Section 175 (Engine Cooling System (2GR-FE)): Radiator: Removal

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag activation.
REMOVE BATTERY CLAMP SUB-ASSEMBLY (See appropriate step(s) under REMOVAL )
REMOVE BATTERY INSULATOR
REMOVE BATTERY
REMOVE NO. 1 ENGINE UNDER COVER (See appropriate step(s) under REMOVAL )
DRAIN ENGINE COOLANT (See REPLACEMENT )
REMOVE V-BANK COVER SUB-ASSEMBLY (See appropriate step(s) under REMOVAL )
REMOVE RADIATOR SUPPORT OPENING COVER (See appropriate step(s) under REMOVAL )
REMOVE RADIATOR GRILLE SUB-ASSEMBLY (See appropriate step(s) under REMOVAL and DISASSEMBLY )
DISCONNECT HOOD LOCK SWITCH CONNECTOR

Fig 1: Identifying Hood Lock Switch Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT NO. 1 WATER BY-PASS HOSE
1. Disconnect the hose from the radiator reservoir. (See Fig 2).
DISCONNECT NO. 5 WATER BY-PASS HOSE
1. Disconnect the hose from the radiator.
  
  Fig 2: Disconnecting Water By-Pass Hoses
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 WATER BY-PASS PIPE
1. Disconnect the pipe from the No. 1 radiator hose.
2. Remove the 2 bolts and pipe.
DISCONNECT COOLING FAN ECU HARNESS (w/o Trailer Towing System)
1. Disconnect the fan ECU connector.
2. Detach the 3 harness clamps from the fan shroud and upper radiator support.
  
  Fig 3: Disconnecting Fan ECU Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT COOLING FAN ECU HARNESS (w/Trailer Towing System)
1. Disconnect the 2 fan ECU connectors.
2. Detach the 3 harness clamps from the fan shroud and upper radiator support.
  
  Fig 4: Disconnecting 2 Fan ECU Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT HORN CONNECTOR
1. Disconnect the 2 horn connectors.
REMOVE UPPER RADIATOR SUPPORT BRACKET
1. Remove the 2 bolts and 2 upper radiator support brackets.
  
  Fig 5: Removing Upper Radiator Support Brackets Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 FAN SHROUD
1. Remove the 2 bolts.
2. Detach the 2 claws and No. 2 shroud.
  
  Fig 6: Detaching Claws & No. 2 Shroud
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY
1. Remove the 4 bolts and upper radiator support with hood lock.
  
  Fig 7: Removing Upper Radiator Support With Hood Lock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT OIL COOLER INLET HOSE
DISCONNECT OIL COOLER OUTLET HOSE
DISCONNECT NO. 1 RADIATOR HOSE

Fig 8: Disconnecting Radiator Hoses & Water By-Pass Hose
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT NO. 2 RADIATOR HOSE
DISCONNECT NO. 2 WATER BY-PASS HOSE
1. Disconnect the by-pass hose from the radiator reservoir and radiator.
REMOVE RADIATOR ASSEMBLY
1. Detach the cooler condenser from the radiator.
  HINT:
  
  After detaching the condenser, make sure that all 4 fan shroud cushions are present.
2. Remove the radiator with the 2 radiator support lower cushions.
  HINT:
  
  After detaching the radiator, make sure that all 2 radiator support lowers are present.
REMOVE FAN SHROUD WITH COOLING FAN
1. Remove the 2 bolts and fan shroud with cooling fan from the radiator.
  
  Fig 9: Removing Fan Shroud & Fan From Radiator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002