Toyota RAV4 (XA40) 2013-2018 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:
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 ...
Removal
Hint:
Use the same procedures for the rh side and lh side.
The procedures listed below are for the lh side.
Disconnect cable from negative battery terminal
Notice:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and se ...
Removal
Disconnect cable from negative battery
terminal
Caution:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
Remove no. 1 Engine cover (see page es-410)
Remove camshaft timing oil cont ...