How to replace the Seals for the Oil Cooler Housing?

1996 TOYOTA RAV4
200,000 MILES • 2.0L • 4 CYL • 2WD • AUTOMATIC
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RO83AA
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I would like some help on how to replace the Seals for the Oil Cooler Housing for the vehicle listed above.
Mar 20, 2023 at 9:56 PM
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STRAILER
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Yep, when these go bad, they can allow oil to mix with the coolant and vice versa. Here are the instructions on how to change out the engine oil cooler and seals. Check out the images (below). Please let us know if you need anything else to get the problem fixed.
Mar 21, 2023 at 10:16 AM
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RO83AA
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Thanks. Am I going to get new gaskets and if so which ones? The first image is cut off at the top could you tell what it is? Where did you find these instructions and images? I could not find anything online.
Mar 25, 2023 at 2:05 PM
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STRAILER
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There is nothing above the cutoff part, this is how the images are. Do you have any questions about the job? We are here to help.
Mar 26, 2023 at 12:57 PM
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RO83AA
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So, it looks like 2 gaskets will need to be replaced. Exhaust manifold gasket. Then 1 at the bottom to where it connects to the Exhaust pipe (blue circle)? I don't know what the gasket is called or if it has a part number. Do you have information about it? Also is it possible to disconnect this portion of the Exhaust pipe at the connection circled in red?
Mar 27, 2023 at 11:59 AM
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RO83AA
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Hello is anyone able to help me with this part of the job?
Mar 28, 2023 at 8:47 PM
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RO83AA
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I removed the screws attached to the bolts in the front part of the exhaust but I can not find room to separate it from the part above it.
Mar 30, 2023 at 12:28 PM
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STRAILER
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So, you can't separate the exhaust where you want to (circled in red). You will need to remove the entire head pipe. Also, the gasket you need is called a flange gasket. Spray WD40 to help remove the bolts. Also, I see two of the nuts removed but there are three did you get all three removed? There will be more fasteners you will need to remove before the exhaust can be removed, please upload more pictures of any problems you have.
Mar 31, 2023 at 8:23 AM
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RO83AA
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After sliding the exhaust hanger, there was flexibility with the front end of the exhaust. With help, we were able to remove the Manifold and Sub-Manifold. We tried to remove the seals and gasket of the Oil Cooler Housing without draining the coolant, but the larger O-ring had turned really hard, and it was difficult to remove. We had to chip away at the O-ring and carefully scrape away harder parts. Used some cleaner to help soften those parts leaving residue. This Housing must have been leaking for a long time because there is a lot of oily sludge to clean up. I think since we have everything exposed. I should replace the 2 hoses (bypass hoses). Is there a part number for these hoses? One of the local Toyota dealerships had a difficult time finding the hose. They ordered a set that they think are the proper replacement hoses. The picture of the Oil Cooler Housing has the new O-ring and smaller gasket.
Apr 4, 2023 at 1:15 PM
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STRAILER
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Nice work on cleaning the gasket surfaces, I would replace those hoses I think you can use regular heater hose 5/8 you can get at any auto part store. Please let me know how it goes.
Apr 5, 2023 at 10:13 AM
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RO83AA
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Okay, I'm back the Oil Cooler Housing. Unfortunately, I had to stop working on this project but I'm ready to finish. Is there a torque spec for the small bolt holding up the Housing and the large bolt mechanism that goes in the middle of the Housing?
May 10, 2023 at 10:48 AM
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STRAILER
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Yep, here you go.

TIGHTENING SPECIFICATIONS
Oil Cooler to Cylinder Block
Union Bolt .................... 78 Nm (58 ft. lbs.)
Nut .................... 8.8 Nm (78-inch lbs.)

Please let us know if you need anything else to get the problem fixed.
May 11, 2023 at 8:58 AM