Toyota RAV4 manuals

Toyota RAV4 Service Manual: Reassembly

Hint:

Use high-temperature grease to lubricate the bearings, gears, return spring and steel ball when assembling the starter.

  1. Install planetary gear

  1. Apply grease to the planetary gears and pin parts of the planetary shaft.
  2. Install the 3 planetary gears.

Toyota RAV4. Install planetary gear


  1. Install starter armature assembly

Toyota RAV4. Install starter armature assembly


  1. Apply grease to the plate washer and the armature shaft.
  2. Install the starter armature to the starter commutator end frame.
  3. Using snap ring pliers, install the plate washer and a new snap ring.
  4. Using a vernier caliper, measure length of the snap ring.

Maximum length: 5.0 Mm (0.197 In.)

If the length is greater than the maximum, replace it with a new snap ring.

Toyota RAV4. Install starter armature assembly


  1. Install starter commutator end frame cover

Toyota RAV4. Install starter commutator end frame cover


  1. Install the end frame cover to the commutator end frame.
  1. Install starter armature plate

Toyota RAV4. Install starter armature plate


  1. Insert the armature plate to the starter yoke.
  2. Align the keyway of the starter plate with the key inside the starter yoke, and install the starter plate.
  1. Install starter commutator end frame assembly

Toyota RAV4. Install starter commutator end frame assembly


  1. Align the rubber of the end frame with the cutout of the starter yoke.
  2. Install the end frame to the starter yoke.
  1. Install starter yoke assembly

  1. Align the protrusion of the starter yoke with the cutout of the starter drive housing.

Toyota RAV4. Install starter yoke assembly


  1. Install the starter yoke with the 2 through-bolts.

    Torque: 5.9 N*m (60 kgf*cm, 52 in.*Lbf)

Toyota RAV4. Install starter yoke assembly


  1. Install magnetic switch assembly

Toyota RAV4. Install magnetic switch assembly


  1. Apply grease to the plunger and the hook.
  2. Hang the plunger hook of the magnetic switch to the drive lever.
  3. Install the plunger and return spring.

Toyota RAV4. Install magnetic switch assembly


  1. Install the magnetic switch with the 2 screws.

    Torque: 7.5 N*m (76 kgf*cm, 66 in.*Lbf)

Toyota RAV4. Install magnetic switch assembly


  1. Connect the lead wire to the magnetic switch with the nut.

    Torque: 10 n*m (102 kgf*cm, 7 ft.*Lbf)

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 ...

Installation
Install starter assembly Install the starter with the 2 bolts. Torque: 37 n*m (377 kgf*cm, 27 ft.*Lbf) Connect the starter connector. Install the terminal nut and cover the nu ...

Other materials:

Maintenance requirements
To ensure safe and economical driving, day-to-day care and regular maintenance are essential. It is the owner’s responsibility to perform regular checks. Toyota recommends the following maintenance: General maintenance General maintenance should be performed on a daily basis. This can be done ...

Disassembly (2005/11-2006/01)
Remove front axle inboard joint boot no. 2 Clamp lh One touch type: Using a screwdriver, remove the no. 2 Inboard joint boot clamp, as shown in the illustration. Claw engagement type: Using needle-nose pliers, remove the no. 2 Inboard joint boot clamp, as shown in t ...

Data list / active test
Hint: Using the intelligent tester's data list allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the data list early in troubleshooting is one way to save time. Data list for occupant classification ecu Connect the intelligent test ...

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