Engine TOYOTA RAV4 1996 Service Repair Manual

Fig. 1: Identifying A/C Amplifier Connector Terminals
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
A/C SWITCH
Disconnect negative battery cable and wait at least 90 seconds. Remove glove box and lower instrument finish
panel. Disconnect control cables. Remove A/C switch and disconnect wire harness connector. Check continuity
at specified terminals. See A/C SWITCH CONTINUITY
table. See Fig. 2 . A/C switch has a diode, check
continuity in both directions before replacing switch.
A/C SWITCH CONTINUITY
2 & Ground
Refrigerant Pressure At 28-495 psi (1.97-34.8 kg/cm2 )Battery Voltage
Refrigerant Pressure Less Than 28 psi (1.97 kg/cm2 ) Or More Than 495 psi
(34.8 kg/cm
2 )
No Voltage
7 & Ground
Magnetic Clutch DisengagedBattery Voltage
Magnetic Clutch EngagedLess Than 1 Volt
12 & Ground
Magnetic Clutch DisengagedLess Than 1 Volt
Magnetic Clutch EngagedZero Volts
(1)Engine running at idle, temperature control lever is at the MAX COOL position, and blower switch is
on HI position.
Switch PositionContinuity Between Terminal No.

1999 Toyota RAV4
1999 MANUAL A/C-HEATER SYSTEMS RAV4
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Fig. 2: Identifying A/C Switch Terminals
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
CONDENSER FAN MOTOR
1. Install manifold gauge set. Start engine and turn blower switch to HI position. Set temperature to cool.
Turn A/C on. Fan should not operate below 181°F (83°C). Fan should operate at or above 199°F (93°C).
Fan should operate at low speed with refrigerant pressure less than 220 psi (15.5 kg/cm
2 ). Fan should
operate at high speed with refrigerant pressure above 220 psi (15.5 kg/cm
2 ). If fan does not operate as
specified, go to next step.
2. Disconnect fan motor 3-pin connector. Apply battery voltage to fan motor side of connector. Fan motor
should rotate smoothly and current draw should be 9.1-11.1 amps. If operation is not as specified, replace
condenser fan motor.
CONDENSER FAN & COMPRESSOR CLUTCH RELAYS
Compressor Clutch Relay & Condenser Fan Relay No. 3
Remove appropriate relay. See WIRING DIAGRAMS . Check continuity between terminals No. 1 and 2. See
Fig. 3
. Ensure continuity exists. If continuity does not exist, replace relay. Apply battery voltage between
terminals No. 1 and 2. Continuity should exist between terminals No. 3 and 5. If continuity does not exist,
replace relay.
Condenser Fan Relay No. 1
OFF(1)
ON5 & 6
(1)With A/C switch in either position, continuity should exist between terminals No. 1 and 3 for A/C
switch illumination. With A/C switch off, continuity should not exist between any other terminals.

1999 Toyota RAV4
1999 MANUAL A/C-HEATER SYSTEMS RAV4
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Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
IDLE AIR CONTROL (IAC) VALVE
Start engine and bring to normal operating temperature. Turn A/C switch on, set blower switch to high position
and adjust temperature control lever to maximum cooling. Ensure compressor clutch is engaged. Using
tachometer, ensure when compressor clutch engages, idle RPM increases 100-200 RPM and decreases a similar
amount when clutch is disengaged. If idle does not react as specified, check IAC valve and air intake system.
COMPRESSOR CLUTCH & COMPRESSOR LOCK SENSOR
Inspect pressure plate and rotor for signs of oil contamination. Check clutch bearing for noisy operation and
grease leakage. Check compressor lock sensor resistance. Disconnect compressor clutch/lock sensor 3-pin
connector. Measure resistance between terminals No. 1 (White wire) and No. 2 (Blue wire). Resistance should
be 65-125 ohms at 68°F (20°C). Replace as necessary. Check magnetic clutch operation. Apply battery voltage
to compressor clutch connector terminal No. 3 (Black wire). Connect negative battery lead to ground. Ensure
compressor clutch is energized. If compressor clutch is not energized, replace compressor clutch.
THERMISTOR
1. Disconnect negative battery cable and wait at least 90 seconds. Remove lower trim panel and glove box.
Disconnect thermistor 2-pin connector from top of evaporator case. See Fig. 6
. Measure resistance of
thermistor while still installed.
2. Resistance should be 1500 ohms at 77°F (25°C) ambient temperature. If resistance is not within
specification, replace thermistor. If resistance is as specified, go to next step.
3. Remove evaporator case. See EVAPORATOR ASSEMBLY
under REMOVAL & INSTALLATION.
Disassemble evaporator case and remove thermistor. Check thermistor operation. Submerge thermistor at
least 3.94" (100 mm) deep in cold water. See Fig. 7
.
4. Place thermometer in water and measure resistance of thermistor at various temperatures. Use ice or hot
water to vary water temperature. If readings are not within specification, replace thermistor. See
THERMISTOR RESISTANCE VALUES
table.
THERMISTOR RESISTANCE VALUES
Water Temperature °F (°C)Ohms
77 (25)1300-1800
68 (20)1700-2200
59 (15)2200-2600
50 (10)2800-3300
41 (5)3700-4200
32 (0)4600-5300

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Fig. 7: Testing Thermistor
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
PRESSURE SWITCH
Compressor Clutch Control
Install manifold gauge set. Start and run engine at 2000 RPM. Turn A/C on. Observe system pressure.
Disconnect pressure switch connector. Connect ohmmeter positive lead to terminal No. 4 of pressure switch and
negative lead to terminal No. 1. See Fig. 8
. Continuity should not exist when high-side pressure is more than
455 psi (32.0 kg/cm
2 ) or low-side pressure is less than 28 psi (2.0 kg/cm2 ). Replace switch if continuity is not
as specified.
Condenser Fan Control
Install manifold gauge set. Start and run engine at 2000 RPM. Turn A/C on. Observe system pressure.
Disconnect pressure switch connector. Connect ohmmeter positive lead to terminal No. 2 of pressure switch and
negative lead to terminal No. 3. See Fig. 8
. Continuity should not exist when system pressure exceeds 220 psi
(15.5 kg/cm
2 ). Continuity should exist when system pressure drops to 178 psi (12.5 kg/cm2 ). Replace switch if
it does not function as specified.

1999 Toyota RAV4
1999 MANUAL A/C-HEATER SYSTEMS RAV4
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Fig. 8: Identifying Dual-Pressure Switch Connector Terminals
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
IDLE AIR CONTROL (IAC) VALVE
Start engine and bring to normal operating temperature. Turn A/C switch on, set blower switch to high position
and adjust temperature control lever to maximum cooling. Ensure compressor clutch is engaged. Using
tachometer, ensure when compressor clutch engages, idle RPM increases 100-200 RPM and decreases a similar
amount when clutch is disengaged. If idle does not react as specified, check IAC valve and air intake system.
REMOVAL & INSTALLATION
WARNING:To avoid injury from accidental air bag deployment, read and carefully
follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR
BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY article in
GENERAL SERVICING.

1999 Toyota RAV4
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COMPRESSOR
Removal
1. If possible, run A/C system for 10 minutes. Disconnect negative battery cable and wait at least 90
seconds. Disconnect compressor clutch electrical connector.
2. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect compressor
hoses and cap hose ends to keep moisture out of system. Remove right side engine undercover, if
necessary. Loosen lock nut and belt adjusting bolt at generator. Remove compressor drive belt. Remove
compressor mounting bolts. Remove compressor.
Installation
To install, reverse removal procedure. Tighten mounting bolts and compressor hoses to specification. See
TORQUE SPECIFICATIONS
. Evacuate, charge and leak test system.
CONDENSER
Removal
Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect negative battery
cable and wait at least 90 seconds. Disconnect A/C lines from condenser. Plug all openings. Remove 2
condenser mounting bolts and condenser.
Installation
To install, reverse removal procedure. Tighten condenser hoses to specification. See TORQUE
SPECIFICATIONS . If installing a new condenser, add 1.4 ounces of refrigerant oil to compressor. Evacuate,
charge and leak test system.
EVAPORATOR ASSEMBLY
Removal
Disconnect negative battery cable and wait at least 90 seconds. Discharge A/C system, using approved
refrigerant recovery/recycling equipment. Remove glove box assembly. Using knife, cut off glove compartment
reinforcement. Disconnect inlet lines, outlet lines and grommets from evaporator. Plug openings. Disconnect
electrical leads from evaporator. Remove 3 attaching screws and 3 nuts. Remove evaporator assembly.
Disassembly
Remove blower resistor and A/C amplifier. Release spring clips holding covers together. Remove 4 screws at
case joints. Separate upper and lower cases from evaporator core. Remove evaporator from lower case. Remove
thermistor and expansion valve. See Fig. 9
. NOTE: For removal and installation procedures not covered in this article, see HEATER
SYSTEMS - RAV4, TACOMA & 4RUNNER article.

1999 Toyota RAV4
1999 MANUAL A/C-HEATER SYSTEMS RAV4
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Sunday, November 22, 2009 10:29:28 AMPage 13 © 2005 Mitchell Repair Information Company, LLC.

Removal
Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect negative battery
cable and wait at least 90 seconds. Remove engine coolant reservoir and air cleaner case and duct. Disconnect
A/C lines from receiver-drier and plug all openings. Remove mounting bolts and receiver-drier.
Installation
To install, reverse removal procedure. If installing a new receiver-drier, add 0.3 ounce of refrigerant oil before
reassembly. Evacuate, charge and leak test system.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
WIRING DIAGRAMS
ApplicationFt. Lbs. (N.m)
Compressor Mounting Stud35 (47)
Compressor Mounting Stud Nut20 (27)
Compressor-To-Engine Bolts27 (37)
Evaporator Hose Fittings
Inlet Fitting10 (14)
Outlet Fitting24 (33)
INCH Lbs. (N.m)
Refrigerant Hoses
To Compressor89 (10)
To Condenser89 (10)
To Expansion Valve48 (5.4)
To Receiver-Drier89 (10)

1999 Toyota RAV4
1999 MANUAL A/C-HEATER SYSTEMS RAV4
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Fig. 1: Testing Bulb Check Relay (Tacoma & 4Runner)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
DOOR COURTESY SWITCH
Land Cruiser, RAV4, Sienna & 4Runner
Turn ignition switch to OFF position. Locate door courtesy switch in door jamb. Check for continuity between
door courtesy switch terminal and switch body. With switch pin released (switch ON), continuity should exist.
With switch pin pushed in (switch OFF), no continuity should exist. If continuity is not as specified, replace
door courtesy switch.
ENGINE COOLANT TEMPERATURE GAUGE & SENDER
Wiring Harness Operational Test
1. Disconnect coolant temperature sender connector. See ENGINE COOLANT TEMPERATURE
SENDER LOCATION table. Turn ignition switch to ON position. Temperature gauge should indicate
COOL. Turn ignition switch to OFF position. Connect a 12-volt, 3.4-watt test light between coolant
temperature sender harness connector terminal and
ground.

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2. Turn ignition switch to ON position. Test light should be on and temperature gauge should slowly move
to HOT. If gauge functions as specified, replace sending unit. If gauge does not function as specified,
perform TEMPERATURE GAUGE RESISTANCE TEST
.
Engine Coolant Temperature (ECT) Sender
1. Turn ignition switch to OFF position. Disconnect ECT sender 1-pin connector. See ENGINE
COOLANT TEMPERATURE SENDER LOCATION table. Drain cooling system and remove ECT
sender. Place probe end of ECT sender and thermometer in a container of water. Connect an ohmmeter
between ECT sender terminal and ECT sender body.
2. Heat water and note resistance reading. See ENGINE COOLANT TEMPERATURE SENDER
RESISTANCE table. If resistance is not as specified, replace ECT sender.
ENGINE COOLANT TEMPERATURE SENDER LOCATION
ENGINE COOLANT TEMPERATURE SENDER RESISTANCE
Temperature Gauge Resistance Test
Turn ignition switch to OFF position. Remove instrument cluster. Using ohmmeter, check gauge resistance
between appropriate terminals on back of instrument cluster. See TEMPERATURE GAUGE RESISTANCE
SPECIFICATIONS table. See Fig. 2 -Fig. 8 . If resistance is not as specified, replace temperature gauge. If
resistance is as specified, repair open or short circuit in wiring harness.
TEMPERATURE GAUGE RESISTANCE SPECIFICATIONS
ApplicationLocation
Land CruiserTop Front Of Engine
SiennaTop Of Engine
RAV4Rear Of Cylinder Head, Exhaust Side
Tacoma & 4Runner
4-Cyl.Right Side Of Engine, Under Intake
Manifold
V6Left Cylinder Head
Tundra
V6In Rear Of Intake Manifold
V8In Front Water By-Pass Joint, Next To
ECT Sensor
Application & Water Temp. °F (°C)Ohms
Land Cruiser, Sienna, RAV4 & Tundra
122 (50)160-240
248 (120)17-21
Tacoma & 4Runner
122 (50)234-314
248 (120)24-31

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1999-2000 ACCESSORIES & EQUIPMENT Instrument Panels - Trucks
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Fig. 15: Testing Rheostat Light Control (RAV4, Tacoma, Tundra & 4Runner)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
LOW OIL PRESSURE SWITCH
RAV4, Sienna, Tacoma, Tundra Without Tachometer & 4Runner
Disconnect low oil pressure switch connector. See OIL PRESSURE SWITCH LOCATION table. Using an
ohmmeter, check for continuity between oil switch and ground. Continuity should exist with engine off.
Continuity should not exist with engine running. If continuity is not as specified, replace low oil pressure
switch.
OIL PRESSURE SWITCH LOCATION
NOTE: Tundra models without a tachometer are equipped with an oil pressure switch.
Tundra models with a tachometer are equipped with an oil pressure sender. For
oil pressure sender testing, see OIL PRESSURE GAUGE & SENDER
.
ApplicationLocation
RAV4Rear Of Cylinder Head, Exhaust Side
SiennaLower Left Front Of Cylinder Block
Tacoma & 4Runner
4-CylinderRight Side Of Cylinder Block
V6Left Front Of Cylinder Block
TundraBeside Oil Filter

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1999-2000 ACCESSORIES & EQUIPMENT Instrument Panels - Trucks
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