TOYOTA RAV4 1996 Service Repair Manual

Fig. 12: Solenoid Drive Pinion Return Test (Avalon, Camry, Camry Solara & 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
Microsoft
Sunday, November 22, 2009 10:19:18 AMPage 16 © 2005 Mitchell Repair Information Company, LLC.

Fig. 13: Solenoid Pull-In Coil Test (Celica Shown; Land Cruiser, RAV4, Tacoma 4-Cyl. & 4Runner 4-
Cyl. Are Similar)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Starters
Microsoft
Sunday, November 22, 2009 10:19:18 AMPage 17 © 2005 Mitchell Repair Information Company, LLC.

Fig. 14: Solenoid Hold-In Coil Test (Celica Shown; Land Cruiser, RAV4, Tacoma 4-Cyl. & 4Runner 4-
Cyl. Are Similar)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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

Fig. 15: Solenoid Drive Pinion Return Test (Celica Shown; Land Cruiser, RAV4, Tacoma 4-Cyl. &
4Runner 4-Cyl. Are Similar)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
REMOVAL & INSTALLATION
STARTER
Removal & Installation (Avalon, Camry, Camry Solara & Sienna)
1. Disconnect negative battery cable and then positive cable. Remove battery and tray. If equipped with
cruise control, remove cruise control actuator cover, cruise control actuator and actuator bracket from
body mount.
2. On all models, remove starter terminal/wire cover and remove starter wires. Remove starter. To install,
reverse removal procedure. Tighten starter bolts to specification. See TORQUE SPECIFICATIONS
.
Removal & Installation (Celica)
1. Disconnect negative battery cable. Disconnect air intake temperature sensor connector from air cleaner

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

assembly. If equipped with cruise control, remove cruise control actuator cable from clamps.
2. On California models, remove air hose for idle-up from air cleaner hose. On all models, disconnect 4
clamps, and disconnect air cleaner cap from air cleaner case. Loosen hose clamp, and disconnect air
cleaner hose from throttle body.
3. Remove air cleaner cap and air cleaner hose assembly. Remove air filter. Disconnect 2 engine wires from
clamps on air cleaner case. Remove 3 bolts and air cleaner case. Remove battery. If equipped with cruise
control, disconnect cruise control actuator connector.
4. Remove 3 bolts, and disconnect actuator from body bracket. On all models, disconnect starter connector.
Remove nut, and disconnect starter cable. Remove 2 bolts, and disconnect oxygen sensor connector and
engine wire brackets from starter. Remove starter. To install, reverse removal procedure. Tighten starter
bolts to specification. See TORQUE SPECIFICATIONS
.
Removal & Installation (Corolla)
1. Disconnect negative battery cable and then positive cable. Remove battery and tray. Remove engine
coolant reservoir. Remove engine splash shield from underneath right side of compartment.
2. Remove starter terminal/wire cover and remove starter wires. Remove starter bolts and starter. Note
starter mounting bolt locations (bolts are different lengths). To install, reverse removal procedure. Tighten
starter bolts to specification. See TORQUE SPECIFICATIONS
.
Removal & Installation (Land Cruiser & Tundra V8)
1. Starter is located underneath intake manifold. See Fig. 16 . Disconnect negative battery cable. Remove
cover from top of engine. Remove air cleaner intake hose. Disconnect accelerator cable. Remove intake
manifold. See CYLINDER HEAD & MANIFOLDS
in 4.7L article in ENGINES.
2. Remove starter wires and remove starter. To install, reverse removal procedure. Tighten starter bolts to
specification. See TORQUE SPECIFICATIONS
.

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Starters
Microsoft
Sunday, November 22, 2009 10:19:18 AMPage 20 © 2005 Mitchell Repair Information Company, LLC.

Fig. 16: Locating Intake Manifold & Starter Components (Land Cruiser & Tundra 4.7L)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Starters
Microsoft
Sunday, November 22, 2009 10:19:18 AMPage 21 © 2005 Mitchell Repair Information Company, LLC.

Removal & Installation (RAV4)
Disconnect negative battery cable. Remove engine coolant reservoir. Disconnect relay connectors, PCV hose,
intake air temperature sensor connector, air cleaner intake hose, remaining hoses and lines for air cleaner
removal. Remove air cleaner assembly. Disconnect starter connector. Remove starter wires and remove starter.
To install, reverse removal procedure. Tighten starter bolts to specification. See TORQUE
SPECIFICATIONS .
Removal & Installation (Tacoma, Tundra V6 & 4Runner)
Removal and installation is basically an unbolt and bolt-on procedure. Tighten starter bolts to specification. See
TORQUE SPECIFICATIONS
.
OVERHAUL
NOTE: See Fig. 17 for overhaul procedure.

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

Fig. 17: Exploded View Of Reduction Gear Starter (Avalon Shown; All Others Are Similar)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
STARTER SPECIFICATIONS
STARTER SPECIFICATIONS (4-CYLINDER)
ApplicationSpecification
Camry, Camry Solara, Corolla & RAV4
Brush Minimum Length.394" (10.0 mm)
Brush Spring Load
1.2 kW3.0-4.4 Lbs. (14-20 N)
1.4 kW4.0-5.3 Lbs. (18-24 N)
Commutator
Minimum Diameter1.14" (29.0 mm)

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Starters
Microsoft
Sunday, November 22, 2009 10:19:18 AMPage 23 © 2005 Mitchell Repair Information Company, LLC.

STARTER SPECIFICATIONS (V6)
Minimum Undercut Depth.008" (.2 mm)
Runout.002" (.05 mm)
Armature Core Runout.002" (.05 mm)
Celica
Brush Minimum Length.394" (10.0 mm)
Brush Spring Load4.0-5.3 Lbs. (18-24 N)
Commutator
Minimum Diameter1.14" (29.0 mm)
Minimum Undercut Depth.008" (.2 mm)
Runout.002" (.05 mm)
Armature Core Runout.002" (.05 mm)
Tacoma & 4Runner
Brush Minimum Length
1.4 kW.394" (10.0 mm)
2.0 kW.354" (9.0 mm)
Brush Spring Load
1.4 kW4.0-5.3 Lbs. (18-24 N)
2.0 kW5.0-6.2 Lbs. (22-28 N)
Commutator
Minimum Diameter
1.4 kW1.14" (29.0 mm)
2.0 kW1.34" (34 mm)
Minimum Undercut Depth.008" (.2 mm)
Runout.002" (.05 mm)
Armature Core Runout.002" (.05 mm)
ApplicationSpecification
Avalon, Camry, Camry Solara & Sienna
Brush Minimum Length.394" (10.0 mm)
Brush Spring Load4.0-5.3 Lbs. (18-24 N)
Commutator
Minimum Diameter1.14" (29.0 mm)
Minimum Undercut Depth.008" (.2 mm)
Runout.002" (.05 mm)
Armature Core Runout.002" (.05 mm)
Tacoma, Tundra & 4Runner
Brush Minimum Length
1.2 & 1.4 kW.394" (10.0 mm)
1.8 kW.354" (9.0 mm)
Brush Spring Load

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Starters
Microsoft
Sunday, November 22, 2009 10:19:18 AMPage 24 © 2005 Mitchell Repair Information Company, LLC.

STARTER SPECIFICATIONS (V8)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
1.2 kW3.1-4.4 Lbs. (14-20 N)
1.4 kW4.0-5.3 Lbs. (18-24 N)
1.8 kW5.0-6.2 Lbs. (22-28 N)
Commutator
Minimum Diameter
1.2 & 1.4 kW1.14" (29.0 mm)
1.8 kW1.34" (34 mm)
Minimum Undercut Depth.008" (.2 mm)
Runout.002" (.05 mm)
Armature Core Runout.002" (.05 mm)
ApplicationSpecification
Land Cruiser
Brush Minimum Length.354" (9.0 mm)
Brush Spring Load4.8-6.2 Lbs. (22-28 N)
Commutator
Minimum Diameter1.34" (34 mm)
Minimum Undercut Depth.008" (.2 mm)
Runout.002" (.05 mm)
Armature Core Runout.002" (.05 mm)
Tundra
Brush Minimum Length
1.4 kW.354" (10.0 mm)
2.0 kW.354" (9.0 mm)
Brush Spring Load
1.4 kW4.0-5.3 Lbs. (18-24 N)
2.0 kW5.0-6.2 Lbs. (22-28 N)
Commutator
Minimum Diameter1.34" (34 mm)
1.4 kW1.14" (29.0 mm)
2.0 kW1.34" (34 mm)
Minimum Undercut Depth.008" (.2 mm)
Runout.002" (.05 mm)
Armature Core Runout.002" (.05 mm)
ApplicationFt. Lbs. (N.m)
Starter Mounting Bolts

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Starters
Microsoft
Sunday, November 22, 2009 10:19:18 AMPage 25 © 2005 Mitchell Repair Information Company, LLC.