key TOYOTA RAV4 1996 Service Repair Manual

zDisassembly (A-540E)
zDisassembly (A-540H)
zDisassembly (A-541E)
zDisassembly & Reassembly
(Upper Valve Body - A-540E, A-540H & A-541E)
zDisassembly & Reassembly
(Lower Valve Body - A-540E, A-540H & A-541E)
zReassembly (Valve Body Assembly - A-540E)
zReassembly (Valve Body Assembly - A-540H)
zReassembly (Valve Body Assembly - A-541E)
Disassembly (A-540E)
1. Remove No. 1 and No. 2 solenoids. See Fig. 31 . DO NOT use a screwdriver to pry up solenoid(s).
Remove lock-up solenoid. Remove "O" ring(s) from solenoid(s).
2. Remove OD brake accumulator assembly. Remove check ball on No. 1 plate. Applying compressed air to
accumulator cylinder hole, remove piston and spring. Remove 2 "O" rings from piston.
3. Remove bolts from upper valve body and cover. Note bolt length and location for reassembly reference.
Remove upper valve body cover, oil strainer, gaskets and plate. Remove lock-up relay valve sleeve
stopper. Turn assembly over.
4. Remove bolts from lower valve body and cover. Carefully remove lower valve body cover gaskets and
plate. Note location of check balls, retainers, keys and pins in valve body.
5. Remove 2 check balls from lower valve body. Remove 1 bolt from lower valve body. Remove 3 bolts
from upper valve body. Hold No. 1 plate to upper valve body. Lift off upper valve body and plate as a
unit. DO NOT lose check balls, retainers and pins in lower valve bod
y.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
Helpmelearn
November-03-08 10:28:18 AMPage 45 © 2005 Mitchell Repair Information Company, LLC.

1. Remove No. 1 and No. 2 solenoids. See Fig. 32 . DO NOT use a screwdriver to pry up solenoid(s).
Remove "O" ring(s) from solenoid(s). Remove shift solenoid valve SL. Remove shift solenoid valve ST
with check valve sleeve. Remove shift solenoid valve ST from check valve sleeve.
2. Remove key, 2 check valves and check ball from check valve sleeve. Remove OD brake accumulator
assembly. Applying compressed air to accumulator cylinder hole, remove piston and spring. Remove 2
"O" rings from piston.
3. Remove bolts from upper valve body and cover. Note bolt length and location for reassembly reference.
Remove upper valve body cover, oil strainer, gaskets and plate. Remove lock-up relay valve sleeve
stopper. Turn assembly over.
4. Remove bolts from lower valve body and cover. Carefully remove lower valve body cover gaskets and
plate. Note location of check balls, retainers, keys and pins in valve body.
5. Remove 2 check balls from lower valve body. Remove 1 bolt from lower valve body. Remove 3 bolts
from upper valve body. Hold No. 1 plate to upper valve body. Lift off upper valve body and plate as a
unit. DO NOT lose steel balls, retainers and pins in valve body.
Fig. 32: Exploded View Of Valve Body Assembly (A
-540H)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Disassembly (A-541E)
1. Remove No. 1 and No. 2 solenoids with retainers. Remove No. 3 solenoid. Remove lock plate. Remove
OD brake accumulator assembl
y. Apply compressed air to vent hole on side of accumulator cylinder to

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
Helpmelearn
November-03-08 10:28:18 AMPage 47 © 2005 Mitchell Repair Information Company, LLC.

1999 AUTOMATIC TRANSMISSIONS
Toyota & Lexus Shift Lock System
DESCRIPTION
Transmission/transaxle is equipped with a electronically controlled shift lock and key lock system. See Fig. 1 .
Shift lock system prevents shift lever from being moved from Park unless brake pedal is depressed. In case of a
malfunction, shift lever can be released by depressing shift lock override button, located near shift lever. Key
lock system prevents ignition key from being moved from ACC to LOCK position on ignition switch unless
shift lever is in Park.
System consists of brakelight switch, key interlock solenoid, shift lock control switch, shift lock control
Electronic Control Unit (ECU), shift lock solenoid and shift lock release button. All models may not be
equipped with all components. See Fig. 1
.
NOTE: Sienna is equipped with cable operated shift lock system. See CABLE
OPERATED SHIFT LOCK SYSTEM CHECK and ADJUSTMENTS .

1999 Toyota RAV4
1999 AUTOMATIC TRANSMISSIONS Toyota & Lexus Shift Lock System

1999 Toyota RAV4
1999 AUTOMATIC TRANSMISSIONS Toyota & Lexus Shift Lock System
Microsoft
Sunday, November 22, 2009 10:45:59 AMPage 1 © 2005 Mitchell Repair Information Company, LLC.
Microsoft
Sunday, November 22, 2009 10:46:16 AMPage 1 © 2005 Mitchell Repair Information Company, LLC.

Fig. 1: Shift & Key Lock System Component Locations (Typical)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
OPERATION
SHIFT LOCK SYSTEM
With ignition on, when brake pedal is depressed, an input signal is sent from brakelight switch to ECU. With
shift lever in Park, an input signal from shift control switch is input to ECU, indicating shift lever is in Park.
ECU then operates shift lock solenoid, so shift lever can be moved from Park.
KEY LOCK SYSTEM
With ignition in ON or ACC position and shift lever in Park, shift lock control switch opens and voltage from
ECU to key interlock solenoid is turned off. When key interlock solenoid is turned off, ignition key can be
turned from ACC to LOCK position on ignition switch.
COMPONENT TESTS

1999 Toyota RAV4
1999 AUTOMATIC TRANSMISSIONS Toyota & Lexus Shift Lock System
Microsoft
Sunday, November 22, 2009 10:46:00 AMPage 2 © 2005 Mitchell Repair Information Company, LLC.

Replace shift lock solenoid if operating sound cannot be heard.
SHIFT LOCK SOLENOID RESISTANCE SPECIFICATIONS
KEY INTERLOCK SOLENOID
1. Disconnect electrical connector from key interlock solenoid. Using ohmmeter, measure resistance
between key interlock solenoid terminals. See WIRING DIAGRAMS
.
2. Replace key interlock solenoid if resistance is not 12-17 ohms. Apply battery voltage between of key
interlock solenoid terminals. Replace key interlock solenoid if operating sound cannot be heard.
SHIFT LOCK CONTROL SWITCH
Disconnect electrical connector from shift lock control switch. Using ohmmeter, check continuity between
specified terminals in relation to shift lever. See WIRING DIAGRAMS
. See SHIFT LOCK CONTROL
SWITCH CONTINUITY table. Replace switch if continuity is not as specified.
SHIFT LOCK CONTROL SWITCH CONTINUITY
CABLE OPERATED SHIFT LOCK SYSTEM CHECK
Sienna
Ensure shift lock cable does not interfere with wiring harness. Ensure ignition switch turns to LOCK position
when shift lever is in "P" position. Ensure brake pedal returns fully. Ensure shift lock is released when brake
pedal is depressed with ignition switch at ACC, ON or START position.
ADJUSTMENTS
PARKING LOCK CABLE
ApplicationOhms
Avalon, Camry, Camry Solara & Tacoma (A43D)30-35
Celica, Corolla, GS300, GS400 & 4Runner21-27
ES300 & RX30029-36
Land Cruiser, LS400, LX470, SC300, SC400 & Tacoma (A-340E/F)20-28
RAV426-33
NOTE: Continuity must be checked in accordance with position of release button on
shift lever and shift lever position.
Shift Lever Position & ConditionTerminals
Any Other Gear Except ParkP & P2
Park & Release Button Not PushedP & P1
Park & Release Button Is PushedP & P1 Or P & P2

1999 Toyota RAV4
1999 AUTOMATIC TRANSMISSIONS Toyota & Lexus Shift Lock System
Microsoft
Sunday, November 22, 2009 10:46:00 AMPage 9 © 2005 Mitchell Repair Information Company, LLC.

Fig. 2: Exploded View Of Compressor Clutch (Ford FS-10 Shown; Halla FX-15 Is Similar)
Courtesy of MAZDA MOTORS CORP.
HARRISON HD6/HT6 6-CYLINDER
CLUTCH COIL & BEARING ASSEMBLY
Removal
1. Remove compressor from vehicle. Place compressor in Holding Fixture (J-33026). Using Clutch
Plate/Hub Remover/Installer (J-33013-B), remove compressor clutch plate and hub. See Fig. 3
.
2. Position remover/installer center screw forcing tip flat against compressor shaft and thread
remover/installer into hub. End of shaft will be damaged if forcing tip is not flat. Hold remover/installer
body and turn center screw into remover/installer body and remove clutch plate and hub. Remove shaft
key from compressor shaft.
3. Remove snap ring. Install Pulley/Bearing Puller Guide (J-33023-A) on front head. Position
Pulley/Bearing Puller (J-41552) into inner circle of slots on pulley. Turn puller clockwise until engaged in
pulley slots. Tighten puller screw against puller guide until pulley is removed.
4. Disconnect clutch coil connector. Scribe match marks on compressor and clutch coil connector for
installation reference. Install Puller Pilot Adapter (J-33023-A) on front head of compressor. Install Puller
Crossbar (J-8433-1), Puller Legs (J-33025), and Forcing Screw (J-8433-3). Tighten puller forcing screw
CAUTION: DO NOT hammer on compressor shaft or clutch hub to remove clutch
plate. Internal compressor damage will result.

1999 Toyota RAV4
1999 GENERAL SERVICING Compressor Servicing
Microsoft
Sunday, November 22, 2009 10:31:50 AMPage 4 © 2005 Mitchell Repair Information Company, LLC.

against pilot adapter and remove clutch coil. See Fig. 3.
Installation
1. Align clutch reference marks made during removal. Position Clutch Coil Installer (J-33024) over internal
opening of clutch coil housing and align with front head of compressor. Position Puller Crossbar (J-8433-
1) and Through-Bolts (J-33026) so Forcing Screw (J-8433-3) is centered in clutch coil installer center
hole. Ensure through-bolts are fully threaded into holding fixture.
2. Tighten forcing screw against installer to press clutch coil onto compressor front head. Ensure clutch coil
and installer stay aligned during installation. When clutch coil is fully seated on front head, stake front
head and clutch coil. Using a 1/8" (3.2 mm) punch, stake clutch coil inner ring in 3 places, 120 degrees
apart. Stake size should be 1/2 the area of punch tip and 0.010-0.015" (0.28-0.38 mm) deep.
3. Position Pulley/Bearing Installer (J-33017) and Pulley/Bearing Puller Guide (J-33023-A) over inner race
of pulley bearing. Position Puller Crossbar (J-8433-1) and Through-Bolts (J-33026) so Forcing Screw (J-
8433-3) is centered over puller guide. Ensure through-bolts are fully threaded into holding fixture.
4. Tighten forcing screw against puller guide to press pulley and bearing assembly onto front head of
compressor. Ensure puller guide and front head of compressor stay aligned during installation. Install
snap ring.
5. Install shaft key into clutch plate and hub. Ensure shaft key protrudes about 1/8" (3.2 mm) out of keyway.
Ensure friction surfaces of clutch plate and pulley are clean. Ensure shaft key and keyway in hub are
aligned and position clutch plate and hub onto compressor shaft.
6. Install Clutch Plate/Hub Remover/Installer (J-33013-B) with forcing screw in installation position. Body
of remover/installer should be backed off from hub enough to allow forcing screw to be threaded onto
compressor shaft.
7. Hold forcing screw and tighten installer body to press hub onto compressor shaft. Before pressing clutch
plate and hub to final position, remove installer and ensure shaft key is still in keyway. Continue pressing
clutch plate and hub until air gap between friction surfaces is 0.020-0.030" (0.51-0.76 mm).
SHAFT SEAL
Removal
1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Loosen and reposition
compressor in mounting bracket. Remove clutch plate and hub assembly. See CLUTCH COIL &
BEARING ASSEMBLY . See Fig. 3 .
2. Remove shaft seal snap ring. Thoroughly clean all surfaces around seal including inside of compressor
neck and exposed parts of seal, snap rin
g groove, and compressor shaft. Insert shaft Seal CAUTION: When installing clutch plate and hub, if forcing screw is fully threaded
onto end of compressor shaft or installer body is held and forcing screw is
rotated, the shaft key will bind and break the clutch hub.
NOTE: It is not necessary to replace compressor shaft seal because of small amounts
of refrigerant oil seepage. Replace compressor shaft seal when a refrigerant
leak is detected.

1999 Toyota RAV4
1999 GENERAL SERVICING Compressor Servicing
Microsoft
Sunday, November 22, 2009 10:31:50 AMPage 5 © 2005 Mitchell Repair Information Company, LLC.

Removal
1. Remove compressor from vehicle. Place compressor in Holding Fixture (J-41790). Use Clutch Plate
Spanner (J-33027) to hold clutch plate. Remove compressor shaft nut.
2. Use Clutch Plate Remover/Installer (J-33013-B) to remove compressor clutch plate and hub. See Fig. 4
.
Hold remover body and turn center screw into remover body to remove clutch plate and hub. Ensure
forcing tip on remover/installer center screw is flat or end of shaft/axial plate will be damaged. Remove
key from compressor shaft.
3. Remove snap ring. Install Puller Pilot/Guide (J-33023-A) on front head. Position Pulley and Bearing
Puller (J-41552) into inner circle of slots on pulley. Turn puller clockwise in slots to engage puller tangs
with pulley. Tighten puller forcing screw against puller pilot/guide and remove pulley.
4. Disconnect clutch coil lead. Scribe marks on compressor and clutch coil for installation reference. Install
Puller Pilot/Guide (J-33023-A) on front head. Remove clutch coil using puller pilot/guide and 2-jaw
puller. Position puller
jaws under edge of clutch coil. CAUTION: DO NOT hammer on compressor shaft or clutch hub to remove clutch
plate. Internal compressor damage will result.

1999 Toyota RAV4
1999 GENERAL SERVICING Compressor Servicing
Microsoft
Sunday, November 22, 2009 10:31:50 AMPage 8 © 2005 Mitchell Repair Information Company, LLC.

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
Microsoft
Sunday, November 22, 2009 10:31:50 AMPage 10 © 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.