check oil TOYOTA RAV4 1996 Service Service Manual

Transmission (Pickup 4WD W/3.0L V6 & 1995 4Runner 4WD W/V6)
1. Remove transmission oil pan drain plugs from transmission. See Fig. 4 . Allow fluid to fully drain. If
replacing transmission oil strainer, remove transmission oil pan and gasket.
2. Remove bolts, transmission oil strainer and gasket (if equipped). Thoroughly clean transmission oil pan.
Using NEW gasket (if equipped), install transmission oil strainer. Install and tighten bolts to
specification. See TORQUE SPECIFICATIONS
.
3. Using NEW gasket, install transmission oil pan (if removed). Install and tighten bolts to specification See
TORQUE SPECIFICATIONS
. Fill transmission through dipstick tube to specified capacity using
recommended fluid. See RECOMMENDED FLUID
under LUBRICATION.
4. Ensure vehicle is on a level surface. Apply parking brake. Start engine and apply brakes. Move gearshift
from Park through Low and back to Park.
5. Check fluid level on transmission dipstick. Add proper type fluid so fluid level is at the COOL range
marked on the dipstick. Operate vehicle to normal operating temperature and recheck. See CHECKING
FLUID LEVEL under LUBRICATION. CAUTION: When removing transmission oil strainer, note bolt size and length
for reassembly reference.

1996 Toyota 4Runner
TRANSMISSION SERVICING - A/T AUTOMATIC TRANSMISSION SERVICING Toyota
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Fig. 4: Identifying Transmission Oil Pan Drain Plugs (Pickup 4WD With 3.0L V6 & 1995 4Runner 4WD
With V6)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Transmission (All Others)
1. Remove transmission oil pan drain plug from transmission oil pan. Allow fluid to fully drain. If replacing
transmission oil strainer, remove transmission oil pan and gasket.
2. Remove bolts, transmission oil strainer and gasket (if equipped). Thoroughly clean transmission oil pan.
Using NEW gasket (if equipped), install transmission oil strainer. Install and tighten bolts to
specification. See TORQUE SPECIFICATIONS
.
3. Using NEW gasket, install transmission oil pan (if removed). Install and tighten bolts to specification See
TORQUE SPECIFICATIONS
. Fill transmission through dipstick tube to specified capacity using
recommended fluid. See RECOMMENDED FLUID
under LUBRICATION.
4. Ensure vehicle is on a level surface. Apply parking brake. Start engine and apply brakes. Move gearshift
from Park through Low and back to Park.
5. Check fluid level on transmission dipstick. Add proper type fluid so fluid level is at the COOL range
marked on the dipstick. Operate vehicle to normal operating temperature and recheck. See CHECKING
FLUID LEVEL under LUBRICATION.
Transmission Differential (Avalon, Camry, Celica 2.2L 5S-FE, Corolla 1.6L 4A-FE & Tercel 3-Speed)
1. Remove oil filler and drain plugs from differential. See Fig. 1 . Allow fluid to drain. Reinstall drain plug.
2. Fill differential through oil filler plug hole to specified capacity using recommended fluid. See
RECOMMENDED FLUID
under LUBRICATION. Ensure fluid is level with bottom edge of filler plug
hole. Reinstall filler plug.
Transfer Case (Land Cruiser, Pickup, Previa, Tacoma, T100 & 4Runner)
1. Remove filler plug located on rear of transfer case. Remove drain plug from bottom of transfer case.
Allow fluid to drain. Reinstall drain plug.
2. Fill transfer case through oil filler plug hole to specified capacity using recommended fluid. See
RECOMMENDED FLUID
under LUBRICATION. Ensure fluid is level with bottom edge of filler plug
hole. Reinstall filler plug.
Transfer Case (RAV4)
1. Remove drain plug from bottom of transfer case. Allow fluid to drain. Reinstall drain plug. Fill transfer
case through transfer case oil dipstick tube to specified capacity using recommended fluid. See
RECOMMENDED FLUID
under LUBRICATION.
2. Check fluid level on transfer case dipstick. Fluid level should be in the LOW to HIGH range. Add fluid if CAUTION: When removing transmission oil strainer, note bolt size and length
for reassembly reference.

1996 Toyota 4Runner
TRANSMISSION SERVICING - A/T AUTOMATIC TRANSMISSION SERVICING Toyota
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Fig. 11: Adjusting Park/Neutral Switch (Typical)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
TRANSFER CASE SHIFT LINKAGE
Pickup & 1995 4Runner
1. Loosen shift rod nut on cross shaft for transfer case. Cross shaft is located at rear of transfer case, just
above the drive shaft flange. Push control shaft for transfer case shift linkage fully toward front of
vehicle.
2. Pull control shaft toward rear of vehicle one notch to the "H4" position. Ensure transfer case gearshift is
in "H4" position. While holding transfer case gearshift lightly toward "H4" position, tighten shift rod nut
on cross shaft. Check transfer case operation.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ApplicationFt. Lbs. (N.m)
Transmission Oil Pan Drain Plug
Avalon & Camry36 (49)
Celica
1.8L (7A-FE)13 (18)
2.2L (5S-FE)36 (49)
Corolla
1.6L (4A-FE)36 (49)
1.8L (7A-FE)13 (18)
Land Cruiser15 (20)

1996 Toyota 4Runner
TRANSMISSION SERVICING - A/T AUTOMATIC TRANSMISSION SERVICING Toyota
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Fig. 9: Measuring Axle Shaft Length (Rear)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Installation
To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .
After installation, check ABS speed sensor signal and wheel alignment.
Removal RAV4
1. Raise and support vehicle. Remove rear wheels. Drain differential oil into proper container. Remove ABS
speed sensor (if equipped). Remove cotter pin and lock cap. Apply brakes and remove nut.
2. Place match-marks on axle shaft flange and differential flange for installation reference. Remove 4 nuts
and washers. Using a plastic hammer, tap axle shaft from rear hub. Remove rear axle. See Fig. 10
.

1999 Toyota RAV4
1999-2000 DRIVE AXLES AWD & FWD Axle Shafts - RAV4 & RWD Axle Shafts - MR2
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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
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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
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Fig. 4: Exploded View Of Compressor (Harrison V7 7-Cyl.)
Courtesy of GENERAL MOTORS CORP.
Installation
1. Align reference marks made during removal. Using Puller Adapter (J-33024) and 2-jaw puller, press
clutch coil onto compressor. Position puller jaws under compressor mounting bosses. Ensure clutch coil
and installer stay lined up during installation.
2. Position pulley on compressor. Place Bearing Installer (J-33017) and Clutch Plate Remover/Installer (J-
33013-B) over inner race of bearing. Place Adapter (J-42126) onto remover/installer and reposition center
forcing screw into the opposite end of the remover/installer.
3. Back body of remover/installer off enough to allow center forcing screw to be threaded onto end of
compressor shaft several turns. Hold center forcing screw while turning hex portion of remover/installer
several turns. DO NOT allow center forcing screw to turn. Continue turning remover/installer until pulley
bearing is pressed onto compressor enough to clear snap ring groove. Install snap ring with chamfer side
facing up. Install key in clutch plate, allowing key to protrude about 1/8" (3.2 mm) from rear of clutch
plate.
4. Install clutch plate on compressor shaft. Hold center forcing screw and turn hex portion of
remover/installer several turns to press clutch plate onto compressor. Remove remover/installer and
ensure key is still in keyway. Reinstall remover/installer and check air gap before installing clutch plate to
its final position. Air gap between friction surfaces should be 0.015" (0.38 mm). Using spanner, install
compressor shaft nut. Tighten shaft nut to 13 ft. lbs. (18 N.m). Check components for proper rotation.
SHAFT SEAL
Removal
1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove compressor
from vehicle. Remove clutch plate and hub assembly. See CLUTCH COIL & BEARING
ASSEMBLY . See Fig. 4 .
2. Remove shaft seal snap ring. Ensure all surfaces around seal are clean. Insert Shaft Seal
Remover/Installer (J-42136) into shaft seal. Rotate handle clockwise to seat seal remover/installer in seal.
Remove shaft seal. Ensure shaft and inside of compressor neck are clean and free of foreign material.
Thoroughly clean "O" ring groove in front head.
Installation
1. Install Shaft Seal Protector (J-34614) over compressor shaft. With shaft seal protector in place, lubricate
shaft seal with refrigerant oil and install on to Shaft Seal Remover/Installer (J-34614).
2. Push shaft seal into compressor using a rotary motion until seal bottoms. Install new snap ring with flat
side against seal. Install clutch plate and hub assembly onto compressor shaft. See CLUTCH COIL &
BEARING ASSEMBLY .
KEIHIN SCROLL
NOTE: If compressor shaft seal leaks, replace compressor.

1999 Toyota RAV4
1999 GENERAL SERVICING Compressor Servicing
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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
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2. If replacing pulley bearing, remove bearing snap ring. Using Thrust Plates (VW401 and VW402), Thrust
Bushing (VW412) and Thrust Tube (VW455), press bearing out of pulley. Mark position of clutch coil.
Remove clutch coil snap ring and clutch coil.
Installation
1. To install, reverse removal procedure. Ensure clutch coil is positioned correctly and install snap ring.
Using Thrust Plates (VW401 and VW402) and Thrust Bushings (VW412 and VW473), press bearing into
pulley until fully seated. Install bearing snap ring.
2. Using Thrust Plates (VW401 and VW402) and Thrust Bushings (VW412 and VW441), press pulley
assembly onto compressor shaft. Install pulley assembly lock ring. Install clutch plate and compressor
shaft nut. Tighten compressor shaft nut until the air gap is 0.028" (0.71 mm).
3. To check air gap, position a depth gauge on edge of pulley and measure distance to clutch plate. Using a
fused jumper wire, energize clutch coil and measure distance from edge of pulley to clutch plate again.
Air gap is the difference between first and second measurement. Ensure air gap is 0.028" (0.71 mm). To
adjust air gap, tighten or loosen compressor shaft nut.
Fig. 12: Exploded View Of Compressor (Sanden 7
-Cyl.)
Courtesy of VOLKSWAGEN UNITED STATES, INC.
SHAFT SEAL
Removal (Jaguar)

1999 Toyota RAV4
1999 GENERAL SERVICING Compressor Servicing
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2. Install compressor housing "O" ring to compressor housing. Align compressor front head with
compressor housing and install. Tighten front head bolts "A" first and then front head bolts "B" in a
crisscross pattern. See Fig. 14
. Tighten bolts "A" to 10 ft. lbs. (13 N.m) and bolts "B" to 17 ft. lbs. (23
N.m). Remove shaft seal protector. To complete installation, reverse removal procedure.
ZEXEL ROTARY VANE
CLUTCH COIL & BEARING
Removal (Honda, Isuzu & Kia)
1. Using clutch disc/plate holder, remove clutch disc/plate bolt. Using puller and forcing screw, remove
clutch disc/plate. See Fig. 15
or Fig. 16 .
2. Remove shim(s) and snap ring. On DKV-14D compressor, use pulley puller pilot to protect compressor
shaft. On all models, use a puller to remove pulley. Remove screw for clutch coil lead. Remove 3 clutch
coil screws and clutch coil.
Installation
1. To install, reverse removal procedure. Align clutch coil pin with hole in front head of compressor and
install clutch coil. Tighten clutch coil screws to 44 INCH lbs. (5 N.m). Using pulley installer and drive
handle, tap pulley onto compressor. On all models, install new snap ring.
2. On DKV-14D compressor, tighten clutch plate bolt to 113 INCH lbs. (13 N.m) Using feeler gauge, ensure
air gap between clutch plate and pulley is 0.012-0.024" (0.30-0.60 mm). If air gap is incorrect, add or
remove shim(s) as necessary.
Removal (Nissan)
1. Hold clutch disc using clutch disc holder and remove center bolt. Using Clutch Disc Puller (J-38874),
remove clutch disc and adjustment shim(s).
2. Remove snap ring. Remove pulley using Pilot (J-39023) and universal 2-jaw puller. Position puller jaws
onto edge of pulley to prevent pulley groove from being deformed. Remove clutch coil lead, 3 clutch coil
retaining screws, and clutch coil. See Fig. 15
or Fig. 16 .
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 pin in clutch coil with hole in front head of compressor. Ensure coil lead is installed in original NOTE: Subaru recommends replacing compressor as an assembly if there is a clutch
or compressor shaft seal failure.
NOTE: On Kia, shaft seal servicing procedure is not available from manufacturer.

1999 Toyota RAV4
1999 GENERAL SERVICING Compressor Servicing
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