TOYOTA RAV4 1996 Service Repair Manual

S00254
40 mm
Contact Plate 20 mm
37 mmWooden
Block
(kgf/cm2) =Ram diameter (cm)
100 kgf
2x 3.14 (π)
2
(psi) =Ram diameter (in.)
221 lbf
2x 3.14 (π)
2
(kPa) = (kgf/cm2) x 98.1
(kPa) = (psi) x 6.9
P25832
SST
P25833
ST−16
− STARTINGSTARTER
1996 RAV4 (RM447U)
8. TIGHTEN TERMINAL NUT
(a) Put a wooden block on the contact plate and press it down
with a hand press.
Dimensions of wooden block:
20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
Press force:
981 N (100 kgf, 221 lbf)
NOTICE:
Check the diameter of the hand press ram. Then cal-
culate the gauge pressure of the press when
981 N (100 kgf, 221 lbf) of force is applied.
Gauge pressure:
If the contact plate is not pressed down with the spe-
cified pressure, the contact plate may tilt due to coil
deformation or the tightening of the nut.
(b) Using SST, tighten the nuts to the specified torque.
SST 09810−38140
Torque: 17 N·m (170 kgf·cm, 12 ft·lbf)
NOTICE:
If the nut is over tightened, it may cause cracks on the in-
side of the insulator.
9. CLEAN CONTACT SURFACES OF CONTACT PLATE
AND PLUNGER
Clean the contact surfaces of the remaining contact plate and
plunger with a dry shop rag.
10. REINSTALL MAGNETIC SWITCH END COVER
Install the plunger, new gasket and end cover with the 3 bolts.
Torque: 2.5 N·m (26 kgf·cm, 23 in.·lbf)

ST05N−01
− STARTINGSTARTER
ST−17
1996 RAV4 (RM447U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page ST−5).
HINT:
Use high−temperature grease to lubricate the bearings, springs, steel ball and gears when assembling the
starter.

ST05O−01
P14353
Terminal 50
Terminal C
Battery
P14354
Terminal C
DisconnectBattery
P14355
Battery
Disconnect
P14356
Terminal 50
AmmeterBattery
Terminal 30 ST−18
− STARTINGSTARTER
1996 RAV4 (RM447U)
TEST
NOTICE:
These tests must be done within 3 to 5 seconds to avoid
burning out the coil.
1. DO PULL−IN TEST
(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the clutch pinion gear moves outward.
2. DO HOLD−IN TEST
With battery connected as above with the clutch pinion gear
out, disconnect the negative (−) lead from terminal C. Check
that the pinion gear remains out.
3. INSPECT CLUTCH PINION GEAR RETURN
Disconnect the negative (−) lead from the switch body.
Check that the clutch pinion gear returns inward.
4. DO NO−LOAD PERFORMANCE TEST
(a) Connect the battery and ammeter to the starter as shown.
(b) Check that the starter rotates smoothly and steadily with
the pinion gear moving out. Check that the ammeter
shows the specified current.
Specified current: 90 A or less at 11.5 V

ST05P−01
− STARTINGSTARTER
ST−19
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page ST−4).