Starting System (2GR-FE): Other Toyota RAV4 III

SYSTEM DIAGRAM

The starting system rotates the starter motor according to the signals from the ignition switch and PNP switch.

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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 BATTERY CLAMP SUB-ASSEMBLY Loosen the bolt and nut, and remove the battery clamp.
3. REMOVE BATTERY INSULATOR
4. REMOVE BATTERY
5. REMOVE BATTERY TRAY
6. REMOVE FRONT BATTERY CARRIER Disconnect the 2 clamps of the engine wire. Remove the 4 bolts and front battery carrier.
7. REMOVE BATTERY BRACKET REINFORCEMENT Remove the 2 bolts and battery bracket reinforcement.
8. REMOVE STARTER ASSEMBLY Disconnect the starter connector. Open the terminal cap, remove the nut and disconnect the starter wire. Remove the 2 bolts and starter.

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1. REMOVE MAGNETIC SWITCH ASSEMBLY Remove the nut and disconnect the lead wire from the magnetic switch assembly. Remove the 2 screws holding the magnetic switch assembly to the starter drive housing assembly. Remove the magnetic switch assembly. Remove the return spring and plunger from the starter drive housing assembly.
2. REMOVE STARTER YOKE ASSEMBLY Remove the 2 through-bolts, and pull out the starter yoke assembly together with the starter commutator end frame assembly.
3. REMOVE STARTER COMMUTATOR END FRAME ASSEMBLY Remove the starter commutator end frame assembly from the starter yoke assembly.
4. REMOVE STARTER ARMATURE PLATE Remove the starter armature plate from the starter yoke assembly.
5. REMOVE STARTER COMMUTATOR END FRAME COVER Using a screwdriver, pry out the starter commutator end frame cover.
6. REMOVE STARTER ARMATURE ASSEMBLY Using snap ring pliers, remove the snap ring and plate washer. Remove the starter armature assembly from the starter commutator end frame assembly.
7. REMOVE PLANETARY GEAR Remove the 3 planetary gears from the starter drive housing assembly.

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1. INSPECT STARTER ASSEMBLY CAUTION: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. Perform the pull-in test. Disconnect the lead wire from terminal C. 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. Perform the hold-in test. 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. Check the clutch pinion gear return. 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. Perform the no-load performance test. 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) Clamp the starter in a vise. Connect the battery and an ammeter to the starter as shown in the illustration. 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.
2. INSPECT MAGNETIC SWITCH ASSEMBLY Check the plunger. Push in the plunger and check that it returns quickly to its original position. If necessary, replace the magnetic switch assembly. Check if the pull-in coil has an open circuit. Measure the resistance between terminals 50 and C. Standard resistance: 1 ohms or lower If the result is not as specified, replace the magnetic switch assembly. Check if the hold-in coil has an open circuit. Measure the resistance between terminal 50 and the switch body. Standard resistance: 2 ohms or lower If the result is not as specified, replace the magnetic switch assembly.
3. INSPECT STARTER ARMATURE ASSEMBLY Check if the commutator has an open circuit. Measure the resistance between the segments of the commutator. Standard resistance: 1 ohms or lower If the result is not as specified, replace the starter armature assembly. Check if the commutator is grounded. Measure the resistance between the commutator and armature coil core. Standard resistance: 10 kohms or higher If the result is not as specified, replace the starter armature assembly. 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. 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 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. Check the brush insulation. Measure the resistance between the positive (+) and negative (-) brush. Standard resistance: 10 kohms or higher If the result is not as specified, repair or replace the starter commutator end frame assembly.
5. INSPECT STARTER CLUTCH Check the starter clutch. 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.