This procedure covers removal and replacement of the engine oil cooler assembly on the 2019-2024 Toyota RAV4 with 2.5L I4 engine, including coolant drainage, hose disconnection, and component reinstallation.

Warnings

Tools required

Parts

• Engine oil cooler assembly × 1 — Use OEM specification
• Oil cooler gasket/O-ring kit × 1 — Use OEM specification
• Coolant hose clamps (if damaged) × 2 — Replace as needed

Fluids

• Toyota Super Long Life Coolant (Pink) — 3 qt

Preparation

1. Ensure engine is completely cool to the touch (minimum 2 hours after operation)
2. Park vehicle on level surface and engage parking brake
3. Disconnect negative battery terminal to prevent electrical issues
4. Remove engine splash shield/under cover if equipped for access to drain plug
5. Place drain pan under radiator drain plug location

Procedure

1. 1

   Drain engine coolant
   Locate the radiator drain plug at the bottom of the radiator on the driver's side. Slowly loosen and remove the coolant drain plug, allowing coolant to drain into the pan. Remove the radiator cap to speed drainage. Drain approximately 3 quarts or until coolant level is below the oil cooler location on the engine block.
   Torque spec

   Coolant Drain Plug15 Nm (11 lb-ft)
2. 2

   Access oil cooler location
   The oil cooler is mounted on the front-lower section of the engine block, below the thermostat housing. Remove any plastic engine covers by pulling upward on the clips. You may need to remove or reposition the air intake duct for better access depending on your working position.
3. 3

   Disconnect coolant hoses
   Identify the two coolant hoses connected to the oil cooler assembly. Use pliers to compress and slide the spring clamps away from the connection points. Twist and pull the hoses off the cooler nipples. Expect residual coolant to drain; have towels ready. Inspect hoses for cracks or deterioration.
   ⚠Coolant hoses may be stiff from heat cycles. Avoid excessive force that could crack the oil cooler nipples. Gently twist while pulling.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
4. 4

   Remove oil cooler mounting bolts
   Locate the two mounting bolts securing the oil cooler to the engine block. These are typically 12mm bolts. Using a socket and ratchet, remove both mounting bolts completely. Keep bolts organized for reinstallation.
   Torque spec

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

   Remove oil cooler assembly
   Carefully pull the oil cooler assembly away from the engine block. There will be an O-ring or gasket seal that may cause resistance. Twist gently while pulling to break the seal. Once removed, place the old cooler in a drain pan as residual oil may drip out. Inspect the mounting surface on the engine block.
6. 6

   Clean mounting surface
   Using a plastic scraper or gasket remover tool, carefully clean all old gasket material and residue from the engine block mounting surface. Ensure the surface is completely clean and dry. Do not allow debris to fall into any open engine passages. Wipe clean with a lint-free cloth.
   ⚠Do not use metal scrapers that could gouge the aluminum engine block surface. Use only plastic tools to prevent damage to sealing surfaces.
7. 7

   Prepare new oil cooler
   Unpack the new oil cooler assembly and verify it matches the old unit. Install new O-rings or gaskets onto the cooler according to the kit instructions. Lightly coat the O-rings with clean engine oil or coolant to aid installation and prevent tearing. Ensure O-rings are seated properly in their grooves.
8. 8

   Install new oil cooler
   Align the new oil cooler with the mounting holes on the engine block. Carefully push the cooler into place, ensuring the O-rings seat properly against the block surface. Start both mounting bolts by hand to ensure proper thread engagement before tightening.
9. 9

   Torque mounting bolts
   Using a torque wrench, tighten the oil cooler mounting bolts to specification in a crisscross pattern (alternating between bolts). This ensures even pressure on the gasket and proper sealing.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
10. 10

    Reconnect coolant hoses
    Slide the coolant hoses back onto the oil cooler nipples, ensuring they are fully seated (you should feel them bottom out). Position the spring clamps or install new clamps over the hose connections in the correct location (typically 10-15mm from the end of the nipple). Ensure clamps are securely fastened.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
11. 11

    Reinstall drain plug and refill coolant
    Install the radiator drain plug with a new washer if available and torque to specification. Reinstall the radiator cap temporarily. Using the coolant refill funnel, slowly add Toyota Super Long Life Coolant (pink) to the radiator until full. Start the engine and allow it to warm to operating temperature while adding coolant as the system burps air.
    ℹ️The cooling system may take 10-15 minutes to fully burp air. Keep coolant level topped up during this process and watch for leaks around the oil cooler.
    Torque spec

    Coolant Drain Plug15 Nm (11 lb-ft)
12. 12

    Check for leaks and verify operation
    With the engine at operating temperature, carefully inspect all connections at the oil cooler for coolant leaks. Check both hose connections and the mounting surface. Turn off the engine and allow to cool slightly, then top off coolant to the proper level. Reinstall any removed covers, air ducts, and splash shields.

Reassembly

1. Reinstall engine splash shield/under cover with appropriate fasteners
2. Reinstall air intake duct and any engine covers removed for access
3. Reconnect negative battery terminal
4. Double-check all fasteners are tightened and no tools are left in engine bay

Verification

• Start engine and verify no coolant leaks at oil cooler assembly or hose connections
• Allow engine to reach full operating temperature and recheck for leaks
• Verify coolant level is at proper mark on overflow reservoir when engine is cool
• Check engine oil level and condition; oil should not appear milky or diluted with coolant
• Monitor coolant level over the next few days of driving to ensure system is properly filled

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