This procedure covers the removal and replacement of the engine cooling fan motor assembly on a 2019-2024 Toyota RAV4 with the 2.5L I4 gasoline engine.

Warnings

Tools required

Parts

• Cooling fan motor assembly × 1 — Use OEM specification
• Radiator drain plug gasket × 1 — Use OEM specification

Fluids

• Toyota Super Long Life Coolant (Pink) — 2 qt

Preparation

1. Ensure engine is completely cold to the touch (minimum 2 hours after last operation)
2. Disconnect negative battery cable and secure away from terminal
3. Wait minimum 90 seconds after battery disconnect for system capacitors to discharge
4. Remove engine under covers if equipped using 10mm socket
5. Place drain pan under radiator drain plug location on passenger side lower corner

Procedure

1. 1

   Drain cooling system
   Open the radiator drain plug located at the lower passenger side of the radiator by turning counterclockwise. Allow approximately 2 gallons of coolant to drain into the pan. Once drained, remove and inspect the drain plug gasket for damage and replace if necessary.
2. 2

   Disconnect upper radiator hose
   Locate the upper radiator hose connection at the radiator. Use hose clamp pliers or flathead screwdriver to release the spring clamp, then slide it back along the hose. Twist the hose gently to break the seal, then pull away from radiator neck. Remaining coolant will drain.
   Torque spec

   Hose Clamps4 Nm (3 lb-ft)
3. 3

   Remove air intake components
   Remove the engine air intake duct and air cleaner assembly to gain access to the fan shroud. Disconnect the air intake sensor connector, loosen the hose clamps at the throttle body and air cleaner outlet, then remove the mounting bolts securing the air cleaner housing.
4. 4

   Disconnect cooling fan electrical connector
   Locate the cooling fan motor electrical connector on the fan shroud assembly. Press the locking tab and pull the connector straight out. Do not pull on wires. Route the wire harness clear of the fan shroud.
   Torque spec

   Electrical Connector5 Nm (4 lb-ft)
5. 5

   Disconnect auxiliary connections
   If equipped, disconnect any auxiliary cooler lines or transmission cooler lines from the radiator. Use a flare nut wrench to prevent damage to fittings. Cap or plug open lines to prevent contamination.
6. 6

   Remove fan shroud mounting bolts
   Locate the four fan shroud mounting bolts securing the assembly to the radiator. These are positioned at the top corners and lower positions of the shroud. Remove all four bolts using a 10mm socket. Support the fan shroud assembly during removal of the final bolt.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
7. 7

   Remove fan shroud assembly
   Carefully lift the cooling fan and shroud assembly straight up and out of the engine compartment. The assembly will clear the radiator once lifted approximately 6 inches. Tilt slightly toward the engine if needed to clear obstacles. Place assembly on clean work surface.
8. 8

   Remove fan motor from shroud
   With the fan shroud on a stable work surface, locate the three or four fan motor mounting bolts securing the motor to the shroud. Remove these bolts using a 10mm socket. Note the position of any wiring clips or brackets. Separate the motor from the shroud assembly.
   Torque spec

   Fan Motor Bolts8 Nm (6 lb-ft)
9. 9

   Install new fan motor to shroud
   Position the new cooling fan motor onto the shroud, aligning all mounting holes. Ensure any wiring clips or brackets are correctly positioned. Install the fan motor bolts hand-tight, then torque to specification in a cross pattern.
   Torque spec

   Fan Motor Bolts8 Nm (6 lb-ft)
10. 10

    Reinstall fan shroud assembly
    Lower the complete fan shroud assembly into the engine compartment, ensuring it seats properly against the radiator mounting points. Align all four mounting bolt holes. Install mounting bolts hand-tight initially, then torque to specification.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
11. 11

    Reconnect electrical and hose connections
    Reconnect the cooling fan motor electrical connector until it clicks into place. Reinstall the upper radiator hose onto the radiator neck, ensuring it seats fully. Position the hose clamp 1/4 inch from the hose end and secure.
    Torque spec

    Electrical Connector5 Nm (4 lb-ft)

    Hose Clamps4 Nm (3 lb-ft)
12. 12

    Reinstall air intake components
    Reinstall the air cleaner housing and intake duct in reverse order of removal. Ensure all clamps are tight and the air intake sensor is properly connected. Verify no tools or parts are left in the engine bay.
13. 13

    Refill cooling system
    Close the radiator drain plug and torque to specification. Fill the cooling system with Toyota Super Long Life Coolant (Pink) mixed to manufacturer specification (typically 50/50 with distilled water). Fill through the radiator cap or coolant reservoir as applicable until level reaches the cold fill line.
14. 14

    Bleed cooling system and test
    Reconnect the negative battery cable. Start the engine and allow it to reach operating temperature with the heater on maximum. Monitor coolant level and add as needed. Check for leaks around all connections. Verify the cooling fan activates when the engine reaches normal operating temperature. Top off coolant as needed after cooling system is fully bled.

Reassembly

1. Torque all fasteners to specified values using a calibrated torque wrench
2. Ensure all electrical connectors are fully seated and locked
3. Verify hose clamps are positioned correctly and tightened to specification
4. Reinstall any removed under covers or splash shields

Verification

• Start engine and verify no coolant leaks at radiator hose, drain plug, or cooler line connections
• Allow engine to reach full operating temperature and verify cooling fan activates automatically
• Listen for abnormal fan motor noise during operation
• Verify coolant level is at proper cold fill mark after system has fully bled and cooled
• Confirm no warning lights are illuminated on instrument cluster
• Test drive vehicle and monitor temperature gauge remains in normal range

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