Toyota RAV4 Service Manual: 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 and pin parts of
the planetary shaft.
- Install the 3 planetary gears.

- Install starter armature assembly

- Apply grease to the plate washer and the armature
shaft.
- Install the starter armature to the starter commutator
end frame.
- Using snap ring pliers, install the plate washer and a
new snap ring.
- 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.

- Install starter commutator end frame cover

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

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

- Align the rubber of the end frame with the cutout of
the starter yoke.
- Install the end frame to the starter yoke.
- Install starter yoke assembly
- Align the protrusion of the starter yoke with the cutout of the starter
drive housing.

- Install the starter yoke with the 2 through-bolts.
Torque: 5.9 N*m (60 kgf*cm, 52 in.*Lbf)

- Install magnetic switch assembly

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

- Install the magnetic switch with the 2 screws.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*Lbf)

- Connect the lead wire to the magnetic switch with
the nut.
Torque: 10 n*m (102 kgf*cm, 7 ft.*Lbf)
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 ...
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:
Diagnostic trouble code chart
If a dtc is displayed during the dtc check, check the circuit
listed for the dtc in the table below (refer to the appropriate
page).
Hint:
When the srs warning light remains on and the normal
system code is output, a decrease in the source voltage is
likely to occur. This malfunction is n ...
Language
Setting the language
Via iDrive:
"CAR"
"Settings"
"General settings"
"Language:"
"System language"
Select the desired setting.
The setting is stored for the driver profile currently
used.
Setting the voice dialog
Set the voice dialog for the voice activation system.
Additional information:
...
Installation
Install no. 2 Radiator grille lower
Install the radiator grille and attach the 16 claws.
Install no. 1 Radiator grille lower
Install the radiator grille and attach the 16 claws.
Install radiator grille
Install the radiator grille with the 6 claws.
...