TOYOTA RAV4 2006 Service Repair Manual

2AZ-FE STARTING – STARTERST–9
ST
INSPECTION
1. INSPECT STARTER ASSEMBLY
NOTICE:
These tests must be performed within 3 to 5 seconds
to avoid burning out the coil.
(a) 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.
(b) 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.
(c) Check the clutch pinion gear return.
(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.
(d) Perform the no-load performance test.
(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.
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ST–102AZ-FE STARTING – STARTER
ST
2. INSPECT MAGNETIC SWITCH ASSEMBLY
(a) Check the plunger.
(1) Push in the plunger and check that it returns
quickly to its original position.
If necessary, replace the magnetic switch
assembly.
(b) Check if the pull-in coil has an open circuit.
(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.
(c) Check if the hold-in coil has an open circuit.
(1) 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.
3. INSPECT STARTER ARMATURE ASSEMBLY
(a) 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.
(b) 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.
(c) 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.
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2AZ-FE STARTING – STARTERST–11
ST
(d) 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.
4. INSPECT STARTER COMMUTATOR END FRAME
ASSEMBLY
(a) 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.
(b) Check the brush insulation.
(1) 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.
5. INSPECT STARTER CLUTCH
(a) 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.
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ST–122AZ-FE STARTING – STARTER
ST
REASSEMBLY
HINT:
Use high-temperature grease to lubricate the bearings,
gears, return spring and steel ball when assembling the
starter.
1. INSTALL PLANETARY GEAR
(a) Apply grease to the planetary gears and pin parts of
the planetary shaft.
(b) Install the 3 planetary gears.
2. INSTALL STARTER ARMATURE ASSEMBLY
(a) Apply grease to the plate washer and the armature
shaft.
(b) Install the starter armature to the starter commutator
end frame.
(c) Using snap ring pliers, install the plate washer and a
new snap ring.
(d) 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.
3. INSTALL STARTER COMMUTATOR END FRAME
COVER
(a) Install the end frame cover to the commutator end
frame.
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2AZ-FE STARTING – STARTERST–13
ST
4. INSTALL STARTER ARMATURE PLATE
(a) Insert the armature plate to the starter yoke.
(b) Align the keyway of the starter plate with the key
inside the starter yoke, and install the starter plate.
5. INSTALL STARTER COMMUTATOR END FRAME
ASSEMBLY
(a) Align the rubber of the end frame with the cutout of
the starter yoke.
(b) Install the end frame to the starter yoke.
6. INSTALL STARTER YOKE ASSEMBLY
(a) Align the protrusion of the starter yoke with the
cutout of the starter drive housing.
(b) Install the starter yoke with the 2 through-bolts.
Torque: 5.9 N*m (60 kgf*cm, 52 in.*lbf)
7. INSTALL MAGNETIC SWITCH ASSEMBLY
(a) Apply grease to the plunger and the hook.
(b) Hang the plunger hook of the magnetic switch to the
drive lever.
(c) Install the plunger and return spring.
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ST–142AZ-FE STARTING – STARTER
ST
(d) Install the magnetic switch with the 2 screws.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
(e) Connect the lead wire to the magnetic switch with
the nut.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALLATION
1. INSTALL STARTER ASSEMBLY
(a) Install the starter with the 2 bolts.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
(b) Connect the starter connector.
(c) Install the terminal nut and cover the nut with the
cap.
Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf)
2. INSTALL BATTERY BRACKET REINFORCEMENT
(a) Install the bracket reinforcement.
Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
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2AZ-FE STARTING – STARTERST–15
ST
3. INSTALL FRONT BATTERY BRACKET
(a) Install the bracket front with the 4 bolts.
Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
(b) Attach the 2 wire harness clamps.
4. INSTALL BATTERY
5. INSTALL BATTERY INSULATOR
6. INSTALL BATTERY CLAMP
(a) Attach the hook of the battery clamp to the battery
bracket front.
(b) Temporarily tighten the nut and install the bolt.
(c) Adjust the battery clamp's position.
(d) Fully tighten the nut and bolt.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
(e) Attach the 2 wire harness clamps.
7. CONNECT CABLE TO POSITIVE BATTERY
TERMINAL
8. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
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2AZ-FE STARTING – IGNITION SWITCHST–19
ST
If the result is not as specified, replace the switch
assembly.
INSTALLATION
1. INSTALL IGNITION SWITCH ASSEMBLY
(a) Install the ignition switch with the 2 screws.
(b) Install the ignition key cylinder light connector.
(c) Install the ignition switch connector.
2. INSTALL STEERING COLUMN COVER LOWER
(a) Attach the 4 claws to install the steering column
lower cover.
3. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
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ST–62GR-FE STARTING – STARTER
ST
REMOVAL
1. 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.
2. REMOVE BATTERY CLAMP SUB-ASSEMBLY
(a) Loosen the bolt and nut, and remove the battery
clamp.
3. REMOVE BATTERY INSULATOR
4. REMOVE BATTERY
5. REMOVE BATTERY TRAY
6. REMOVE FRONT BATTERY CARRIER
(a) Disconnect the 2 clamps of the engine wire.
(b) Remove the 4 bolts and front battery carrier.
7. REMOVE BATTERY BRACKET REINFORCEMENT
(a) Remove the 2 bolts and battery bracket
reinforcement.
8. REMOVE STARTER ASSEMBLY
(a) Disconnect the starter connector.
(b) Open the terminal cap, remove the nut and
disconnect the starter wire.
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2GR-FE STARTING – STARTERST–7
ST
(c) Remove the 2 bolts and starter.
DISASSEMBLY
1. REMOVE MAGNETIC SWITCH ASSEMBLY
(a) Remove the nut and disconnect the lead wire from
the magnetic switch assembly.
(b) Remove the 2 screws holding the magnetic switch
assembly to the starter drive housing assembly.
(c) Remove the magnetic switch assembly.
(d) Remove the return spring and plunger from the
starter drive housing assembly.
2. REMOVE STARTER YOKE ASSEMBLY
(a) Remove the 2 through-bolts, and pull out the starter
yoke assembly together with the starter commutator
end frame assembly.
3. REMOVE STARTER COMMUTATOR END FRAME
ASSEMBLY
(a) Remove the starter commutator end frame
assembly from the starter yoke assembly.
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