TOYOTA RAV4 2006 Service Repair Manual

ST–82GR-FE STARTING – STARTER
ST
4. REMOVE STARTER ARMATURE PLATE
(a) Remove the starter armature plate from the starter
yoke assembly.
5. REMOVE STARTER COMMUTATOR END FRAME
COVER
(a) Using a screwdriver, pry out the starter commutator
end frame cover.
6. REMOVE STARTER ARMATURE ASSEMBLY
(a) Using snap ring pliers, remove the snap ring and
plate washer.
(b) Remove the starter armature assembly from the
starter commutator end frame assembly.
7. REMOVE PLANETARY GEAR
(a) Remove the 3 planetary gears from the starter drive
housing assembly.
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2GR-FE STARTING – STARTERST–9
ST
INSPECTION
1. INSPECT STARTER ASSEMBLY
CAUTION:
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
assembly as shown in the illustration. Check
that the clutch pinion gear extends.
If the clutch pinion gear does not move, replace
the magnetic switch assembly.
(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 assembly.
(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 assembly.
(d) Perform the no-load performance test.
(1) Connect the lead wire to terminal C. Make sure
that the lead is not grounded.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(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 the test result is not as specified,
overhaul the starter assembly.
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ST–102GR-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:
1
or lower
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:
2
or lower
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:
1
or lower
If the result is not as specified, replace the
starter 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
starter 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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2GR-FE STARTING – STARTERST–11
ST
(d) Using a vernier caliper, measure the commutator's
length.
Standard length:
3.1 mm (0.122 in.)
Maximum length:
3.8 mm (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:
9.0 mm (0.354 in.)
Minimum length:
4.0 mm (0.158 in.)
If the length is less than the minimum, replace the
starter commutator 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 starter commutator 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–122GR-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 washers and the armature
shaft.
(b) Install the starter armature assembly to the starter
commutator end frame assembly.
(c) Using snap ring pliers, install the plate washer and a
new snap ring.
(d) Using a vernier caliper, measure the 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 starter commutator end frame cover to
the starter commutator end frame assembly.
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2GR-FE STARTING – STARTERST–13
ST
4. INSTALL STARTER ARMATURE PLATE
(a) Insert the starter armature plate to the starter yoke
assembly.
(1) Align the keyway of the starter armature plate
with the key inside the starter yoke assembly,
and install the starter armature plate.
5. INSTALL STARTER COMMUTATOR END FRAME
ASSEMBLY
(a) Align the rubber of the starter end frame assembly
with the cutout of the starter yoke assembly.
(b) Install the starter commutator end frame assembly
to the starter yoke assembly.
6. INSTALL STARTER YOKE ASSEMBLY
(a) Align the protrusion of the starter yoke assembly
with the cutout of the starter drive housing
assembly.
(b) Install the starter yoke assembly with the 2 through-
bolts.
Torque: 6.0 N*m (61 kgf*cm, 53 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
assembly on the drive lever.
(c) Install the plunger and return spring.
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ST–142GR-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, 88 in.*lbf)
2. INSTALL BATTERY BRACKET REINFORCEMENT
(a) Install the battery bracket reinforcement with the 2
bolts.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
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2GR-FE STARTING – STARTERST–15
ST
3. INSTALL FRONT BATTERY CARRIER
(a) Install the front battery carrier with the 4 bolts.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
(b) Connect the 2 clamps of the engine wire.
4. INSTALL BATTERY TRAY
5. INSTALL BATTERY
6. INSTALL BATTERY INSULATOR
7. INSTALL BATTERY CLAMP SUB-ASSEMBLY
(a) Install the battery clamp by tightening the bolt and
nut.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) for nut
8.5 N*m (87 kgf*cm, 75 in.*lbf) for bolt
8. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
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2GR-FE STARTING – IGNITION SWITCHST–19
ST
INSTALLATION
1. INSTALL IGNITION SWITCH ASSEMBLY
(a) Install the ignition switch with the 2 screws.
(b) Connect the ignition key cylinder light connector.
(c) Connect the ignition switch connector.
2. INSTALL STEERING COLUMN COVER LOWER
(a) Install the steering column cover lower (see page
SR-20).
3. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
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2AZ-FE CHARGING – GENERATORCH–9
CH
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 FAN AND GENERATOR V BELT
(a) Remove the belt (see page EM-6).
3. REMOVE GENERATOR ASSEMBLY
(a) Disconnect the generator connector.
(b) Remove the terminal cap.
(c) Remove the nut and disconnect the generator wire.
(d) Remove the bolt and wire harness clamp bracket.
(e) Remove the wire harness clamps.
(f) Remove the 2 bolts and generator.
DISASSEMBLY
1. REMOVE GENERATOR PULLEY WITH CLUTCH
(a) Remove the cap from the pulley.
(1) Using a screwdriver, puncture the center of the
cap and pry it off.
NOTICE:
Do not reuse the cap.
(b) Install SST to the pulley and vise as shown in the
illustration.
SST 09820-63020
(c) Mount SST (A) in a vise.
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