Toyota RAV4 (XA40) 2013-2018 Service Manual: Inspection
- Inspect starter assembly
Notice:
These tests must be performed within 3 to 5 seconds
to avoid burning out the coil.
- Perform the pull-in test.
- Disconnect the lead wire from terminal c.
- Connect the battery to the magnetic switch as
shown in the illustration. Check that the clutch
pinion gear extends.
If the clutch pinion gear does not move, replace
the magnetic switch.

- Perform the hold-in test.
- Maintain the battery connections of the pull-in
test above, but disconnect the negative (-) lead
from terminal c. Check that the pinion gear
remains extended.
If the clutch pinion gear returns inward, replace
the magnetic switch.

- Check the clutch pinion gear return.

- Disconnect the negative (-) lead from the
switch body. Check that the clutch pinion gear
returns.
If the clutch pinion gear does not return,
replace the magnetic switch.
- Perform the no-load performance test.

- Connect the lead wire to terminal c. Make sure
that the lead is not grounded.
- Clamp the starter in a vise.
- Connect the battery and an ammeter to the
starter as shown in the illustration.
- Check that the starter rotates smoothly and
steadily while the pinion gear is moving out.
Then measure the current.
Standard current:
90 a or less at 11.5 V
If result is not as specified, replace the starter
assembly.
- Inspect magnetic switch assembly
- Check the plunger.

- Push in the plunger and check that it returns
quickly to its original position.
If necessary, replace the magnetic switch
assembly.
- Check if the pull-in coil has an open circuit.

- Measure the resistance between terminals 50
and c.
Standard resistance:
below 1
If the result is not as specified, replace the
magnetic switch assembly.
- Check if the hold-in coil has an open circuit.
- Measure the resistance between terminal 50
and the switch body.

Standard resistance:
below 2 
If the result is not as specified, replace the
magnetic switch assembly.
- Inspect starter armature assembly

- Check if the commutator has an open circuit.
- Measure the resistance between the segments
of the commutator.
Standard resistance:
below 1 
If the result is not as specified, replace the
armature assembly.
- Check if the commutator is grounded.
- Measure the resistance between the
commutator and armature coil core.
Standard resistance:
10 k
or higher
If the result is not as specified, replace the
armature assembly

- Check the commutator for contamination and burns
on its surface.
If the surface is dirty or burnt, correct it with
sandpaper (no. 400) Or a lathe
- Using a vernier caliper, measure the commutator's
length.
Standard length:
3.1 To 3.8 Mm (0.122 To 0.150 In.)
If the length is greater than the maximum, replace
the starter armature assembly.

- Inspect starter commutator end frame assembly
- Using a vernier caliper, measure the brush length.

Standard length:
4.0 To 9.0 Mm (0.158 To 0.359 In.)
If the length is less than the minimum, replace the
end frame assembly.
- Check the brush insulation.
- Measure the resistance between the positive
(+) and negative (-) brush.

Standard resistance:
10 k
or higher
If the result is not as specified, repair or replace
the end frame assembly.
- Inspect starter clutch

- Check the starter clutch.
- Rotate the clutch pinion gear counterclockwise
and check that it turns freely. Try to rotate the
clutch pinion gear clockwise and check that it
locks.
If necessary, replace the starter drive housing
assembly.
Remove magnetic switch assembly
Remove the nut and disconnect the lead wire from
the magnetic switch.
Remove the 2 screws holding the magnetic switch
to the starter drive housin ...
Hint:
Use high-temperature grease to lubricate the bearings,
gears, return spring and steel ball when assembling the
starter.
Install planetary gear
Apply grease to the planetary gears an ...
Other materials:
Precaution
If any of following conditions are met,
keep engine idling with a/c on (engine
speed at less than 2000 rpm) for at least 1
minute:
Refrigerant gas has been refilled or a/c parts have
been replaced.
A long time has elapsed since the engine was
stopped.
Notice:
If the engine s ...
Installation
Install rear differential support
Install the differential support to the differential
carrier with the 4 bolts.
Torque: 98 n*m (999 kgf*cm, 72 ft.*Lbf)
Install rear differential no. 1 And no. 2 Support
Install the differential no. 1 And no. 2 Supports with
the 4 bo ...
Parts location
System diagram
...