TOYOTA RAV4 1996 Service Repair Manual

Ensure clutch coil lead is positioned properly. Ensure snap rings are installed with beveled side facing
out. Tighten shaft bolt to 10-13 ft. lbs. (14-17 N.m).
2. Check air gap between clutch plate and pulley. Position dial indicator on clutch plate. Energize clutch coil
and zero dial indicator. De-energize clutch coil and measure air gap (clutch plate movement). Ensure air
gap between clutch plate and pulley is 0.014-0.026" (0.35-0.65 mm). If air gap is incorrect, add or remove
shim(s) as necessary. Ensure pulley rotates freely.
Removal (All Others)
1. Hold clutch plate stationary, and remove clutch plate center nut or bolt. On Lexus and Toyota, remove
clutch plate using Clutch Plate Remover (07112-66040). On other models, remove clutch plate using a 2-
jaw or 3-jaw puller.
2. On all models, remove shim(s) and pulley snap ring. See Fig. 6
, Fig. 7 , or Fig. 8 . Tap pulley off
compressor shaft using a plastic hammer. If pulley cannot be removed, use a 2-jaw or 3-jaw puller.
Position puller jaws onto edge of pulley to prevent pulley groove from being deformed. Disconnect clutch
coil lead. Remove clutch coil snap ring and clutch coil.
Installation
1. To install, reverse removal procedure. Ensure clutch coil is positioned correctly. Ensure new snap rings
are installed with beveled side facing out. On Lexus and Toyota, tighten clutch plate center bolt to 115
INCH lbs. (13 N.m). On all other models, tighten shaft bolt (or nut) to 11-15 ft. lbs. (15-20 N.m).
2. On Lexus and Toyota, ensure air gap between clutch plate and pulley is 0.014-0.026" (0.35-0.65 mm). On
all other models, ensure air gap between clutch plate and pulley is 0.016-0.024" (0.41-0.61 mm). On all
models, if air gap is incorrect, add or remove shim(s) as necessary.
NOTE: On some compressors, it is necessary to use a dial indicator on clutch plate to
check air gap. Energize clutch coil and zero dial indicator. De-energize clutch
coil and measure air gap. Ensure air gap is as specified.

1999 Toyota RAV4
1999 GENERAL SERVICING Compressor Servicing
Microsoft
Sunday, November 22, 2009 10:31:50 AMPage 14 © 2005 Mitchell Repair Information Company, LLC.

1999 Toyota RAV4
1999 GENERAL SERVICING Compressor Servicing
Microsoft
Sunday, November 22, 2009 10:31:50 AMPage 15 © 2005 Mitchell Repair Information Company, LLC.

Fig. 6: Exploded View Of Compressor (Nippondenso 10-Cyl. -Honda Shown; Others Are Similar)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Fig. 7: Exploded View Of Compressor (Nippondenso 10PA17C 10
-Cyl.)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 8: Exploded View Of Compressor (Nippondenso 10PA17C 10
-Cyl. Shown; 10PA15 & 10PA20 Are

1999 Toyota RAV4
1999 GENERAL SERVICING Compressor Servicing
Microsoft
Sunday, November 22, 2009 10:31:50 AMPage 16 © 2005 Mitchell Repair Information Company, LLC.

Similar)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
SHAFT SEAL
Removal (Mitsubishi)
1. Remove clutch coil. See CLUTCH COIL . See Fig. 8 . Position compressor in a vise so compressor rear
housing is secured to compressor body. Remove front housing through-bolts and front housing.
2. Using a flat-blade screwdriver, remove felt retainer and felt from front housing. Remove shaft seal snap
ring. Using a flat-blade screwdriver, remove shaft seal and "O" ring. See Fig. 8
.
Installation
1. Inspect compressor shaft and front housing bore for damage and/or excessive wear. Ensure "O" ring and
shaft seal seat are clean. Apply refrigerant oil to compressor side of front housing bore. Lubricate "O"
ring and shaft seal with refrigerant oil. Using a 21-mm socket, install shaft seal with "O" ring side facing
away from compressor. Install shaft seal snap ring. See Fig. 8
.
2. Install felt into felt retainer. Using a 14-mm deep socket, install felt and felt retainer. Lubricate
compressor shaft. Install front housing using care not damage shaft seal lip. See Fig. 8
.
3. Alternately tighten front housing through-bolts to 19 ft. lbs. (26 N.m). Install clutch plate center bolt.
Using an INCH-lb. torque wrench, ensure compressor breakaway torque is 43 INCH lbs. (4.9 N.m) or
less. To complete installation, reverse removal procedure. Ensure air gap between clutch plate and pulley
is correct. See CLUTCH COIL
.
PANASONIC ROTARY VANE
CLUTCH COIL
Removal (Mazda)
Hold clutch disc stationary and remove shaft bolt. See Fig. 9 . Remove clutch disc and shim(s) from shaft.
Remove pulley snap ring and remove pulley using a puller if necessary. Remove screw from clutch coil lead.
Remove screws and clutch coil.
Installation
NOTE: Most manufacturers does not provide compressor shaft seal replacement
procedure. If shaft seal oil leak is excessive and/or refrigerant is leaking,
compressor must be replaced. A small amount of refrigerant oil leakage from
compressor shaft seal is normal.
CAUTION: On Mitsubishi, secure rear housing to compressor body using a vise
before removing front housing through-bolts. Compressor rear housing
may separate from compressor body, spilling refrigerant oil.

1999 Toyota RAV4
1999 GENERAL SERVICING Compressor Servicing
Microsoft
Sunday, November 22, 2009 10:31:50 AMPage 17 © 2005 Mitchell Repair Information Company, LLC.

To install, reverse removal procedure. Tighten shaft bolt to 11 ft. lbs. (15 N.m). Ensure air gap is 0.016-
0.023" (0.41-0.58 mm). If air gap is incorrect, add or remove shim(s) as necessary.
THERMAL PROTECTOR
Removal (Mazda)
Remove 2 compressor head cover rear bolts and then 4 upper head cover bolts. Remove thermal protector snap
ring and push thermal protector out from its back side. DO NOT pull on wiring harness. See Fig. 9
.
Installation
1. Ensure thermal protector "O" ring groove in compressor head cover is free of foreign material. Apply
refrigerant oil to "O" ring and install into "O" ring groove. Install thermal protector with wiring harness
leads horizontal to head cover. Install thermal protector snap ring with chamfered edge facing thermal
protector.
2. Apply refrigerant oil to head cover lower "O" ring and install with top side faces upward. Apply clean
refrigerant oil to rear "O" ring and install in head cover. Carefully install head cover onto compressor.
Tighten 2 rear head cover bolts to 115-159 INCH lbs. (13-18 N.m). Tighten 4 lower head cover bolts to
80-106 INCH lbs. (9-12 N.m) in a dia
gonal pattern.

1999 Toyota RAV4
1999 GENERAL SERVICING Compressor Servicing
Microsoft
Sunday, November 22, 2009 10:31:50 AMPage 18 © 2005 Mitchell Repair Information Company, LLC.

Fig. 9: Exploded View Of Compressor (Panasonic)
Courtesy of MAZDA MOTORS CORP.
SANDEN SCROLL
CLUTCH COIL & SHAFT SEAL
Removal (Mitsubishi)
1. Remove drive belt pulley (if equipped). Hold clutch plate using Pliers (MB991367) and Bolts
(MB991386). Use a ratchet and socket to remove clutch hub nut.
2. Remove clutch plate. See Fig. 11
or Fig. 12. Remove snap ring with internal snap ring pliers. Remove
NOTE: Range Rover Sanden compressor servicing procedures are not available from
manufacturer.
NOTE: Due to the variety of clutch and shaft seal configurations, obtain appropriate
A/C compressor service tools for compressor being serviced.

1999 Toyota RAV4
1999 GENERAL SERVICING Compressor Servicing
Microsoft
Sunday, November 22, 2009 10:31:50 AMPage 19 © 2005 Mitchell Repair Information Company, LLC.

clutch hub (rotor). Remove snap ring and clutch coil.
3. Using an awl, remove bearing cover and retainer. Using Bearing Remover (MB991456), engage bearing
grooves. Place base of bearing remover over remover arms and tighten nut.
4. Tighten bearing remover bolt to withdraw bearing from compressor. Engage grooves of Shaft Seal
Remover/Installer (MB991458) and pull straight up on shaft seal.
Installation
1. To install shaft seal, ensure front housing is free of foreign objects. Lubricate Shaft Seal Protector
(MB991459) and place over compressor shaft. Lubricate shaft seal and install using shaft seal
remover/installer. Remove shaft seal protector.
2. Using a 21-mm socket or Drift (MB991301), carefully press bearing onto compressor shaft. Install clutch
coil so that alignment pin is engaged. Install clutch coil snap ring with tapered side facing out.
3. Align armature plate with crankshaft spline. Tighten shaft nut to 12 ft. lbs. (16 N.m). Using feeler gauge,
ensure air gap between pressure plate and pulley is 0.02-0.03" (0.5-0.8 mm) on Diamante and 0.016-
0.024" (0.4-0.6 mm) on all other models. If air
gap is incorrect, add or remove shim(s) as necessary.

1999 Toyota RAV4
1999 GENERAL SERVICING Compressor Servicing
Microsoft
Sunday, November 22, 2009 10:31:50 AMPage 20 © 2005 Mitchell Repair Information Company, LLC.

Fig. 10: Exploded View Of Compressor (Sanden MSC105 Scroll Shown; MSC90C Is Similar)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

1999 Toyota RAV4
1999 GENERAL SERVICING Compressor Servicing
Microsoft
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Fig. 11: Exploded View Of Compressor (Sanden Scroll)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Removal (Honda)
1. Remove shaft nut while holding clutch plate with Clutch Holder (J-37872). Remove pressure plate and
shim(s). Remove snap ring.
2. Using universal puller attached to outer diameter of pulley, and Driver (07947-6340300) in center of
pulley, remove pulley. DO NOT engage puller on belt area. Hold puller in place and tighten screw to
remove pulley. Remove screw for clutch coil lead. Remove snap ring and clutch coil.
Installation
1. To install, reverse removal procedure. Align lug on clutch coil with hole in compressor. Install snap ring
with chamfered side facing out. Position pulley squarely over coil. Using Hub Guide (07945-6920500),
press pulley onto compressor boss. Maximum press load is 5690 psi (400 kg/cm
2 ) or 882 lbs. (400 kg).
2. Tighten shaft nut to 13 ft. lbs. (18 N.m). Using feeler gauge, ensure air gap between pressure plate and
pulle
y is 0.014-0.026" (0.35-0.65 mm). If air gap is incorrect, add or remove shim(s) as necessary.

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

Removal (Mazda)
1. Remove compressor shaft nut while holding clutch plate with Clutch Holder (49-B061-010). Remove
clutch pressure plate and shim(s). If clutch pressure plate cannot be removed by hand, use Pressure Plate
Remover (49-B061-013).
2. Remove pulley assembly snap ring. Install a 2-jaw puller to outer diameter of pulley and a 1.0" (25 mm)
socket to compressor boss, and remove pulley. DO NOT engage puller on belt area. Hold puller in place
and tighten screw to remove pulley. Remove clutch coil snap ring and clutch coil.
Installation
1. To install, reverse removal procedure. Align lug on clutch coil with hole in compressor. Install snap ring
with chamfered side facing out. Position pulley squarely over coil. Ensure compressor boss and inside
area of pulley bearing are clean and free of foreign material. Using Pulley Installer (49-G032-311), press
pulley onto compressor boss.
2. Tighten compressor shaft nut to 14 ft. lbs. (19 N.m). Using feeler gauge, ensure air gap between clutch
pressure plate and pulley is 0.014-0.025" (0.35-0.65 mm). If air gap is incorrect, add or remove shim(s) as
necessary.
SANDEN 7-CYLINDER
CLUTCH COIL & BEARING
Removal (Jaguar)
1. Using 3 bolts, attach Puller (JD166-1) to clutch plate. While holding clutch plate with puller, remove
shaft nut. Install puller bolt in center of puller, and tighten bolt to remove clutch plate.
2. Remove adjustment shim(s) and Woodruff key. Remove pulley snap ring. Install threaded Adapter
(JD166-5), onto compressor shaft. Engage Collets (JD166-5) to inner diameter of pulley and attach Puller
(JD166-1) to collets.
3. Install puller bolt in center of puller, and tighten bolt to remove pulley. Press bearing out of drive belt
pulley. Remove screw for clutch coil lead. Remove snap ring and clutch coil.
Installation
To install clutch coil and bearing, reverse removal procedure. Tighten shaft nut. Ensure air gap is 0.016-
0.031" (0.40-0.80 mm). If air gap is incorrect, add or remove shim(s) as necessary.
Removal (Volkswagen)
1. Remove compressor shaft nut while holding clutch plate with two 1/4" (6 mm) bolts and Spanner Wrench
(Mastercool 90901). Remove clutch plate using two 1/4" (6 mm) bolts and Puller (Mastercool 90902).
Remove pulley assembly lock ring. See Fig. 12
. Using a 2-jaw puller, remove pulley assembly. Position
puller
jaws onto edge of pulley to prevent pulley groove from being deformed. NOTE: If shaft seal leaks, replace compressor.

1999 Toyota RAV4
1999 GENERAL SERVICING Compressor Servicing
Microsoft
Sunday, November 22, 2009 10:31:50 AMPage 23 © 2005 Mitchell Repair Information Company, LLC.