Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001HAFT
Model Year Start: 2019 Model: RAV4 HV Prod Date Range: [02/2019 - 12/2021]
Title: A25A-FXS (COOLING): RADIATOR: REMOVAL; 2019 - 2021 MY RAV4 HV [02/2019 - 12/2021]

REMOVAL

PROCEDURE

1. REMOVE FRONT FENDER FRONT SPLASH SHIELD RH

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+ 2020 MY RAV4 HV [10/2019 - 08/2020]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+ 2021 MY RAV4 HV [08/2020 - 12/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

2. REMOVE FRONT FENDER FRONT SPLASH SHIELD LH

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+ 2020 MY RAV4 HV [10/2019 - 08/2020]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+ 2021 MY RAV4 HV [08/2020 - 12/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

3. REMOVE NO. 1 ENGINE UNDER COVER

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+ 2020 MY RAV4 HV [10/2019 - 08/2020]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+ 2021 MY RAV4 HV [08/2020 - 12/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

4. REMOVE NO. 2 ENGINE UNDER COVER ASSEMBLY

Click here 2019 MY RAV4 HV [02/2019 - 10/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+ 2020 MY RAV4 HV [10/2019 - 08/2020]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+ 2021 MY RAV4 HV [08/2020 - 12/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

5. DRAIN ENGINE COOLANT

Click here 2019 - 2021 MY RAV4 HV [02/2019 - 12/2021]; MAINTENANCE: A25A-FXS COOLANT (for Engine): REPLACEMENT+

6. REMOVE FRONT BUMPER COVER

Click here 2019 - 2020 MY RAV4 RAV4 HV [02/2019 - 08/2020]; EXTERIOR PANELS / TRIM: FRONT BUMPER (except Off Road Package): REMOVAL 2021 MY RAV4 RAV4 HV [08/2020 - 12/2021]; EXTERIOR PANELS / TRIM: FRONT BUMPER (except Off Road Package): REMOVAL

7. REMOVE FRONT BUMPER NO. 2 ENERGY ABSORBER

Click here 2019 - 2020 MY RAV4 RAV4 HV [02/2019 - 08/2020]; EXTERIOR PANELS / TRIM: FRONT BUMPER (except Off Road Package): REMOVAL+ 2021 MY RAV4 RAV4 HV [08/2020 - 12/2021]; EXTERIOR PANELS / TRIM: FRONT BUMPER (except Off Road Package): REMOVAL+

8. REMOVE FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY

Click here 2019 - 2020 MY RAV4 RAV4 HV [02/2019 - 08/2020]; EXTERIOR PANELS / TRIM: FRONT BUMPER (except Off Road Package): REMOVAL+ 2021 MY RAV4 RAV4 HV [08/2020 - 12/2021]; EXTERIOR PANELS / TRIM: FRONT BUMPER (except Off Road Package): REMOVAL+

9. REMOVE INLET AIR CLEANER ASSEMBLY

Click here 2019 - 2020 MY RAV4 HV [02/2019 - 08/2020]; A25A-FXS (ENGINE CONTROL): THROTTLE BODY: REMOVAL+ 2021 - 2024 MY RAV4 HV [08/2020 -        ]; A25A-FXS (ENGINE CONTROL): THROTTLE BODY: REMOVAL+

10. REMOVE UPPER RADIATOR AIR GUIDE PLATE

(a) Remove the 5 clips and radiator upper air guide plate.

11. REMOVE RADIATOR SHUTTER SUB-ASSEMBLY (w/ Grille Shutter)

Click here 2019 - 2021 MY RAV4 RAV4 HV [02/2019 - 12/2021]; EXTERIOR PANELS / TRIM: GRILLE SHUTTER: REMOVAL

12. REMOVE THERMISTOR ASSEMBLY (w/o Grille Shutter)

Click here 2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; HEATING / AIR CONDITIONING: AMBIENT TEMPERATURE SENSOR: REMOVAL+

13. REMOVE NO. 1 RADIATOR AIR GUIDE LH

(a) Remove the clip.

*A

w/o Grille Shutter

*B

w/ Grille Shutter

(b) w/o Grille Shutter:

Detach the claw and guide and remove the No. 1 radiator air guide LH.

(c) w/ Grille Shutter:

Detach the claw and remove the No. 1 radiator air guide LH.

14. REMOVE NO. 1 RADIATOR AIR GUIDE RH

(a) Remove the clip.

(b) Detach the claw and guide and remove the No. 1 radiator air guide RH.

15. REMOVE HOOD LOCK ASSEMBLY

Click here 2019 - 2020 MY RAV4 RAV4 HV [11/2018 - 08/2020]; DOOR / HATCH: HOOD LOCK CONTROL CABLE ASSEMBLY: REMOVAL+ 2021 - 2024 MY RAV4 RAV4 HV [08/2020 -        ]; DOOR / HATCH: HOOD LOCK CONTROL CABLE ASSEMBLY: REMOVAL+

16. REMOVE VEHICLE APPROACHING SPEAKER ASSEMBLY

Click here 2019 - 2024 MY RAV4 RAV4 HV [02/2019 -        ]; VEHICLE PROXIMITY NOTIFICATION SYSTEM: VEHICLE APPROACHING SPEAKER: REMOVAL

17. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY

(a) Disconnect the 2 horn connectors.

(b) Detach the 2 clamps and disconnect the hood lock control cable assembly from the upper radiator support sub-assembly.

*1

Hood Lock Control Cable Assembly

*2

Wire Harness

(c) Detach the 3 clamps amd disconnect the wire harness from the upper radiator support sub-assembly.

(d) Remove the 4 bolts and upper radiator support sub-assembly.

18. DISCONNECT NO. 5 WATER BY-PASS HOSE

(a) Slide the clip and disconnect the No. 5 water by-pass hose from the radiator assembly.

19. DISCONNECT NO. 6 WATER BY-PASS HOSE

(a) Disconnect the No. 6 water by-pass hose from the radiator assembly.

20. DISCONNECT NO. 1 RADIATOR HOSE (w/o Grille Shutter)

(a) Detach the clamp and disconnect the No. 1 radiator hose from the fan with motor assembly.

(b) Slide the clip and disconnect the No. 1 radiator hose from the radiator assembly.

21. DISCONNECT RADIATOR HOSE SUB-ASSEMBLY (w/ Grille Shutter)

(a) Disconnect the No. 2 engine coolant temperature sensor connector.

(b) Detach the clamp and disconnect the radiator hose sub-assembly from the fan with motor assembly.

(c) Slide the clip and disconnect the radiator hose sub-assembly from the radiator assembly.

22. DISCONNECT NO. 2 RADIATOR HOSE

(a) Detach the clamp and disconnect the No. 2 radiator hose from the fan with motor assembly.

(b) Slide the clip and disconnect the No. 2 radiator hose from the radiator assembly.

23. DISCONNECT INVERTER COOLING HOSE

(a) Detach the clamp and disconnect the No. 4 inverter cooling hose from the fan with motor assembly.

*1

No. 4 Inverter Cooling Hose

*2

No. 5 Inverter Cooling Hose

(b) Detach the 3 clamps and disconnect the No. 5 inverter cooling hose from the fan with motor assembly.

24. REMOVE RADIATOR ASSEMBLY

(a) Detach the claw and raise the lock lever to disconnect the cooling fan motor connector as shown in the illustration.

NOTICE:

After disconnecting the cooling fan motor connector, make sure that dirt, water or other foreign matter does not contact the connecting parts of the cooling fan motor connector.

*a

Lock Lever

(b) Detach the 2 wire harness clamps.

(c) Detach the 2 claws.

(d) Detach the 2 guides and disconnect the cooler condenser assembly with the radiator assembly (for Inverter Coolant) from the radiator assembly.

NOTICE:

Make sure not to damage the cooler condenser assembly with the radiator assembly (for Inverter Coolant) when disconnecting the cooler condenser assembly with the radiator assembly (for Inverter Coolant).

(e) Remove the radiator assembly with the fan with motor assembly from the vehicle body.

NOTICE:

Do not apply excessive force to the cooler condenser assembly with the radiator assembly (for Inverter Coolant) or pipe and hose when removing the radiator assembly with the fan with motor assembly.

(f) Detach the 2 claws.

(g) Detach the 2 guides and remove the fan with motor assembly from the radiator assembly.

NOTICE:

Do not damage the radiator assembly when removing the fan with motor assembly.

25. REMOVE RADIATOR SUPPORT CUSHION

(a) Remove the 2 radiator support cushions from the radiator assembly.

26. REMOVE LOWER RADIATOR SUPPORT

(a) Remove the 2 lower radiator supports from the radiator assembly.

27. REMOVE FILLER NECK

(a) Pull out the retainer to disengage the lock claws and pull off the filler neck.

*a

Retainer

Pulling in this Direction

Remove in this Direction

NOTICE:

If the filler neck O-ring is damaged, replace it with a new one.