Complete radiator replacement procedure for 2019-2024 Toyota RAV4 2.5L I4, including coolant drain, component removal, and system refill.

Warnings

Tools required

Parts

• Radiator assembly × 1 — Use OEM specification
• Upper radiator hose × 1 — Reuse if in good condition
• Lower radiator hose × 1 — Reuse if in good condition
• Radiator drain plug seal × 1 — 90044-52002 or equivalent
• Hose clamps × 4 — Replace if corroded

Fluids

• Toyota Super Long Life Coolant (Pink) — 10 qt

Preparation

1. Ensure engine is completely cold. Verify coolant reservoir cap can be touched with bare hand.
2. Park vehicle on level surface and engage parking brake.
3. Remove engine splash shield and undercover using 10mm socket and Phillips screwdriver.
4. Place large drain pan (12+ quarts) under radiator drain area.
5. Disconnect negative battery terminal using 10mm wrench to prevent fan activation.

Procedure

1. 1

   Drain cooling system
   Slowly remove radiator cap to release any residual pressure. Locate radiator drain petcock on driver side lower corner of radiator. Open drain petcock by turning counterclockwise and allow coolant to drain completely into pan. This will take approximately 5-10 minutes.
   Torque spec

   Drain Petcock5 Nm (4 lb-ft)
2. 2

   Remove upper components
   Remove radiator upper cover by removing plastic push clips and screws. Remove air intake duct from front of radiator area for access. Disconnect overflow hose from radiator filler neck.
3. 3

   Disconnect upper radiator hose
   Locate upper radiator hose at top of radiator. Using hose clamp pliers or flat blade screwdriver, loosen hose clamp and slide away from connection point. Twist hose gently to break seal, then pull off radiator neck. Be prepared for residual coolant spillage.
   ⚠Inspect hose for cracks, bulges, or hardening. Replace if condition is questionable.
   Torque spec

   Upper/Lower Hose Clamps3 Nm (2 lb-ft)
4. 4

   Disconnect lower radiator hose
   From underneath vehicle, locate lower radiator hose connection at bottom of radiator. Loosen hose clamp and slide back. Twist and remove hose from radiator. Allow any remaining coolant to drain.
   Torque spec

   Upper/Lower Hose Clamps3 Nm (2 lb-ft)
5. 5

   Disconnect cooling fan connectors
   Locate electrical connectors on radiator cooling fan assembly (typically two connectors on driver side). Press release tabs and disconnect both fan motor connectors. Ensure connectors are moved clear of radiator removal path.
6. 6

   Remove radiator mounting bolts
   Locate radiator mounting brackets at top corners of radiator assembly. Remove mounting bolts (typically two per side, four total) using 12mm socket. Support radiator with one hand while removing final bolts.
   ⚠Radiator is now loose and can fall. Maintain support while removing last fasteners.
   Torque spec

   Radiator Mount Bolts12 Nm (9 lb-ft)
7. 7

   Remove condenser mounting hardware
   The A/C condenser is mounted in front of radiator. Remove upper condenser mounting brackets (two bolts) and carefully separate condenser from radiator. Do not disconnect A/C lines. Support condenser safely to side without stressing refrigerant lines.
8. 8

   Extract radiator assembly
   Carefully lift radiator assembly upward and out of engine bay. Radiator cooling fan assembly is attached and will come out together. Tilt slightly as needed to clear hose connections and engine components. Watch for any remaining connected hoses or wiring.
   ⚠Radiator fins are fragile and sharp. Use care when handling to avoid cuts and damage.
9. 9

   Prepare new radiator
   Compare new radiator to old unit to verify correct replacement. Transfer any necessary hardware from old radiator to new (rubber isolators, mounting brackets if not included). Install new drain plug seal. Close drain petcock finger tight on new radiator.
   Torque spec

   Drain Petcock5 Nm (4 lb-ft)
10. 10

    Install radiator assembly
    Lower new radiator with fan assembly into position in engine bay. Align lower mounting pins with frame slots. Ensure rubber isolators seat properly in frame mounts. Align upper mounting bracket holes.
    ℹ️Verify radiator sits flush and even in mounting points before installing bolts.
11. 11

    Secure radiator mounting bolts
    Install all four radiator mounting bolts and tighten to specification using torque wrench. Do not overtighten as plastic mounting ears can crack. Verify radiator is secure and does not move when gently pulled.
    Torque spec

    Radiator Mount Bolts12 Nm (9 lb-ft)
12. 12

    Reinstall condenser
    Position A/C condenser against front of radiator. Install upper condenser mounting brackets and bolts to specification. Ensure proper clearance between condenser and radiator fins.
13. 13

    Reconnect hoses and electrical
    Connect lower radiator hose to radiator neck and position clamp properly. Tighten hose clamp to specification. Connect upper radiator hose and tighten clamp to specification. Reconnect both cooling fan electrical connectors until they click. Reattach overflow hose to radiator filler neck.
    Torque spec

    Upper/Lower Hose Clamps3 Nm (2 lb-ft)
14. 14

    Refill cooling system
    Using funnel at radiator cap opening, slowly pour Toyota Super Long Life Coolant (pink) until radiator is full. Fill to neck level. Fill coolant reservoir to FULL line. Start engine with radiator cap OFF and allow to idle while monitoring coolant level. Add coolant as level drops during burping process. Gently squeeze upper radiator hose to help release air pockets.
    ⚠Keep hands clear of cooling fan which may activate at any time during warm-up.
15. 15

    Final system bleeding
    Continue running engine until cooling fans cycle on and off at least once (approximately 15 minutes). With engine at operating temperature, verify coolant level remains full at radiator neck and reservoir is at FULL line. Install radiator cap when system is fully burped. Allow engine to cool, then recheck coolant levels and top off reservoir if needed.

Reassembly

1. Reinstall upper radiator cover and secure with screws to specification
2. Reinstall air intake duct to original position
3. Reinstall engine splash shield and undercover
4. Reconnect negative battery terminal
5. Verify drain petcock is closed and not leaking

Verification

• Start engine and verify no coolant leaks at radiator connections, hoses, or drain petcock
• Confirm both cooling fans operate when engine reaches operating temperature
• Check coolant level in reservoir after engine cools completely - should be at FULL line
• Verify radiator cap seals properly and holds pressure
• Test drive vehicle and monitor temperature gauge for normal operation
• Recheck all connections and coolant level after first drive cycle

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