Toyota RAV4 manuals

Toyota RAV4 Service Manual: Inspection

  1. Inspect starter assembly

Notice:

These tests must be performed within 3 to 5 seconds to avoid burning out the coil.

  1. Perform the pull-in test.
  1. Disconnect the lead wire from terminal c.
  2. 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.

Toyota RAV4. Inspect starter assembly


  1. Perform the hold-in test.
  1. 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.

Toyota RAV4. Inspect starter assembly


  1. Check the clutch pinion gear return.

Toyota RAV4. Inspect starter assembly


  1. 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.

  1. Perform the no-load performance test.

Toyota RAV4. Inspect starter assembly


  1. Connect the lead wire to terminal c. Make sure that the lead is not grounded.
  2. Clamp the starter in a vise.
  3. Connect the battery and an ammeter to the starter as shown in the illustration.
  4. 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.

  1. Inspect magnetic switch assembly

  1. Check the plunger.

Toyota RAV4. Inspect magnetic switch assembly


  1. Push in the plunger and check that it returns quickly to its original position.

    If necessary, replace the magnetic switch assembly.

  1. Check if the pull-in coil has an open circuit.

Toyota RAV4. Inspect magnetic switch assembly


  1. Measure the resistance between terminals 50 and c.

Standard resistance: below 1


If the result is not as specified, replace the magnetic switch assembly.

  1. Check if the hold-in coil has an open circuit.
  1. Measure the resistance between terminal 50 and the switch body.

Toyota RAV4. Inspect magnetic switch assembly


Standard resistance: below 2


If the result is not as specified, replace the magnetic switch assembly.

  1. Inspect starter armature assembly

Toyota RAV4. Inspect starter armature assembly


  1. Check if the commutator has an open circuit.
  1. Measure the resistance between the segments of the commutator.

Standard resistance: below 1


If the result is not as specified, replace the armature assembly.

  1. Check if the commutator is grounded.
  1. 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

Toyota RAV4. Inspect starter armature assembly


  1. 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

  2. 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.

Toyota RAV4. Inspect starter armature assembly


  1. Inspect starter commutator end frame assembly

  1. Using a vernier caliper, measure the brush length.

Toyota RAV4. Inspect starter commutator end frame assembly


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.

  1. Check the brush insulation.
  1. Measure the resistance between the positive (+) and negative (-) brush.

Toyota RAV4. Inspect starter commutator end frame assembly


Standard resistance: 10 k  or higher


If the result is not as specified, repair or replace the end frame assembly.

  1. Inspect starter clutch

Toyota RAV4. Inspect starter clutch


  1. Check the starter clutch.
  1. 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.

Disassembly
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 ...

Reassembly
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:

Axle system
Problem symptoms table Hint: Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "suspected area" column of the table. Check each symptom by checking the suspected areas in the order th ...

Disassembly
Fix differential carrier sub-assembly Fix the rear differential carrier in place with the overhaul attachment. Remove stud bolt Remove the 4 stud bolts from the transmission coupling. Remove differential drain plug Using a 10 mm socket hexagon wrench, remove ...

Contact/call history settings
The contact can be transferred from a bluetooth® phone to the system. The contact also can be added, edited and deleted. The call history can be deleted and contact and favorites can be changed. Display the “phone/message settings” screen. Select “contact/call history settings” ...

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