TOYOTA RAV4 1996 Service Repair Manual

Fig. 4: Ignition Switch 8-Pin Connector (All Others)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
PARK/NEUTRAL SWITCH
Adjusting Park/Neutral Switch
Locate park/neutral switch at transmission or transaxle. Loosen park/neutral position switch bolt(s) and verify
shift selector is in "N" position. Align switch shaft groove with neutral basic line on switch. Hold switch in
position and tighten bolt(s) to specification. See TORQUE SPECIFICATIONS .
Park/Neutral Switch Continuity Check
Disconnect electrical connector from park/neutral switch at transmission or transaxle. Using ohmmeter, check
for continuity at specified terminals with gearshift in proper positions. See Fig. 5
. See PARK/NEUTRAL
SWITCH SPECIFICATIONS table. If continuity is not as specified, replace switch.
PARK/NEUTRAL SWITCH SPECIFICATIONS
NOTE: If vehicle will not start with shift lever in Park/Neutral position, verify correct
park/neutral switch adjustment. If park/neutral switch is correctly adjusted,
verify switch continuity.
Application & Gearshift Position
Continuity Between Terminals
No.
Avalon, Camry, Camry Solara & Sienna
Park5 & 6, 2 & 7
Reverse2 & 8
Neutral5 & 6, 2 & 9

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Fig. 5: Identifying Park/Neutral Switch Terminals
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
STARTER RELAY TEST
Land Cruiser
Drive2 & 10
22 & 3
Low2 & 4
Land Cruiser, Tacoma & 4Runner
Park5 & 6, 4 & 7
Reverse4 & 8
Neutral5 & 6, 4 & 10
Drive4 & 9
24 & 2
Low4 & 3
Tundra
Park6 & 9, 3 & 1
Reverse3 & 2
Neutral6 & 9, 3 & 5
Drive3 & 7
23 & 4
Low3 & 8

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1. Locate and remove starter relay. Starter relay is marked "ST". See STARTER RELAY LOCATION
table. Using ohmmeter, verify continuity exists between relay terminals No. 3 and 4. See STEP 1. See
Fig. 6
. Continuity should not exist between terminals No. 1 and 2. If continuity is not as specified,
replace relay.
2. Check relay operation by applying battery voltage to terminals No. 3 and 4. See STEP 2. See Fig. 6
.
Continuity should now exist between terminals No. 1 and 2. If relay does not test as indicated, replace
relay.
All Others
1. Locate and remove starter relay. Starter relay is marked "ST". See STARTER RELAY LOCATION
table. Using ohmmeter, verify continuity between relay terminals No. 1 and 2. See Fig. 7
. Continuity
should not exist between terminals No. 3 and 5. If continuity is not as specified, replace relay.
2. Check relay operation by applying battery voltage through terminals No. 1 and 2. See Fig. 7
. Continuity
should now exist between terminals No. 3 and 5. If relay does not test as indicated, replace relay.
STARTER RELAY LOCATION
ApplicationLocation
Avalon & CorollaIn Engine Compartment Junction Block
Camry, Camry Solara & SiennaIn Engine Compartment Junction Block No. 2
CelicaIn Engine Compartment Junction/Relay Block No. 2
Land CruiserIn Engine Compartment Junction Block
RAV4, Tundra & 4RunnerIn Engine Compartment Relay Block
TacomaIn Engine Compartment Relay Block No. 2

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Starters
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1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Starters
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Fig. 6: Testing Starter Relay (Land Cruiser)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 7: Testing Starter Relay (All Others)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
BENCH TESTING
NO-LOAD TEST
1. Remove starter. Connect ammeter in series between starter motor terminal No. 30 (battery terminal) and a
fully charged 12-volt battery. Connect battery negative to starter case ground. See Fig. 8
or Fig. 9 .
Connect voltmeter to batter
y to observe voltage draw readings.
CAUTION: DO NOT engage starter solenoid for more than 5 seconds during testing,
or damage to coil winding will result.
NOTE: Starter type and kilowatt (kW) rating can be found on a metal label attached to
side of starter.

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2. Connect remote starter or jumper wire to terminals No. 30 and 50 to engage starter. Starter drive pinion
gear should extend quickly and spin smoothly. Verify starter amperage draw and battery voltage draw are
within specifications. See NO
-LOAD TEST SPECIFICATIONS table. Replace starter if not within
specification.
Fig. 8: Starter No
-Load Test (Celica Shown; Land Cruiser, RAV4, Tacoma 4-Cyl. & 4Runner 4-Cyl. Are
Similar)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 9: Starter No-Load Test (Avalon & Sienna Shown; Camry, Camry Solara, Corolla, Tacoma V6,
Tundra & 4Runner V6 Are Similar)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
NO-LOAD TEST SPECIFICATIONS
SOLENOID TESTS
Application (1) Max. Amps @ (Volts)
Minimum
RPM
Avalon, Celica & Sienna 1.4 kW90 (11.5)3000
Camry, Camry Solara, Corolla & RAV4 1.2 & 1.4 kW90 (11.5)3000
Land Cruiser 2.0 kW100 (11.5)2500
Tacoma, Tundra & 4Runner
1.2 & 1.4 kW90 (11.5)3000
1.8 & 2.0 kW100 (11.5)2500
(1)Starter type and kilowatt (kW) rating can be found on a metal label attached to side of starter.

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1.Pull-In Coil Test

Disconnect field coil lead from terminal "C". Connect jumper wires from negative battery terminal to
terminal "C" and to starter housing. When wire is connected from positive battery terminal to terminal
No. 50, clutch pinion gear should extend fully. See Fig. 10
or Fig. 13 . If clutch pinion gear does not
move, replace solenoid. If clutch pinion gear does move, go to next test.
2.Hold-In Coil Test

With battery connected as in previous test and clutch pinion gear still extended, disconnect jumper wire
from starter terminal "C". See Fig. 11
or Fig. 14 . Clutch pinion gear should remain extended. If clutch
pinion gear does not remain extended, replace solenoid. If clutch pinion gear does remain extended, go to
next test.
3.Drive Pinion Return Test

Disconnect jumper wire from negative battery terminal to starter housing. See Fig. 12
or Fig. 15 . Pinion
gear should now retract. If it does not retract, replace solenoid.
STARTER COMPONENT INSPECTION
Armature Coil
1. Using ohmmeter, check for continuity between armature coil core and insulation between commutator
segments. If continuity is present, replace armature. Check armature for shorts using a growler. Replace
armature as necessary.
2. Check for continuity between segments of commutator. If continuity is not present between any segment,
replace armature.
Brushes & Springs
1. Check brush length. If length is less than specification, replace brushes. See STARTER
SPECIFICATIONS . If brushes are okay, go to next step.
2. Check brush holders, springs, spring clip and insulation between positive and negative holders. Verify no
continuity exists between positive and negative brush holders. Repair or replace components as needed.
Clutch Assembly & Gears
1. Inspect teeth on pinion gear, idler gear and clutch assembly for wear or damage. If damaged, replace gear
or clutch assembly and inspect flywheel ring gear for wear or damage.
2. Inspect clutch pinion gear by rotating pinion gear. Depending on engine, pinion gear will rotate freely in
one direction and lock when rotated in opposite direction. On Avalon, Camry, Camry Solara, Celica,
RAV4 and Sienna, clutch pinion
gear will lock when rotated in a clockwise direction. On all other CAUTION: DO NOT engage starter solenoid for more than 5 seconds during testing,
or damage to coil winding will result.

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models, pinion gear will lock in a counterclockwise direction. On all models, replace clutch assembly as
necessary.
Commutator
1. If commutator surface is dirty or burnt, it can be cleaned with No. 400 grit sandpaper or on a lathe. If
commutator runout (out-of-round) is more than .002" (.05 mm), turn commutator on a lathe. If
commutator diameter is less than minimum, replace armature. See STARTER SPECIFICATIONS
.
2. Ensure undercut depth between commutator segments are clean, free of debris, and that edges are smooth.
Minimum undercut depth is .008" (.20 mm). If undercut depth is less than minimum, use a hacksaw blade
to correct to a depth of .008-.024" (.20-.60 mm).
Field Frame (Field Coil)
Verify continuity between lead wire and field coil brush lead. If continuity is not present, replace field coil.
Verify there is no continuity between field coil end and field frame. If continuity exists, replace or repair field
frame.
Fig. 10: Solenoid Pull
-In Coil Test (Avalon, Camry & Sienna Shown; Corolla, Tacoma V6, Tundra &
NOTE: Starter type and kilowatt (kW) rating can be found on a metal label attached to
side of starter.

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Starters
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Sunday, November 22, 2009 10:19:18 AMPage 14 © 2005 Mitchell Repair Information Company, LLC.

4Runner V6 Are Similar)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 11: Solenoid Hold
-In Coil Test (Avalon, Camry & Sienna Shown; Corolla, Tacoma V6, Tundra &
4Runner V6 Are Similar)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Starters
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Sunday, November 22, 2009 10:19:18 AMPage 15 © 2005 Mitchell Repair Information Company, LLC.