2006 TOYOTA RAV4 engine coolant

2AZ-FE COOLING – WATER PUMPCO–11
CO
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
2. REMOVE NO. 1 ENGINE UNDER COVER
3. REMOVE FRONT FENDER APRON RH
4. REMOVE RADIATOR SUPPORT OPENING COVER
5. DRAIN ENGINE COOLANT (See page CO-6)
6. REMOVE FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-6)
7. REMOVE FAN AND GENERATOR V BELT (See page
EM-6)
8. REMOVE GENERATOR ASSEMBLY (See page CH-9)
9. REMOVE WATER PUMP PULLEY
(a) Using SST, remove the 4 bolts and water pump
pulley.
SST 09960-10010 (09962-01000, 09963-00700)
10. REMOVE WATER PUMP ASSEMBLY
(a) Remove the clamp of the crankshaft position sensor
from the water pump.
(b) Disconnect the wire of the crankshaft position
sensor from the clamp bracket.
(c) Remove the 4 bolts, 2 nuts and clamp bracket.
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2AZ-FE COOLING – WATER PUMPCO–13
CO
INSTALLATION
1. INSTALL WATER PUMP ASSEMBLY
(a) Remove any old seal packing material from the
contact surface.
(b) Apply a continuous line of seal packing as shown in
the illustration.
Seal packing:
Toyota Genuine Seal Parking Black, Three
Bond 1207B or equivalent
Standard seal diameter:
2.2 to 2.5 mm (0.09 to 0.10 in.)
NOTICE:
• Remove any oil from the contact surface.
• The parts must be set within 3 minutes after
applying seal packing. Otherwise, the
material must be removed and reapplied.
(c) Install the water pump and clamp bracket with the 4
bolts and 2 nuts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
(d) Install the wire of the crankshaft position sensor
onto the clamp bracket.
(e) Install the clamp of the crankshaft position sensor
onto the water pump.
2. INSTALL WATER PUMP PULLEY
(a) Using SST, install the water pump pulley with the 4
bolts.
SST 09960-10010 (09962-01000, 09963-00700)
Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)
3. INSTALL GENERATOR ASSEMBLY (See page CH-15)
4. INSTALL FAN AND GENERATOR V BELT (See page
EM-7)
5. INSTALL FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-7)
6. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
7. ADD ENGINE COOLANT (See page CO-6)
8. CHECK FOR ENGINE COOLANT LEAKS (See page
CO-1)
9. INSTALL RADIATOR SUPPORT OPENING COVER
10. INSTALL FRONT FENDER APRON RH
11. INSTALL NO. 1 ENGINE UNDER COVER
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CO–162AZ-FE COOLING – THERMOSTAT
CO
INSTALLATION
1. INSTALL THERMOSTAT
(a) Install a new gasket onto the thermostat.
(b) Install the thermostat with the jiggle valve upward.
HINT:
The jiggle valve may be set to within 10
on either
side of the prescribed position.
2. INSTALL WATER INLET
(a) Install the water inlet with the 2 nuts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
3. CONNECT NO. 2 RADIATOR HOSE
4. ADD ENGINE COOLANT (See page CO-6)
5. CHECK FOR ENGINE COOLANT LEAKS (See page
CO-1)
6. INSTALL RADIATOR SUPPORT OPENING COVER
7. INSTALL NO. 1 ENGINE UNDER COVER
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A112181

2AZ-FE COOLING – COOLING FAN MOTORCO–23
CO
INSTALLATION
1. INSTALL RADIATOR ASSEMBLY
(a) Install the radiator (see page CO-32).
2. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
3. ADD ENGINE COOLANT (See page CO-6)
4. CHECK FOR ENGINE COOLANT LEAKS (See page
CO-1)

2AZ-FE COOLING – RADIATORCO–29
CO
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
2. REMOVE RADIATOR SUPPORT OPENING COVER
3. REMOVE BATTERY CLAMP
(a) Remove the bolt, nut and clamp.
4. REMOVE BATTERY
5. REMOVE NO. 1 ENGINE UNDER COVER
6. DRAIN ENGINE COOLANT (See page CO-6)
7. REMOVE RADIATOR GRILLE SUB-ASSEMBLY (See
page ET-6)
8. DISCONNECT HOOD LOCK SWITCH CONNECTOR
9. DISCONNECT NO. 1 WATER BY-PASS HOSE
(a) Disconnect the hose from the radiator reservoir.
10. DISCONNECT NO. 5 WATER BY-PASS HOSE
(a) Disconnect the hose from the radiator.
11. REMOVE NO. 1 WATER BY-PASS PIPE
(a) Disconnect the pipe from the No. 1 radiator hose.
(b) Remove the 2 bolts and the pipe.
12. DISCONNECT COOLING FAN MOTOR HARNESS
(a) Disconnect the 2 fan motor connectors from the 2
fan motors.
A112308
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2AZ-FE COOLING – RADIATORCO–35
CO
14. CONNECT HOOD LOCK SWITCH CONNECTOR
15. INSTALL RADIATOR GRILLE SUB-ASSEMBLY (See
page ET-10)
16. INSTALL BATTERY
17. INSTALL BATTERY CLAMP
(a) Attach the hook of the battery clamp to the battery
bracket.
(b) Temporarily tighten the nut and install the bolt.
(c) Adjust the battery clamp's position.
(d) Fully tighten the bolt and nut.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) for bolt
5.0 N*m (51 kgf*cm, 44 in.*lbf) for nut
18. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
19. ADD ENGINE COOLANT (See page CO-6)
20. CHECK FOR ENGINE COOLANT LEAKS (See page
CO-1)
21. INSTALL RADIATOR SUPPORT OPENING COVER
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A112308

CO–62GR-FE COOLING – COOLING FAN SYSTEM
CO
ON-VEHICLE INSPECTION
HINT:
It is normal for the cooling fan to sometimes rotate when the
ignition switch is turned from ACC to ON.
1. CHECK COOLING FAN OPERATION AT LOW
TEMPERATURES (Below 94
C (201F))
(a) Turn the ignition switch ON with the A/C switch OFF.
(b) Check that the cooling fan stops.
If it does not, check the cooling fan relays and
engine coolant temperature sensor, and then check
for disconnection of the connector or wire breaks
between the cooling fan relay and engine coolant
temperature sensor.
(c) Disconnect the engine coolant temperature sensor
connector.
(d) Check that the cooling fan rotates.
If it does not, check the fuses, cooling fan relays,
ECM and cooling fan, and then check for an open
circuit between the cooling fan relay and engine
coolant temperature sensor.
(e) Reconnect the engine coolant temperature sensor
connector.
2. CHECK COOLING FAN OPERATION AT HIGH
TEMPERATURES (Above 96
C (205F))
(a) Start the engine, and then raise the coolant
temperature to above 96
C (205F).
HINT:
Coolant temperature is the value detected by the
engine coolant temperature sensor on the cylinder
head.
(b) Check that the A/C switch is OFF.
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2GR-FE COOLING – COOLING FAN SYSTEMCO–7
CO
(c) Check that the cooling fan rotates.
If it does not, check the engine coolant temperature
sensor, cooling fan, harness or connector.
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