cooling fan engages automatically when coolant temperature reaches approximately 200°F
• Listen for unusual noises from the fan assembly during operation
• Confirm the fan turns off when coolant temperature drops below the engagement threshold
• Check for coolant leaks around the radiator after test drive
• Verify no warning lights are illuminated on the dashboard

More procedures for this vehicle