Coolant: 2002 ENGINE Cooling - RAV4 2002 ENGINE Cooling - RAV4

2002 Toyota RAV4
2002 ENGINE Cooling - RAV4
2002 ENGINE
Cooling - RAV4
COOLANT
INSPECTION
NOTE: Check the coolant level when the engine is cold.
1. Check engine coolant level at radiator reservoir .
The engine coolant level should be between the "L" and "F" lines.
If low, check for leaks and add "Toyota Long Life Coolant" or equivalent up to between the "L" and "F";
lines.
2. Check engine coolant quality .

a. Remove the radiator cap.
CAUTION: To avoid the danger of being burned, do not remove the radiator
cap while the engine and radiator are still hot, as fluid and
steam can be blown out under pressure.
b. There should not be excessive deposits of rust or scale around the radiator cap or water filler hole,
and the coolant should be free from oil.
If excessively dirty, clean the coolant passages and replace the coolant.
c. Reinstall the radiator cap.
REPLACEMENT
CAUTION: To avoid the danger of being burned, do not remove the radiator cap while
the engine and radiator are still hot, as fluid and steam can be blown out
under pressure.
1. Drain engine coolant .

a. Remove the radiator cap.
b. Loosen the radiator drain plug (on the left side of the radiator lower tank) and engine drain plug,
and drain the coolant.
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2002 Toyota RAV4
Fig. 1: Locating Engine & Radiator Drain Plug

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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November-03-08 7:01:06 PM Page 2 © 2005 Mitchell Repair Information Company, LLC.
2002 Toyota RAV4
c. Close the drain plugs.

Torque: 5 N.m (50 kgf.cm, 43 in..lbf) for engine
2. Fill engine coolant .
a. Slowly fill the system with coolant.
z Use of improper coolants may damage engine cooling system.
z Use "Toyota Long Life Coolant" or equivalent and mix it with plain water according to the
manufacturer's directions.
z Using coolant which includes more than 50 % [freezing protection down to - 35°C (-31°F)]
or 60 % [freezing protection down to -50°C (-58°F)] of ethylene- glycol is recommended but
not more than 70 %.
NOTE: z Do not use an alcohol type coolant or plain water alone.

z The coolant should be mixed with plain water (preferably
demineralized water or distilled water).
Coolant Capacity (W/ Heater)

Transmission
M/T 6.3 liters (6.7 US qts, 5
A/T 6.2 liters (6.6 US qts, 5
zReinstall the radiator cap.

z Start the engine, and bleed the cooling system.
z Refill the radiator reservoir with coolant until it reaches the "F" line.
b. Check engine coolant for leaks .

c. Check engine coolant specific gravity correctly .
WATER PUMP
ON-VEHICLE INSPECTION
NOTE: Be sure to do checking when the engine coolant is changed.
Inspect Water Pump
a. Remove the drive belt (See CHARGING SYSTEM ).

b. Turn the pulley, and check that the water pump bearing moves smoothly and quietly.
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2002 Toyota RAV4
Fig. 2: Checking Water Pump Bearing

If necessary, replace the water pump.
c. Remove the water pump pulley (See REMOVAL ).

d. Visually check the inlet hole and drain hole for coolant leakage.
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2002 Toyota RAV4
Fig. 3: Checking Inlet Hole

If leakage is found, replace the water pump.
e. Reinstall the water pump pulley (See INSTALLATION ).

f. Reinstall the drive belt (See CHARGING SYSTEM ).
COMPONENTS
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2002 Toyota RAV4
Fig. 4: Displaying Water Pump Components

REMOVAL
1. Drain engine coolant (See REPLACEMENT ) .

2. Remove drive belt (See CHARGING SYSTEM ) .
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2002 Toyota RAV4
3. Remove water pump .

a. Using SST, remove the 4 bolts and pump pulley.
SST 09960-10010 (09962-01000, 09963-00600)
Fig. 5: Removing Water Pump

b. Disconnect the crankshaft position sensor wire clamp from the water pump.
c. Disconnect the crankshaft position sensor wire from the clamp on the water pump.
d. Remove the 4 bolts, 2 nuts, wire clamp and water pump.
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2002 Toyota RAV4
Fig. 6: Locating Wire Clamp & Water Pump Fasteners

e. Using a screwdriver, pry between the water pump and cylinder block, and remove the water pump.
NOTE: Be careful not to damage the contact surface of the water pump and
cylinder block.
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2002 Toyota RAV4
Fig. 7: Removing Water Pump

INSTALLATION
1. Install water pump .

a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contacting
surfaces of the water pump and cylinder block.
z Using a razor blade and gasket scraper, remove all the old packing (FIPG) materials from the
gasket surfaces and sealing grooves.
z Thoroughly clean all components to remove all the loose material.
z Using a non-residue solvent, clean both sealing surfaces.
b. Apply seal packing to the water pump as shown in the illustration.

Seal packing: Part No. 08826-00100 or equivalent
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2002 Toyota RAV4
Fig. 8: Applying Seal Packing To Water Pump

z Install a nozzle that has been cut to a 2.2 - 2.5 mm (0.09-0.10 in.) opening.
z Parts must be assembled within 5 minutes of application. Otherwise the material must be
removed and reapplied.
z Immediately remove nozzle from the tube and reinstall cap.
c. Install the water pump and wire clamp with the 4 bolts and 2 nuts.
Torque: 9 N.m (90 kgf.cm, 80 in..lbf)
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2002 Toyota RAV4
Fig. 9: Installing Water Pump & Wire Clamp

d. Install the crankshaft position sensor wire harness clamp to the water pump.
e. Install the crankshaft position sensor wire to the wire clamp on the water pump.
f. Using SST, install the pump pulley with the 4 bolts.
SST 09960-10010 (09962-01000. 09963-00600)
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2002 Toyota RAV4
Fig. 10: Installing Pump Pulley Using SST

Torque: 26 N.m (265 kgf.cm, 19 ft.lbf)

g. Install drive belt (See CHARGING SYSTEM ) .
h. Fill with engine coolant .
i. Start engine and check for coolant leaks .
j. Recheck engine coolant level .
THERMOSTAT
COMPONENTS
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2002 Toyota RAV4
Fig. 11: Identifying Components For Thermostat Removal

REMOVAL
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2002 Toyota RAV4
NOTE: Removal of the thermostat would have an adverse effect, causing a lowering of
cooling efficiency. Do not remove the thermostat, even if the engine tends to
overheat.
1. Drain engine coolant (See REPLACEMENT ) .

2. Remove drive belt (See CHARGING SYSTEM ) .
3. Remove generator (See GENERATOR ) .
4. Remove water inlet and thermostat .
a. Remove the 2 nuts and water inlet.
b. Remove the thermostat.
c. Remove the gasket from the thermostat.
Fig. 12: Removing Water Inlet & Thermostat

INSPECTION
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2002 Toyota RAV4
Inspect Thermostat
Fig. 13: Locating Valve Opening Temperature

NOTE: The thermostat is numbered with the valve opening temperature.
a. Immerse the thermostat in water and gradually heat the water.
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2002 Toyota RAV4
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2002 Toyota RAV4
Fig. 14: Testing Thermostat In Water

b. Check the valve opening temperature.

Valve opening temperature: 80-84°C (176-183.2°F)
If the valve opening temperature is not as specified, replace the thermostat.
c. Check the valve lift.

Valve lift: 10 mm (0.39 in.) or more at 95°C (203°F)
Fig. 15: Checking Thermostat Valve Lift

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2002 Toyota RAV4
If the valve lift is not as specified, replace the thermostat.
d. Check that the valve is fully closed when the thermostat is at low temperatures (below 40°C (104°F)).
If not closed, replace the thermostat.
INSTALLATION
1. Place thermostat in cylinder block .

a. Install a new gasket to the thermostat.
b. Install the thermostat with the jiggle valve upward.
Fig. 16: Locating Jiggle Valve

NOTE: The jiggle valve may be set within 10° of either side of the prescribed
position.
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2002 Toyota RAV4
2. Install water inlet .
Fig. 17: Installing Water Inlet

Install the water inlet with the 2 nuts.

Torque: 9 N.m (90 kgf.cm, 80 in..lbf)
3. Install generator (See CHARGING SYSTEM ) .

4. Install drive belt (See CHARGING SYSTEM ) .
5. Fill with engine coolant (See REPLACEMENT ) .
6. Start engine and check for leaks .
7. Recheck engine coolant level .
RADIATOR
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2002 Toyota RAV4
ON-VEHICLE CLEANING
Using water or a steam cleaner, remove any mud or dirt from the radiator core.
NOTE: If using a high pressure type cleaner, be careful not to deform the fins of the
radiator core. (i.e.Maintain a distance between the cleaner nozzle and radiator
core.)
ON-VEHICLE INSPECTION
1. Remove radiator cap .
CAUTION: To avoid the danger of being burned, do not remove the radiator cap
while the engine and radiator are still hot, as fluid and steam can be
blown out under pressure.
2. Inspect radiator cap .
NOTE: z If the radiator cap has contaminations, always rinse it with water.
z Before using a radiator cap tester, wet the relief valve and pressure
valve with engine coolant or water.
z When performing steps (a) and (b) below, keep the radiator cap tester
at an angle of over 30° above the horizontal.
a. Using a radiator cap tester, slowly pump the tester and check that air is coming from the vacuum
valve.
Pump speed: 1 push/(3 seconds or more)
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2002 Toyota RAV4
Fig. 18: Displaying Radiator Cap Tester

NOTE: Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the radiator cap.
3. Pump the tester and measure the relief valve opening pressure.
Pump speed: 1 push within 1 second
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2002 Toyota RAV4
Fig. 19: Displaying Radiator Cap Tester

NOTE: This pump speed is for the first pump only (in order to close the vacuum
valve). After this, the pump speed can be reduced.
Standard opening pressure: 93-123 kPa (0.95- 1.25 kgf/cm2 ,13.5 -17.8 psi)
Minimum opening pressure: 79 kPa (0.8 kgf/cm2 ,11.5 psi)
NOTE: Use the tester's maximum reading as the opening pressure. If the opening
pressure is less than minimum, replace the radiator cap.
4. Inspect cooling system for leaks .

a. Fill the radiator with coolant and attach a radiator cap tester.
b. Warm up the engine.
c. Pump it to 118 kPa (1.2 kgf/cm2 , 17.1 psi), and check that the pressure does not drop.
If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are
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2002 Toyota RAV4
found, check the heater core, cylinder block and head.
d. Reinstall radiator cap .
COMPONENTS
Fig. 20: Identifying Components For Radiator Removal

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2002 Toyota RAV4
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2002 Toyota RAV4
Fig. 21: Exploded View Of Radiator

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2002 Toyota RAV4
REMOVAL
1. Drain engine coolant.

2. Remove radiator grille .
Remove the 4 screws, 2 clips and radiator grille.
Fig. 22: Locating Radiator Grille Screws

3. Remove front end panel .
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2002 Toyota RAV4
Fig. 23: Removing Front End Panel

Remove the 4 screws and front end panel.
4. Disconnect hood lock .
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2002 Toyota RAV4
Fig. 24: Disconnecting Hood Lock

a. Remove the 3 bolts, and disconnect the hood lock.

b. Disconnect the wire from the clamp.
5. Disconnect upper radiator hose .
6. Remove upper radiator support .
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2002 Toyota RAV4
Fig. 25: Locating Radiator Bolts & Support

Remove the 5 bolts and radiator support.
7. Remove LH engine under cover .

8. Remove radiator reservoir .
9. Remove No. 1 and No. 2 cooling fans (See ELECTRIC COOLING FAN ) .
10. A/T: Disconnect oil 2 hoses .
Disconnect the 2 oil cooler hoses from the radiator.
11. Disconnect ECT switch connector .

12. Disconnect lower radiator hose .
13. Remove radiator .
14. Remove upper and lower radiator supports from radiator .
DISASSEMBLY
1. Remove drain plug .
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2002 Toyota RAV4
a. Remove the drain plug.

b. Remove the O-ring.
2. Assemble SST .
SST 09230-01010
Fig. 26: Displaying SST Assemble

a. Install the claw to the overhaul handle, inserting it in the hole in part "A" as shown in the
diagram.
b. While gripping the handle, adjust the stopper bolts so that dimension "B" is as shown in the
illustration.
Dimension "B": 0.2 - 0.3 mm (0.008 - 0.012 in.)
NOTE: If this adjustment is not done the claw may be damaged.
3. Uncaulk lock plates .

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2002 Toyota RAV4
Fig. 27: Uncaulking Lock Plates

Using SST to release the caulking, squeeze the handle until stopped by the stopper bolts.
SST 09230-01010
4. Remove tanks and "O"-rings .
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2002 Toyota RAV4
Fig. 28: Removing Tanks & "O"-Rings

Lightly tap the bracket of the radiator (or radiator inlet or outlet) with a soft-faced hammer, and remove
the tank and the "O"-ring.
5. A/T: Remove oil cooler pipes from lower tank .
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2002 Toyota RAV4
Fig. 29: Removing Oil Cooler Pipes From Lower Tank

a. Loosen the 2 nuts, and remove the 2 pipes.

b. Remove the 2 nuts.
c. Remove the 2 "O"-rings from the oil cooler.
REASSEMBLY
1. A/T: Install oil cooler pipes to lower tank .
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2002 Toyota RAV4
Fig. 30: Installing Oil Cooler Pipes To Lower Tank

a. Install 2 new O-rings to the oil cooler.

b. Install the 2 nuts.
Torque: 12 N.m (120 kgf.cm, 10 ft.lbf)
c. Install the LH cooler pipe in the direction indicated in the illustration.
Torque: 14.7 N.m (150 kgf.cm, 11 ft.lbf)
d. Install the RH cooler pipe.
Torque: 14.7 N.m (150 kgf.cm, 11 ft.lbf)
2. Inspect lock plate for damage .
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2002 Toyota RAV4
Fig. 31: Inspecting Lock Plates For Damage

NOTE: z If the sides of the lock plate groove are deformed, reassembly of the
tank will be impossible.
z Therefore, first correct any deformation with pliers or similar object.
Water leakage will result if the bottom of the lock plate groove is
damaged.
NOTE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator
core must be replaced.
3. Install new o-rings and tanks .

a. After checking that there are no foreign objects in the lock plate groove, install the new "O"-ring
without twisting it.
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2002 Toyota RAV4
Fig. 32: Installing New "O"-Rings & Tanks

NOTE: When cleaning the lock plate groove, lightly rub it with sand paper
without scratching it.
b. Install the tank without damaging the "O"-ring.

c. Tap the lock plate with a soft-faced hammer so that there is no gap between it and the tank.
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2002 Toyota RAV4
Fig. 33: Tapping Lock Plate

4. Assemble SST .
SST 09230-01010,09231-14010
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2002 Toyota RAV4
Fig. 34: Displaying SST Tool

a. Install the punch assembly to the overhaul handle, inserting it in the hole in part "A" as shown in
the illustration.
b. While gripping the handle, adjust the stopper bolt so that dimension "B" is as shown in the
illustration.
Dimension "B": 8.4 mm (0.331 in.)
5. Caulk lock plate .
a. Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a
few times, fully caulk the lock plate by squeezing the handle until touch the stopper bolt.
SST 09230-01010
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2002 Toyota RAV4
Fig. 35: Caulking Lock Plate

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2002 Toyota RAV4
NOTE: z Do not stake the areas protruding around the pipes, brackets or tank rib
Fig. 36: Displaying Tank Areas

b. The points shown in Fig. 36 cannot be staked with SST. Use pliers or similar object and be careful
not to damage the core plates.
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2002 Toyota RAV4
Fig. 37: Displaying Appropriate Plier Use

c. Check the lock plate height (H) after completing the caulking.
Plate height (H): 8.45 - 8.85 mm (0.3327 - 0.3484 in.)
If not within the specified height, adjust the stopper bolt of the handle again and caulk again.
6. Install drain plug .

a. Install a new O-ring to the drain plug.
b. Install the drain plug.
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2002 Toyota RAV4
Fig. 38: Checking Lock Plate Height

7. Inspect for water leaks .

a. Tighten the drain plug.
b. Plug the inlet and outlet pipes of the radiator with SST.
SST 09230-01010
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2002 Toyota RAV4
Fig. 39: Tightening Drain Plugs Using SST

c. Using a radiator cap tester, apply pressure to the radiator.

Test pressure: 177 kPa (1.8 kgf/cm2 , 26 psi)
d. Submerge the radiator in water.
e. Inspect for leaks.
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2002 Toyota RAV4
Fig. 40: Inspecting For Water Leaks

NOTE: On radiators with resin tanks, there is a clearance between the tank
and lock plate where a minute amount of air will remain, giving the
appearance of an air leak when the radiator is submerged in water.
therefore, before doing the water leak test, first swish the radiator
around in the water until all bubbles disappear.
INSTALLATION
1. Install upper and lower radiator supports to radiator .

2. Install radiator .
3. Connect lower radiator hose .
4. A/T:Connect 2 hoses .
Connect the 2 oil cooler hoses to the radiator.
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2002 Toyota RAV4
5. Connect ECT switch connector .

6. Install No. 1 and No. 2 cooling fans (See ELECTRIC COOLING FAN ) .
7. Install radiator reservoir.
8. Install RH engine under cover .
9. Install upper radiator support .
Fig. 41: Locating Radiator Bolts

Install the radiator upper support with the 5 bolts.
10. Connect upper radiator hose .
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2002 Toyota RAV4
Fig. 42: Locating Upper Radiator Hose Bolts

11. Connect hood lock .

a. Install the hood lock with the 3 bolts.
b. Install the wire from the clamps.
c. Install front end panel .
Install the front end panel with the 4 screws.
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2002 Toyota RAV4
Fig. 43: Locating Front End Panel Screws

d. Install radiator grille .
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Fig. 44: Locating Radiator Grille Screws & Clips

Install the radiator grille with the 4 screws and 2 clips.
e. Fill with engine coolant .

f. Start engine and check for coolant leaks .
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2002 Toyota RAV4

2002 ENGINE Cooling - RAV4

NOTE: Check the coolant level when the engine is cold.

1. Check engine coolant level at radiator reservoir .

2. Check engine coolant quality .

c. Reinstall the radiator cap.

1. Drain engine coolant .

Fig. 1: Locating Engine & Radiator Drain Plug

c. Close the drain plugs.

NOTE: z Do not use an alcohol type coolant or plain water alone.

Coolant Capacity (W/ Heater)

zReinstall the radiator cap.

b. Check engine coolant for leaks .

NOTE: Be sure to do checking when the engine coolant is changed.

Inspect Water Pump

a. Remove the drive belt (See CHARGING SYSTEM ).

Fig. 2: Checking Water Pump Bearing

If necessary, replace the water pump.

c. Remove the water pump pulley (See REMOVAL ).

Fig. 3: Checking Inlet Hole

If leakage is found, replace the water pump.

e. Reinstall the water pump pulley (See INSTALLATION ).

Fig. 4: Displaying Water Pump Components

1. Drain engine coolant (See REPLACEMENT ) .

3. Remove water pump .

Fig. 5: Removing Water Pump

Fig. 6: Locating Wire Clamp & Water Pump Fasteners

Fig. 7: Removing Water Pump

1. Install water pump .

z Using a non-residue solvent, clean both sealing surfaces.

b. Apply seal packing to the water pump as shown in the illustration.

Fig. 8: Applying Seal Packing To Water Pump

Fig. 9: Installing Water Pump & Wire Clamp

Fig. 10: Installing Pump Pulley Using SST

Torque: 26 N.m (265 kgf.cm, 19 ft.lbf)

Fig. 11: Identifying Components For Thermostat Removal

1. Drain engine coolant (See REPLACEMENT ) .

Fig. 12: Removing Water Inlet & Thermostat

Fig. 13: Locating Valve Opening Temperature

NOTE: The thermostat is numbered with the valve opening temperature.

a. Immerse the thermostat in water and gradually heat the water.

Fig. 14: Testing Thermostat In Water

b. Check the valve opening temperature.

If the valve opening temperature is not as specified, replace the thermostat.

c. Check the valve lift.

Fig. 15: Checking Thermostat Valve Lift

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

If the valve lift is not as specified, replace the thermostat.

If not closed, replace the thermostat.

1. Place thermostat in cylinder block .

Fig. 16: Locating Jiggle Valve

2. Install water inlet .

Fig. 17: Installing Water Inlet

Install the water inlet with the 2 nuts.

3. Install generator (See CHARGING SYSTEM ) .

1. Remove radiator cap .

2. Inspect radiator cap .

Fig. 18: Displaying Radiator Cap Tester

NOTE: Push the pump at a constant speed.