Engine TOYOTA RAV4 1996 Service Manual PDF

position. Install and tighten coil screws. Press pulley onto compressor using Pulley Installer (J-39024) and
a hand press. Install pulley snap ring and adjustment shim(s).
3. Install clutch disc and tighten center bolt to 9-11 ft. lbs. (11-15 N.m). Ensure pulley rotates freely. Using
a feeler gauge, ensure air gap between clutch disc and pulley is 0.012-0.024" (0.30-0.61 mm). If air gap is
not as specified, add or remove shim(s) as necessary.
4. Install compressor and any other components. Evacuate and charge A/C system. Operate A/C system and
break-in clutch disc and pulley assembly by engaging and disengaging clutch 30 times during engine
operation.
Fig. 15: Exploded View Of Compressor (Zexel DKV
-14D Rotary Vane)
Courtesy of ISUZU MOTOR CO. NOTE: Compressor shaft seal servicing procedure is not available from manufacturer.
If removed, tighten thermal protector to 11-13 ft. lbs. (15-18 N.m).

1999 Toyota RAV4
1999 GENERAL SERVICING Compressor Servicing
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1999-2000 ENGINE COOLING
Electric Cooling Fans
IDENTIFICATION
ELECTRIC COOLING FAN IDENTIFICATION
DESCRIPTION & OPERATION
Land Cruiser, Tacoma, Tundra and 4Runner use a belt-driven cooling fan attached to the water pump. All other
models use 2 electric cooling fans located directly behind the radiator. Fans are controlled via Engine Coolant
Temperature (ECT) switches/sensors, and turn on when engine coolant temperature is above 208°F (98°C) on
Avalon, Camry with 3.0L, Camry Solara with 3.0L and Sienna. On Camry with 2.2L, Camry Solara with 2.2L,
Celica, Corolla, ECHO, MR2 and RAV4, ECT turns cooling fans on above 199°F (93°C). On Avalon, Camry
with 3.0L, Camry Solara with 3.0L and Sienna, fans will turn off when engine coolant temperature falls below
190°F (88°C). On Camry with 2.2L, Camry Solara with 2.2L, Celica, Corolla and RAV4, fans will turn off
below 181°F (83°C).
SYSTEM TESTS
ELECTRIC COOLING FAN
Avalon (1999), Camry 3.0L, Camry Solara 3.0L & Sienna
1. With engine coolant temperature below 190°F (88°C), turn ignition switch to ON position (engine off).
Ensure fans stop.
2. If fan do not stop, test cooling fan relay and ECT switch. See COOLING FAN RELAYS
and ECT
SWITCH . Check for loose or broken connector or wiring between relay and ECT switch. Repair as
necessary.
3. Disconnect No. 1 ECT switch connector. See ECT SWITCH LOCATIONS
table. With ignition still in
ON position, ensure cooling fan turns on. If not, check fuses, engine main relay, cooling fan relay and
cooling fan motor. Check for short between cooling fan relay and ECT switch.
4. Start engine and raise temperature above 208°F (98°C). Ensure cooling fan turns. If not, replace No. 1
ECT switch.
5. Stop engine and disconnect cooling fan 2-pin connector. With battery connected to ammeter (positive
battery terminal to positive ammeter terminal and negative battery and negative ammeter terminals to
each connector pin), test amperage readings. See Fig. 1
. If readings are not as specified, replace cooling
fan. See COOLING FAN AMPERAGE READINGS
table. Reconnect fan connector.
Avalon (2000)
ApplicationCooling Fan Location
All Models
Condenser Cooling FanPassenger's Side, Rear Of Radiator
Radiator Cooling FanDriver's Side, Rear Of Radiator

1999 Toyota RAV4
1999-2000 ENGINE COOLING Electric Cooling Fans

1999 Toyota RAV4
1999-2000 ENGINE COOLING Electric Cooling Fans
Microsoft
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1. With engine coolant temperature below 181°F (83°C), turn ignition switch to ON position (engine off).
Ensure fans stop.
2. If fans do not stop, test cooling fan relays and ECT switches. See COOLING FAN RELAYS
and ECT
SWITCH . Check for loose or broken connector or wiring between relay and ECT switch. Repair as
necessary.
3. Disconnect No. 1 ECT switch wire connector. Connect jumper wire to No. 1 ECT terminals. Ensure fan
rotates at high speed. If fan does not rotate, check No. 1 cooling fan relay and cooling fan. Reconnect No.
1 switch connector.
4. Disconnect No. 2 switch connector. Ground terminal on No. 2 ECT switch wire harness side connector.
Ensure No. 1 and No. 2 fans rotate at low speed. If fans do not rotate, check No. 2 cooling fan relay, No.
3 cooling fan relay and No. 2 cooling fan. Reconnect No. 2 ECT switch connector.
5. Inspect No. 1 and No. 2 cooling fans. Disconnect cooling fan connector. With battery connected to
ammeter (positive battery terminal to positive ammeter terminal and negative battery and negative
ammeter terminals to each connector pin), test amperage readings. See Fig. 1
. If readings are not as
specified, replace cooling fan. See COOLING FAN AMPERAGE READINGS
table. Reconnect fan
connector.

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1999-2000 ENGINE COOLING Electric Cooling Fans
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1999-2000 ENGINE COOLING Electric Cooling Fans
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Fig. 1: Testing Amperage At Fan Connectors (Corolla Shown; Other Models Similar)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Camry 2.2L, Camry Solara 2.2L, Celica, Corolla, ECHO, MR2 & RAV4
1. With engine coolant temperature below 181°F (83°C), turn ignition switch to ON position (engine off).
Ensure fan stops.
2. If fan does not stop, test cooling fan relay and ECT switch/sensor. See COOLING FAN RELAYS
and
ECT SWITCH
or ECT SENSOR . Check for loose or broken connector or wiring between relay and
ECT switch. Repair as necessary.
3. Disconnect ECT switch/sensor connector. See ECT SWITCH LOCATIONS
table. With ignition still in
ON position, ensure cooling fan turns on. If not, check fuses, engine main relay (if equipped), cooling fan
relay, and cooling fan motor. On MR2, check ECM. On all models, check for short between cooling fan
relay and ECT switch.
4. Start engine and raise temperature above 199°F (93°C). Ensure cooling fan turns. If not, replace ECT
switch/sensor.
5. Stop engine and disconnect cooling fan 2-pin connector. With battery connected to ammeter (positive
battery terminal to positive ammeter terminal and negative battery and negative ammeter terminals to
each connector pin), test amperage readings. See Fig. 1
. If readings are not as specified, replace cooling
fan. See COOLING FAN AMPERAGE READINGS
table. Reconnect fan connector.
ECT SWITCH LOCATIONS
COOLING FAN AMPERAGE READINGS
ApplicationECT Switch Location
All Models
Condenser Cooling FanPassenger's Side, Rear Of Radiator
Radiator Cooling FanDriver's Side, Rear Of Radiator
ApplicationAmps @ 68°F (20°C)
Avalon
19999.2-11.0
20008.5-11.5
Camry & Camry Solara
5S-FE4.9-8.5
1MZ-FE8.3-11.3
Celica
19996.4-7.4
20005.2-8.2
Corolla5.2-8.2
ECHO (1) 7.8-11.8
MR25.7-7.7
RAV49.1-11.1
Sienna

1999 Toyota RAV4
1999-2000 ENGINE COOLING Electric Cooling Fans
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COMPONENT TESTS
COOLING FAN RELAYS
Cooling Fan Relay No. 1 (Avalon, Celica & RAV4 - 1999)
1. Disconnect negative battery cable. Remove cooling fan relay No. 1 from fuse/relay box. See Fig. 2 , Fig.
5 and Fig. 10 . Using an ohmmeter, check for continuity between relay terminals No. 1 and 2, and No. 3
and 4 on Denso type relays. See Fig. 13
. On Bosch type relays, check for continuity between relay
terminals No. 85 and 86, and No. 30 and 87a. If no continuity exists, replace relay.
2. To check relay operation, connect positive battery voltage to terminal No. 1 (Denso type), or No. 86
(Bosch type). Connect ground to terminal No. 2 (Denso type), or No. 85 (Bosch type). Check that no
continuity exists between relay terminals No. 3 and 4 on Denso type relays. On Bosch type relays, check
that no continuity exists between relay terminals No. 30 and 87a. If continuity exists, replace relay.
3. Reinstall cooling fan relay No. 1.
Cooling Fan Relay No. 1 (Avalon, Celica, ECHO & RAV4 - 2000)
1. Disconnect negative battery cable. Remove cooling fan relay No. 1 from fuse/relay box. See Fig. 3 , Fig.
6 , Fig. 8 and Fig. 11 . Using an ohmmeter, check for continuity between relay terminals No. 1 and 2. See
Fig. 14
. If there is no continuity, replace relay. Check that no continuity exists between relay terminals
No. 3 and 5. If continuity exists, replace relay.
2. To check relay operation, connect positive battery voltage to terminal No. 1 and ground to terminal No. 2.
Check for continuity between relay terminals No. 3 and 5. If no continuity exists, replace relay.
3. Reinstall cooling fan relay No. 1.
Cooling Fan Relay No. 1 (Camry, Camry Solara, Corolla & Sienna)
1. Disconnect negative battery cable. Remove cooling fan relay No. 1 from fuse/relay box. See Fig. 4 , Fig.
7 and Fig. 12 . Using an ohmmeter, check for continuity between relay terminals No. 1 and 2, and No. 3
and 4. See Fig. 15
. If no continuity exists, replace relay.
2. To check relay operation, connect positive battery voltage to terminal No. 1 and ground to terminal No. 2.
Check that no continuity exists between relay terminals No. 3 and 4. If continuity exists, replace relay.
3. Reinstall cooling fan relay No. 1.
With "S" Mark8.5-11.5
With "T" Mark14.0-20.0
(1)Amps @ 77°F (25°C)
CAUTION: When battery is disconnected, vehicle computer and memory systems
may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle.
NOTE: Place match marks on all relays for proper reinstallation.

1999 Toyota RAV4
1999-2000 ENGINE COOLING Electric Cooling Fans
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Cooling Fan Relay No. 2 (Except Avalon)
1. Disconnect negative battery cable. Remove cooling fan relay No. 2 from fuse/relay box. See Fig. 4 -Fig.
12 . Using an ohmmeter, check for continuity between relay terminals No. 1 and 2, and No. 3 and 4. See
Fig. 13
-Fig. 15 . If no continuity exists, replace relay. Check that no continuity exists between relay
terminals No. 3 and 5. If continuity exists, replace relay.
2. To check relay operation, connect positive battery voltage to terminal No. 1 and ground to terminal No. 2.
Check that no continuity exists between relay terminals No. 3 and 4. If continuity exists, replace relay.
Check for continuity between relay terminals No. 3 and 5. If no continuity exists, replace relay.
3. Reinstall cooling fan relay No. 2.
Cooling Fan Relay No. 2 (Avalon)
1. Disconnect negative battery cable. Remove cooling fan relay No. 2 from fuse/relay box. See Fig. 2 and
Fig. 3
. Using an ohmmeter, check for continuity between relay terminals No. 1 and 2, and No. 3 and 4 on
Denso type relay. On Bosch type relay, check for continuity between relay terminals No. 85 and 86, and
No. 30 and 87a. See Fig. 13
and Fig. 14 . If there is no continuity, replace relay.
2. To check relay operation, connect positive battery voltage to terminal No. 1 (Denso type), or No. 85
(Bosch type). Connect ground to terminal No. 2 (Denso type), or No. 86 (Bosch type). Check that no
continuity exists between relay terminals No. 3 and 4 (Denso type), or No. 30 and 87a (Bosch type). If
continuity exists, replace relay. Check for continuity between relay terminals No. 3 and 5 (Denso), or No.
30 and 87 (Bosch). If no continuity exists, replace relay.
3. Reinstall cooling fan relay No. 2.
Cooling Fan Relay No. 3
1. Disconnect negative battery cable. Remove cooling fan relay No. 3 from fuse/relay box. See Fig. 2 - Fig.
12 . Using an ohmmeter, check for continuity between relay terminals No. 1 and 2 (Denso type), or No.
85 and 86 (Bosch type). See Fig. 13
- Fig. 15 . If no continuity exists, replace relay. Check that no
continuity exists between relay terminals No. 3 and 5 (Denso type), or No. 30 and 87 (Bosch type). If
continuity exists, replace relay.
2. To check relay operation, connect positive battery voltage to terminal No. 1 (Denso type), or No. 86
(Bosch type). Connect ground to terminal No. 2 (Denso type), or No. 85 (Bosch type). Check for
continuity between relay terminals No. 3 and 5 (Denso type), or No. 30 and 87 (Bosch type). If no
continuity exists, replace relay.
3. Reinstall cooling fan relay No. 3.
Engine Main Relay (Except 2000 Avalon, 2000 Celica, ECHO & MR2)
1. Disconnect negative battery cable. Remove engine main relay from fuse/relay box. See Fig. 2 -Fig. 12 .
Using an ohmmeter, check for continuity between relay terminals No. 3 and 5, and No. 2 and 4. See Fig.
16 . If no continuity exists, replace relay. Check that no continuity exists between relay terminals No. 1
and 2. If continuit
y exists, replace relay. NOTE: ECHO is not equipped with cooling fan relay No. 3.

1999 Toyota RAV4
1999-2000 ENGINE COOLING Electric Cooling Fans
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2. To check relay operation, connect positive battery voltage to terminal No. 3 and ground to terminal No. 5.
Check that no continuity exists between relay terminals No. 2 and 4. If continuity exists, replace relay.
Check for continuity between relay terminals No. 1 and 2. If no continuity exists, replace relay.
3. Reinstall en
gine main relay.

1999 Toyota RAV4
1999-2000 ENGINE COOLING Electric Cooling Fans
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Fig. 2: Identifying Relay Locations (Avalon - 1999)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999-2000 ENGINE COOLING Electric Cooling Fans
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Fig. 3: Identifying Relay Locations (Avalon - 2000)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999-2000 ENGINE COOLING Electric Cooling Fans
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