This procedure covers the removal and replacement of the upper radiator hose on a 2019-2024 Toyota RAV4 with the 2.5L I4 gasoline engine.

Warnings

Tools required

Parts

• Upper radiator hose × 1 — Use OEM specification
• Hose clamps (if corroded or damaged) × 2 — Use OEM specification

Fluids

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

Preparation

1. Ensure the engine is completely cold to the touch
2. Park the vehicle on level ground and engage the parking brake
3. Open the hood and secure it in the open position
4. Place a drain pan beneath the radiator drain plug location
5. Locate the upper radiator hose running from the top of the radiator to the engine thermostat housing

Procedure

1. 1

   Relieve cooling system pressure
   Slowly turn the radiator cap counterclockwise to the first detent and allow any residual pressure to escape. Wait until no hissing is heard, then remove the cap completely.
2. 2

   Drain coolant
   Open the radiator drain plug at the bottom of the radiator and drain approximately 2 quarts of coolant into the drain pan. This is enough to lower the coolant level below the upper hose connection. Close the drain plug once sufficient coolant has been drained.
3. 3

   Remove radiator side hose clamp
   Locate the hose clamp securing the upper radiator hose to the radiator inlet neck. Using a flathead screwdriver or hose clamp pliers, loosen the clamp by turning the screw counterclockwise or squeezing and sliding the spring clamp back along the hose, away from the radiator connection point.
4. 4

   Remove engine side hose clamp
   Locate the hose clamp securing the upper radiator hose to the thermostat housing on the engine. Loosen this clamp using the same method as the radiator side, moving the clamp away from the connection point on the thermostat housing.
5. 5

   Disconnect upper radiator hose
   Twist the hose gently while pulling to break the seal at both the radiator and thermostat housing connections. Remove the hose completely from the vehicle. Expect residual coolant to drain from the hose and connections. Use shop rags to catch any spillage.
6. 6

   Inspect connections and clean surfaces
   Inspect the radiator inlet neck and thermostat housing connection points for cracks, corrosion, or damage. Clean both surfaces with a shop rag to remove any old coolant residue or debris. Check hose clamps for corrosion or damage and replace if necessary.
7. 7

   Install new upper radiator hose
   Position the new upper radiator hose onto the thermostat housing first, ensuring it seats fully onto the connection. Then connect the radiator end, ensuring the hose is fully seated on the radiator inlet neck. Verify the hose routing matches the original configuration and does not contact any sharp edges or moving components.
8. 8

   Secure hose clamps
   Slide both hose clamps into position, approximately 1/4 inch from the end of each hose connection. Tighten each clamp to the specified torque to ensure a proper seal without damaging the hose.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
9. 9

   Refill coolant
   Using a funnel, slowly add Toyota Super Long Life Coolant (Pink) to the radiator until the coolant level reaches the base of the filler neck. Add coolant slowly to allow air to escape and prevent air pockets from forming in the system.
10. 10

    Bleed cooling system
    With the radiator cap still removed, start the engine and allow it to idle. As the engine warms, the thermostat will open and coolant will circulate. Add additional coolant as needed to maintain the proper level. Run the engine until the cooling fan cycles on, indicating the system has reached operating temperature. Squeeze the upper radiator hose several times to help purge air bubbles.
11. 11

    Final coolant level adjustment
    Turn off the engine and allow it to cool for 15-20 minutes. Check the coolant level in the radiator and top off if necessary to bring it to the base of the filler neck. Install the radiator cap securely. Check the coolant overflow reservoir and fill to the FULL mark if needed.

Reassembly

1. Ensure the radiator cap is installed securely with the pressure relief valve properly seated
2. Verify all hose clamps are torqued to specification and positioned correctly
3. Wipe down any coolant spills from the engine bay and radiator area

Verification

• Start the engine and visually inspect both hose connections for coolant leaks while the engine warms up
• Check for leaks again after the engine reaches operating temperature and the cooling fan cycles
• Verify the coolant level in the overflow reservoir is at the FULL mark when the engine is cold
• After the first drive cycle, recheck coolant level and inspect connections for any signs of weeping or leakage
• Monitor the engine temperature gauge during initial test drive to confirm normal operating temperature

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