TOYOTA RAV4 1996 Service Repair Manual

Fig. 14: Charging System Wiring Diagram (Sienna)

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Generators & Regulators
Microsoft
Sunday, November 22, 2009 10:13:08 AMPage 30 © 2005 Mitchell Repair Information Company, LLC.

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Generators & Regulators
Microsoft
Sunday, November 22, 2009 10:13:08 AMPage 31 © 2005 Mitchell Repair Information Company, LLC.

Fig. 15: Charging System Wiring Diagram (Tacoma)

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Generators & Regulators
Microsoft
Sunday, November 22, 2009 10:13:08 AMPage 32 © 2005 Mitchell Repair Information Company, LLC.

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Generators & Regulators
Microsoft
Sunday, November 22, 2009 10:13:08 AMPage 33 © 2005 Mitchell Repair Information Company, LLC.

Fig. 16: Charging System Wiring Diagram (2000 Tundra)

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Generators & Regulators
Microsoft
Sunday, November 22, 2009 10:13:08 AMPage 34 © 2005 Mitchell Repair Information Company, LLC.

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Generators & Regulators
Microsoft
Sunday, November 22, 2009 10:13:08 AMPage 35 © 2005 Mitchell Repair Information Company, LLC.

Fig. 17: Charging System Wiring Diagram (4Runner)

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Generators & Regulators
Microsoft
Sunday, November 22, 2009 10:13:08 AMPage 36 © 2005 Mitchell Repair Information Company, LLC.

1999 GENERAL SERVICING
Compressor Servicing
CALSONIC
CLUTCH COIL
Removal
1. Using Clutch Disc Wrench (J-41260), remove clutch plate bolt. Using Clutch Disc Puller (J-38874),
remove clutch plate. Insert clutch disc puller pins into clutch disc holes. Rotate holder clockwise to lock it
into clutch disc. Tighten clutch disc puller center bolt and remove clutch disc plate and shims. Remove
pulley assembly snap ring. See Fig. 1
.
2. Using a 2-jaw puller, remove pulley assembly. Position puller jaws onto edge of pulley to prevent pulley
groove from being deformed. Remove clutch coil harness clip, clutch coil snap ring, and clutch coil.
Installation
1. Ensure clutch disc and pulley contact surfaces are clean and free of excessive grooving and/or excessive
heat damage. Check clutch coil for loose connection or cracked insulation. Replace components as
necessary. Replace clutch disc and pulley assembly as a set.
2. Align clutch coil pin with hole in front head of compressor. Install clutch coil harness clip and clutch coil
snap ring. Using hand press and Pulley Installer (J-41261), install pulley assembly. Install pulley
assembly snap ring. Install original shim(s) and clutch disc. Using Clutch Disc Wrench (J-41260), install
and tighten center bolt to 10 ft. lbs. (14 N.m). Ensure pulley turns smoothly.
3. Using a feeler gauge check clutch plate and pulley assembly air gap. Air gap should be 0.012-
0.024" (0.30-0.60 mm). If air gap is incorrect, add or remove shims as necessary.
4. Install compressor and any other components. Evacuate and charge A/C system. Operate A/C system and
engage and disengage A/C compressor clutch about 30 times to break in replacement clutch disc and
pulle
y assembly. NOTE: Due to the variety of clutch and shaft seal configurations, obtain appropriate
A/C compressor service tools for compressor being serviced.
NOTE: Subaru recommends replacing compressor as an assembly if there is a clutch
or compressor shaft seal failure.

1999 Toyota RAV4
1999 GENERAL SERVICING Compressor Servicing

1999 Toyota RAV4
1999 GENERAL SERVICING Compressor Servicing
Microsoft
Sunday, November 22, 2009 10:31:50 AMPage 1 © 2005 Mitchell Repair Information Company, LLC.
Microsoft
Sunday, November 22, 2009 10:31:54 AMPage 1 © 2005 Mitchell Repair Information Company, LLC.

Fig. 1: Exploded View Of Compressor (Calsonic V6)
Courtesy of NISSAN MOTOR CO.
FORD FS-10 & HALLA FX-15
CLUTCH COIL
Removal
1. Hold clutch plate stationary and remove clutch plate center bolt. Remove clutch plate. If clutch plate
cannot be removed by hand, use an 8 x 1.25-mm bolt threaded into clutch plate to remove clutch plate
and shim(s). See Fig. 2
. Mark position of clutch coil electrical connector.
2. Remove pulley snap ring and pulley assembly. Position appropriate shaft protector over compressor nose
opening. Position jaws of a 2-jaw puller behind back edge of clutch coil. Position puller forcing screw on
center of shaft protector and remove clutch coil from compressor.
Installation
1. Ensure clutch coil mounting surface is clean. Place clutch coil over compressor nose opening with clutch
coil electrical connector correctly positioned. Position appropriate clutch coil installing adapter over
compressor nose opening and inner radius of clutch coil.
2. Position forcing screw of puller on center of installing adapter. Position jaws of puller on rear side of
compressor front mounts and tighten forcing screw. Ensure clutch coil bottoms against front head of
compressor all around clutch coil outer diameter.
3. Install pulley assembly. Install snap ring with bevel side of snap ring facing out. Install shim(s) and clutch

1999 Toyota RAV4
1999 GENERAL SERVICING Compressor Servicing
Microsoft
Sunday, November 22, 2009 10:31:50 AMPage 2 © 2005 Mitchell Repair Information Company, LLC.

plate. Install a new clutch plate bolt and tighten to 97-123 INCH lbs. (11-14 N.m).
4. On Nissan Quest, install dial indicator at clutch plate and set to zero. Energize clutch coil and measure air
gap between clutch plate and pulley. Air gap should be 0.020-0.033" (0.45-0.85 mm).
5. On Hyundai and Mazda, use a feeler gauge to check air gap between clutch plate and pulley at 3 places
around pulley. On Hyundai, air gap should be 0.016-0.024" (0.41-0.61 mm).
6. On Mazda, air gap should be 0.014-0.033" (0.35-0.84 mm). On all models, if air gap is incorrect, add or
remove shims as necessary.
SHAFT SEAL
Removal
1. Hold clutch plate stationary and remove clutch plate center bolt. Remove clutch plate. If clutch plate
cannot be removed by hand, use an 8 x 1.25-mm bolt threaded into clutch plate to remove clutch plate
and shim(s). See Fig. 2
.
2. Remove shaft seal felt from nose of compressor. Thoroughly clean seal area of compressor using low-
pressure compressed air and a lint-free cloth. Remove compressor shaft seal internal snap ring. Position
shaft seal remover over compressor shaft.
3. Push shaft seal remover downward against seal. Ensure end of shaft seal remover is engaged with inside
of seal. Hold hex part of seal remover and rotate shaft seal remover handle clockwise to expand remover
tip inside seal. Pull shaft seal from compressor.
Installation
1. Lubricate shaft seal protector and shaft seal with refrigerant oil. Install shaft seal on shaft seal protector so
lip seal is toward compressor (large end of shaft seal protector).
2. Install shaft seal protector on compressor shaft. Using shaft seal installer, push shaft seal down seal
protector until seal is seated.
3. Remove shaft seal installer and protector. Install a new shaft seal snap ring and shaft seal felt. Install shim
(s) and clutch plate. Install a new clutch plate bolt and tighten to 97-123 INCH lbs. (11-14 N.m).
4. Use a feeler gauge to check air gap between clutch plate and pulley at 3 places around pulley. On
Hyundai Accent, air gap should be 0.016-0.024" (0.41-0.61 mm).
5. On all other models, air gap should be 0.014-0.033" (0.35-0.84 mm). If air gap is incorrect, add or remove
shims as necessary.

1999 Toyota RAV4
1999 GENERAL SERVICING Compressor Servicing
Microsoft
Sunday, November 22, 2009 10:31:50 AMPage 3 © 2005 Mitchell Repair Information Company, LLC.