TOYOTA RAV4 1996 Service Repair Manual

P13527
(1)
(2)(3) (4)
P13743
P13718
P13528
P13466
ST−6
− STARTINGSTARTER
1996 RAV4 (RM447U)
(b) Remove these parts from the magnetic switch:
(1) Starter housing and clutch assembly
(2) Return spring
(3) Idler gear
(4) Bearing
4. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch
shaft hole.
5. REMOVE BRUSH HOLDER
(a) Remove the 2 screws and end cover from the field frame.
Torque: 1.5 N·m (15 kgf·cm, 13 in.·lbf)
(b) Using a screwdriver, hold the spring back and disconnect
the brush from the brush holder.
Disconnect the 4 brushes, and remove the brush holder.
NOTICE:
Check that the positive (+) lead wires are not grounded.
6. REMOVE ARMATURE FROM FIELD FRAME

P10584
Ohmmeter
Continuity
ST0N6−01
P10585
Ohmmeter
No Continuity
P10586
P10587
ST0040
− STARTINGSTARTER
ST−7
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT ARMATURE COIL COMMUTATOR FOR
OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature.
2. INSPECT ARMATURE COIL COMMUTATOR FOR
GROUND
Using an ohmmeter, check that there is no continuity between
the commutator and armature coil core.
If there is continuity, replace the armature.
3. INSPECT COMMUTATOR FOR DIRTY AND BURNT
SURFACES
If the surface is dirty or burnt, correct it with sandpaper (No.400)
or on a lathe.
4. INSPECT COMMUTATOR CIRCLE RUNOUT
(a) Place the commutator on V−blocks.
(b) Using a dial gauge, measure the circle runout.
Maximum circle runout: 0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on a lathe.
5. INSPECT COMMUTATOR DIAMETER
Using a vernier caliper, measure the commutator diameter.
Standard diameter: 30.0 mm (1.181 in.)
Minimum diameter: 29.0 mm (1.142 in.)
If the diameter is less than minimum, replace the armature.
6. INSPECT UNDERCUT DEPTH
Check that the undercut depth is clean and free of foreign mate-
rials. Smooth out the edge.
Standard undercut depth: 0.6 mm (0.024 in.)
Minimum undercut depth: 0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a
hacksaw blade.

P10588
Ohmmeter
Continuity
P10589
Ohmmeter
No Continuity
Z10079
Brush Holder Side
Field Frame Side Length
Length ST−8
− STARTINGSTARTER
1996 RAV4 (RM447U)
7. INSPECT FIELD FRAME (FIELD COIL) FOR OPEN
CIRCUIT
Using an ohmmeter, check that there is continuity between the
lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
8. INSPECT FIELD FRAME (FIELD COIL) FOR GROUND
Using an ohmmeter, check that there is no continuity between
the field coil end and field frame.
If there is continuity, repair or replace the field frame.
9. INSPECT BRUSH LENGTH
Using a vernier caliper, measure the brush length.
Standard length: 15.5 mm (0.610 in.)
Minimum length: 10 mm (0.394 in.)
If the length is less than minimum, replace the brush holder and
field frame.

ST0019
P13481
Ohmmeter
No Continuity
P02612
Lock
Free
− STARTINGSTARTER
ST−9
1996 RAV4 (RM447U)
10. INSPECT BRUSH SPRING LOAD
Take the pull scale reading the instant the brush spring sepa-
rates from the brush.
Standard spring installed load:
1.2 kw type13.7 − 19.6 N (1.39 − 1.99 kgf, 3.06 − 4.38 lbf)
1.4 kw type17.6 − 23.5 N (1.79 − 2.39 kgf, 3.94 − 5.36 lbf)
Minimum spring installed load:
1.2 kw type9.8 N (0.99 kgf, 2.20 lbf)
1.4 kw type11.8 N (1.20 kgf, 2.65 lbf)
If the installed load is not within specification, replace the brush
springs.
11. INSPECT BRUSH HOLDER INSULATION
Using an ohmmeter, check that there is no continuity between
the positive (+) and negative (−) brush holders.
If there is continuity, repair or replace the brush holder.
12. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idler gear and clutch
assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the drive plate ring gear for wear or
damage.
13. INSPECT CLUTCH PINION GEAR
Hold the starter clutch and rotate the pinion gear counterclock-
wise, and check that it turns freely. Try to rotate the pinion gear
clockwise and check that it locks.
If necessary, replace the clutch assembly.
14. INSPECT REAR BEARING
Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
15. INSPECT FRONT BEARING
Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.

S02334
Terminal 50
Continuity
Terminal COhmmeter
S02333
Terminal 50
ContinuityOhmmeter ST−10
− STARTINGSTARTER
1996 RAV4 (RM447U)
16. DO MAGNETIC SWITCH PULL−IN COIL OPEN
CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minals 50 and C.
If there is no continuity, check and replace the magnetic switch.
17. DO MAGNETIC SWITCH HOLE−IN COIL OPEN
CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minal 50 and the switch body.
If there is no continuity, replace the magnetic switch.

P00231
ST0N7−01
P00649
P00232
P00243
Stop Collar
Pinion Gear
Compression
Spring
P00239
− STARTINGSTARTER
ST−11
1996 RAV4 (RM447U)
REPLACEMENT
1. REPLACE CLUTCH ASSEMBLY
(a) Disassembly of starter housing and clutch assembly.
(1) Mount a brass bar in a vise, and install the starter
housing and clutch assembly to the brass bar.
(2) Push down the pinion gear.
(3) Using a plastic−faced hammer, tap down the stop
collar.
(4) Using a screwdriver, pry out the snap ring.
(5) Remove these parts:
Stop collar
Pinion gear
Compression spring
(6) Push down the starter housing, and remove the
spring retainer.

P00241
Starter Housing
Starter Clutch
Compression SpringClutch Shaft
P00241
Starter Housing
Starter Clutch
Compression SpringClutch Shaft
P00244
P00240
(A)
(B)
(C)
(D)
P00230
ST−12
− STARTINGSTARTER
1996 RAV4 (RM447U)
(7) Disassemble these parts:
Starter housing
Starter clutch
Compression spring
Clutch shaft
(b) Assemble starter housing and clutch assembly.
(1) Assemble these parts:
Starter housing
Starter clutch
Compression spring
Clutch shaft
(2) Mount a brass bar in a vise, install the starter hous-
ing and clutch assembly to the brass bar.
(3) Push down the starter housing, and install these
parts:
Spring retainer...(D)
Compression spring...(C)
Pinion gear...(B)
Stop collar...(A)
(4) Push down the pinion gear.
(5) Using snap ring pliers, install a new snap ring.

P00233
P00648
P10593
SST
P10594
P10595
SST
− STARTINGSTARTER
ST−13
1996 RAV4 (RM447U)
(6) Using pliers, compress the snap ring.
(7) Check that the snap ring fits correctly.
(8) Remove the starter housing and clutch assembly
from the brass bar.
(9) Using a plastic−faced hammer, tap the clutch shaft
and install the stop collar onto the snap ring.
2. REPLACE REAR BEARING
(a) Using SST, remove the bearing.
SST 09286−46011
(b) Using a press, press in a new bearing.
3. REPLACE FRONT BEARING
(a) Using SST, remove the bearing.
SST 09286−46011

P10596
Upward
DownwardSST
P25830
P25831
P25836
SST ST−14
− STARTINGSTARTER
1996 RAV4 (RM447U)
(b) Using SST and a press, press in a new bearing.
NOTICE:
Be careful of the bearing installation direction.
SST 09820−00030
4. REMOVE MAGNETIC SWITCH END COVER
Remove the 3 bolts, end cover, gasket and plunger.
5. INSPECT CONTACT PLATE FOR WEAR
Using vernier calipers, measure the contact plate for depth of
wear.
Maximum wear: 0.9 mm (0.035 in.)
If the depth of wear is greater than the maximum, replace the
contact plate.
6. REMOVE TERMINAL KIT PARTS
(a) Using SST, loosen the terminal nuts.
SST 09810−38140
(b) Terminal C:
Remove the terminal nut, wave washer, terminal insulator
(outside), O−ring, terminal bolt, contact plate and terminal
insulator (inside).
(c) Terminal 30:
Remove the terminal nut, wave washer, terminal insulator
(outside), packing, O−ring, terminal bolt, contact plate,
terminal insulator (inside) and insulation paper.

S00256
Long
Short
Up
Down (1) (2) (3) (4)
(6)
(5) (7)
(8)
P25834
(1) (2) (3)
(6)
(5) (4)(7) Long
Short Up
Down
− STARTINGSTARTER
ST−15
1996 RAV4 (RM447U)
7. REINSTALL TERMINAL KIT PARTS
(a) Install these new parts (Terminal 30):
(1) Insulation paper
(2) Terminal insulator (inside)
(3) Contact plate
(4) Terminal bolt
(5) O−ring
(6) Packing and terminal insulator (outside)
Install the packing to the terminal insulator, and
install them.
HINT:
Match the protrusion of the insulator with the indentation of the
housing.
(7) Wave washer
(8) Terminal nut
NOTICE:
Be careful to install the terminal insulators (inside) and
wave washers in the correct direction.
(b) Install these new parts (Terminal C):
(1) Terminal insulator (inside)
(2) Contact plate
(3) Terminal bolt
(4) O−ring
(5) Terminal insulator (outside)
(6) Wave washer
(7) Terminal nut
NOTICE:
Be careful to install the terminal insulators (inside) and
wave washers in the correct direction.
(c) Temporarily tighten the terminal nuts.