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98 Rav4 radiator installation
Hi ya’ll! Dne’ here! Today I started working on the radiator removal on my youngest daughters 98 Rav4 AWD, with 289,000 miles. However, it’s not the original radiator. It was replaced at 144,000.
This removal/installation is a modified version in that I’m going to modify the radiator support for an easier installation of the radiator (not removal in my case). This will require cutting the radiator support for what I’m wanting to carry out. But for those who may “think out of the box” like me, read on! ; )
(Please check out at the end of this blog for a viewers project pics of doing this simple mod!! 😉 )
However, I did begin by removing the radiator the “normal” way. I fought it all the way just to get the radiator out!
A picture before diving in!
Owning a MaxJax lift really makes my life easier! During this removal, I had the Rav up and down several times!
OK, here we go~ start taking stuff off! I don’t think I need to go into detail about the little things. If you’re able to tackle something like this, common sense will be your “spider sense”. ; )
Air box removed, dryer unbolted from the frame to allow movement of the condensor, the tranny dipstick tube retainer bolt was loosened so the dipstick tube could be moved so the driver’s side fan could be removed, but not easily.
Notice the AC line is unbolted to allow greatest movement without draining the system. Don’t stretch them too much!
I have a pry bar (round end) inserted into the transmission dipstick tube so I can move it, plus keeps the hole plugged so nothing will fall down it! That would be horrible!
below: The passenger side fan just will not let the radiator come out! The lower radiator hose “thing”(you know, where the lower radiator hose attaches) is just too long. Even with the electric fan totally unbolted it was difficult, but did come out with a little force. God I hope I didn’t damage the condenser!
Note (Important): the bottom of the condensor needs to be lifted slightly off of its perch and moved slight forward to allow the radiator to be pulled upwards and eventually out.
This is the left side (drivers) grommet which the prongs of the radiator go into to hold the bottom in place. These stick to the radiator making the initial pull up to get it lose stubborn.
A view of the HOLE where the radiator was. It’s tight.
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I purchased my radiator off of Ebay from Radiator Classic for 86.00, free shipping with a lifetime warranty. Can’t beat that!
Maybe it was fate! But my new radiator was out of square! I sent it back and should receive the replacement in a couple of days. Radiator Classic jumped right on it to get another radiator to me when I called them, they were great to deal with! This little break of waiting for the next radiator allowed me to think about the idea of cutting the radiator support which also holds the hood latch. I lost more sleep thinking about this!
Here’s where it starts! I bolted the fans back on to the old radiator just to see how thick it would be, will it work? What if I screw up! 🙁
I used a sawzall with a metal-cutting blade to make the cuts. The cuts were thought out to be the best place for the cut. This metal cuts very easily. One cut down, then a little lower, a horizontal cut to release the support.
There’s a crazy amount of room with this support out-of-the-way! Awesome!
Here’s all the parts that were removed including the radiator support part that I cut out.
NOTE(again) With the fans bolted to the radiator, the entire system can be placed in its perch. This is a no brainer to me! If someone later needs to service the radiator, or electric fans, or anything on the front of the engine, they will be easily serviced by unbolting the radiator support!
Just setting the rad support in its place.
NOTE: If you do this, be sure to trim off the sharp parts~!!~ They are razor-sharp!
There’s a little flange that needs to be flattened out.
A pair of pliers does the trick. This needs to be flattened so the splice will fit.
Look at all that precious room would you!! 😉
Making a splice to put the radiator support back in. This took a little time and patience, but patience? I have plenty of patience! : ) NOTE: I think if I had to do this splicing over again, I would have used my mig welder and welded one side reducing the number of bolts used.
Here the rad support is temporarily bolted back in. Of course I had to make a trip to ACE hardware to get the bolts I needed. What would I do without ACE!! 😉
NOTE: Beneath the radiator support lie the hood release cable and an electric loom. Don’t cut those!!!!!
This morning, FedEx delivered my replacement radiator! I was able to get right on it and finish this job! I need to get back on my 59 Apache! However, here I have both electric fans bolted to the new radiator. I cleaned them well so they look new! After all, this little Rav deserves special attention~! It has been a Valiant Steed!
Here is the finished product! The radiator works great! I’m very pleased with the outcome! I know that if this new radiator were to fail, I could have it back out within 30 minutes!
I hope you have found some useful information here. Even if you do not choose this way, maybe some of the pictures will be useful. Please subscribe to Classic Cars and Tools~ I always have something going on! ; ) dne’
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Since the posting of the Rav4 radiator installation “mod”, I’ve had several good people out there do what I did in this blog and respond with good results!;) This blog gets many hits daily, and no telling how many people have performed this simple procedure! 😉 I’m happy to have helped!!
The next 4 pictures are from Arne, he has a ’96 Rav4. He performed the radiator support modification to allow easy access to replace the radiator! I’m pleased that he sent the pictures and happily excited that he shared these pictures!
As I mentioned earlier on, Look at all that precious room!! 😉 Way to go Arne!
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Oct, 09, 2012
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Great job! Do you think you could have removed and replaced the radiator without cutting out the support beam? Last time I replaced my Rav radiator I had to get the AC gas removed so I could move the condensor. I’m curious as to whether unbolting the ‘dryer’ (if that is the black cylindrical thing attached with two bolts that has a metal hose going to it from the right side condensor under the air filter and radiator overflow tank) would allow enough leeway to manoeuvre the condensor to get the radiator out and then back in?
Hi Andrew! Good question, and the answer is Yes, I could have removed the radiator the “normal” way, but, the old rav4 has right at 300,000 miles and I felt, why not remove it the way I did. However, I was having a great deal of trouble just getting it out! I was worried about damaging the new radiator! Imagine getting it all together and it became damaged during the install and having to pull it out again? eek! It was a challenge to see if I could do what I wanted to do. When I bought the Rav, it had 144,ooo and I had the radiator replaced then. Actually it appears to be an easy task at first,looks like it should just clear the tight opening to get it out, but diving into it, it’s a pretty taxing job! I had unbolted the dryer and it was moved pretty much out of the way, but there was a worry about breaking/cracking a line. This AC system has the original charge of 134, imagine that! I didn’t want to disturb it, but still removal of the support proved to be neat! If I have to remove the radiator again, it will be a snap! Hopefully this will be the last radiator! lol I was imagining some company/or individual making a splice kit to make the “Modification” easier vs making the splices the way I did. It’s a shame the radiator support wasn’t designed this way in the beginning~ it just makes working on the front of the engine so accessible! You saw the pics. And setting the complete radiator/fans installed as a single unit~ pleasureable, if that’s a word! lol Thank you so much for visiting my site and asking that question, and I love compliments! Last word, The early RAv4’s are the most reliable, functional, practical, I feel safe due to great visibility cause of all the windows! I did home health in some pretty harsh parts of the country, the constant 4 wheel drive kept me safe and out of trouble! My daughter has been driving it for the past few years~ I keep it functioning~ after it passes 300,000, I would like to retire the Rav4~ but the darn thing is like the Bunny rabbit that keeps on going and going! ; ) I may make it my next restoration project, but all it would need is a paint job and maybe a new engine~ the interior is still perfect! ok ok, THanks again Andrew~ hey, sign up for updates by entering your email address and you’ll receive emails as I post, which isn’t all that often~ I try to keep it interesting and offer a little humor! Have a great day down under! friends! ; ) dne’
Are there any photos of the spline and it looks like Arne cut his in a different spot, Arne any photos of your sline
Hi Larry, I have no other pictures other than what’s on the blog, if I remember correctly, seems like Arne did do it a little differently that I. When you say “spline” are your referring to the actual radiator support which was cut? Just confused on spline.
thanks,
dne’ 😉
Diane and Larry, I have a few pictures of the radiator support after I cut it out. Let me know if you’re interested. Thanks!
Arne and Diane
Thanks for the reply, I have a note in to Arne for a sketch or dImensions of the joining piece ( spline ). A big step to get out the sawzall and have at it. I want to have all my ducks in a row before I start.
Just take your time, DON’T FORGET TO MOVE THE WIRING LOOM WHICH IS INSIDE THAT SUPPORT! The metal cuts very easily with a sawzall, and remember the cut edges are sharp~
dne’ 😉
Larry, I sent Arne your email address, maybe he can lend a hand here, so I hope he finds you and helps with resolving your question.
dne’ 😉
Larry, in case you didn’t know, you can click on any photo and it will enlarge, perhaps to help you see a little better with a blow up view.
dne’ 😉
Thanks dne’!
Well spotted with the down under comment – must have been my accent. 🙂
They are a great car. Mine’s also a ’98, but the steering is on the right side…
I replaced the radiator a few years ago, but when I did, I didn’t realise that damn condensor would be such a pain, but I never thought to unbolt the dryer, in fact I’ve only ever seen comments on the Internet saying the AC needs to be discharged to get the condensor out of the way so congrats on thinking about it in a different way – and even more so for the idea to cut the radiator support!
I see that the US had some early model electric RAV’s too – that would be an interesting model to have.
I’ll keep in touch, especially if I go the same way as you with the raddie support modification!
cheers
Andrew
p,s. love the Mustang!
Hey Andrew~! The Aussie accent? omg, I Love the accent! I don’t know if yo read the blog on my 57 chevy Bel-air, but a man in Melbourne bought it a little time back.I really miss that car! His name is Tony, and he does Elvis impersonations along with a few other celebrities, but I think his main income is from a Door company of some sort. Cool, An electric RAV? I’ll have to look into that! Hey Andrew, I had that dryer dangling, it’s just the condensor really needs to come out I think to do it the conventional way, not the naynay way! lol My grandaughter calls me naynay! Hm, maybe if the condensor was removed, the entire fan/radiator system might come out as a unit? something to think about. Most mechanic shops will evacuate an ac system for little or no charge to keep the environment better off. Then in doing so, you can open the lines, but generaly the dryer should be replaced after doing so(another cost, I”m sure a dryer for this little car isn’t cheap either). I”ll have to take a look at my rav4 pics and study if the complete rad/fan assembly would come out if the condensor was removed. It’s just the AC system works so well, I didn’t want to mess it up and have more money going into the project! oh, you like my Mustang! My first true project! I sunk a bunch of change into that cute car! lol WEll Andrew, I have a full day to get something done on my 59 Chevy truck, I’d better get after it! Be sweet and be cool, So what are we considered? if you’re “down under” are we “up above?” ; )
dne’
Great idea to cut the radiator support! I was at a dead end in my efforts to get the old radiator out, so I looked online to get some pointers. After reading about evacuating the A/C (confirming my fears), I ran into your site. Your unique approach seemed a lot more tempting! A few hours later the job was done, and actually, it all looks so right! Like you said: Toyota should have designed it like that in the first place.
If you are interested in another design aspect of cars (brakes!), feel free to have a look at my site: brakepower.com
Anyways, thank you so much for your help by thinking out of the box and posting it online!!!
Arne
Arne~ thank you so much for such a nice reply on this radiator installation! I’m so happy that it worked out for you! It’s a little nervy to cut the radiator support, but sure makes life a lot easier! I probably wouldn’t do this on someone’s Rav4, but on my own vehicles~ I take my own risks and if things work out; I pass the word!;) I’ll check out your brakepower.com! 😉
Thanks again!!!
dne’
Needed to replace the Radiator on my 97 Rav4 ,and used this tip today. Wow. What an awesome idea!!! Saved me from buying R-134, as well as skinning knuckles. Wasn’t too tough either. Thanks for being so creative, and extra thanks for sharing.
Paul, that is fantastic! I’m so pleased that this idea helped someone! If you don’t mind, take a finished picture of your repair and I’ll post it on that particular blog. The Rav4 radiator blog receives many hits(meaning people look through the blog), but you’re the only one so far that has actually done the radiator support “mod” or reported it to me. But wasn’t it awesome once the support was out of the way!! Thank you! 😉
dne’
Hi Dne’, on October 13 of 2013, thanks to you I also cut the rad support. Have a couple of great pics, but don’t know how to send them to you (the reply box only accepts text).
Arne
Awesome Arne! You can send a pic to me at Classiccarsandtools@gmail.com, or information@Classiccarsandtools.com, then I’ll respond back to how you would like the pic/s posted.
dne’;)