1996 TOYOTA RAV4 Service Repair Manual

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.

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.