1996 TOYOTA RAV4 Service Repair Manual

ST05I−03
S01781
PCV Hose
IAT Sensor
Connector
Air Cleaner Case AssemblyStarter
Starter WireAir Cleaner Cap Assembly
VSV Air Hose
Starter Connector
Skid Control
Relay Connectors
Engine Coolant Reservoir ElementHigh−tension Cord ST−2
− STARTINGSTARTER
1996 RAV4 (RM447U)
STARTER
COMPONENTS

B03395
Stop Collar
Compression
Spring
Spring
RetainerStarter Housing
Starter
Clutch
Compression
Spring
Clutch Shaft  Snap Ring
Pinion Gear
Idler Gear
Steel BallBearing
Return Spring Starter Housing and
Clutch Assembly
 Terminal 30 Kit Part Terminal C Kit Part
Terminal Nut
Wave
Washer
Insulator
Packing
O−Ring
Terminal
Outer
Terminal Insulator
InnerContact PlateTerminal Bolt
 Dust Protector Brush Holder  O−Ring Field Frame
Lead Terminal
Plunger
 Gasket
End Cover Terminal
Outer O−Ring
Wave
Washer
Terminal Nut
Terminal
Insulator
Inner
Contact Plate Terminal Bolt
End Cover
 O−Ring  Front Bearing
Armature
 Rear Bearing
 Non−reusable part
− STARTINGSTARTER
ST−3
1996 RAV4 (RM447U)

ST05J−03
S01596(1) (2)
(3)(5)
(4)
S01642
Disconnect
S01783
ST−4
− STARTINGSTARTER
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE ENGINE COOLANT RESERVOIR
2. REMOVE AIR CLEANER CAP ASSEMBLY
(a) Disconnect these hoses, cord and connectors:
(1) Skid control relay connectors
(2) High−tension cord from the air cleaner hose and
resonator
(3) IAT sensor connector
(4) PCV hose from the air cleaner hose
(5) Air hose from the air cleaner cap assembly
(b) Disconnect the 4 clamps and air cleaner cap assembly
from the air cleaner case assembly.
(c) Loosen the hose clamp, and disconnect the air cleaner
hose from the throttle body.
(d) Remove the air cleaner cap assembly.
3. REMOVE AIR CLEANER CASE ASSEMBLY
(a) Disconnect the VSV from the air cleaner case assembly.
(b) Remove the 3 bolts and air cleaner case assembly.
4. REMOVE STARTER
(a) Disconnect the starter connector.
(b) Remove the nut, and disconnect the starter wire.
(c) Remove the 2 bolts and starter.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

ST0N5−01
S02332
P13717
S02331
P13464
− STARTINGSTARTER
ST−5
1996 RAV4 (RM447U)
DISASSEMBLY
HINT:
At the time of installation, please refer to the following item.
Use high−temperature grease to lubricate the bearings,
springs, steel ball, and gears when assembling the starter.
1. REMOVE DUST PROTECTOR
2. REMOVE FIELD FRAME AND ARMATURE
(a) Remove the nut, and disconnect the lead wire from the
magnetic switch terminal.
Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
(b) Remove the 2 through bolts.
Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
(c) Pull out the field frame together with the armature.
NOTICE:
At the time of installation, please refer to the following item.
Align the protrusion of the field frame with the groove of the
magnetic switch.
(d) Remove the O−ring from the field frame.
HINT:
At the time of installation, please refer to the following item.
Use a new O−ring.
3. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY
AND GEAR
(a) Remove the 2 screws.
Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)

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.