OEM 2001 Toyota RAV4 Starter Motor

2001 Toyota RAV4 Parts Questions & Experts Answers

• Q: How to service and repair the starter motor on 2001 Toyota RAV4?

  A: The starter motor service and repair process starts with dust protector removal followed by field frame and armature access after disconnecting the magnetic switch terminal wire and removing two through bolts whose torque should be 5.9 N.m (60 kg.cm, 52 in.lb). You should fully extract the field frame together with its armature while maintaining proper alignment between the field frame protrusion and magnetic switch indentation before removing its O-ring for new O-ring installation. Unscrew the two screws torque to 5.9 N.m (60 kg.cm, 52 in.lb) which will allow you to extract the starter housing and clutch assembly and the gear component. Then remove the starter housing and clutch assembly and return spring and idler gear and bearing from the magnetic switch. Use a magnetic finger tool to extract the steel ball from the clutch shaft hole followed by unscrewing two screws on the brush holder before removing the end cover from the field frame which requires torque at 1.5 N.m (15 kg.cm, 13 in.lb). The brush holder connection with the positive lead wires must be kept isolated during disconnect. After the procedure the technicians can remove the armature from the field frame. When reassembling the device begin by following the opposite steps used during disassembly while applying high-temp grease to the parts including bearings springs steel ball and gears. For clutch assembly replacement workers must use a vise with brass bar to lower the pinion gear and tap the stop collar using a plastic-faced hammer and remove the snap ring alongside stop collar and compression spring. Reassemble the unit by first placing the starter clutch followed by installation of the compression spring and clutch shaft. The same method should be used to secure all components. For bearing replacement workers must employ Special Service Tool: 09286-46011 to extract the front bearing before using Special Service Tool: 09820-00030 with a press to install a new bearing with precise direction orientation. The same procedure should be performed on the second bearing. The procedure for magnet switch terminal part replacements includes removing three bolts while also taking out the end cover gasket and plunger. Next, inspect the contact plate for wear and replace it when the measurement reaches 0.9 mm (0.035 in.). The necessary components for terminals C and 30 require removal with Special Service Tool: 09810-38140 and new parts need installation in the correct direction while tightening terminal nuts using a wooden block and hand press to specified pressures. Technician must use tool Special Service Tool: 09810-38140 to torque terminal nuts to 17 N.m (173 kg.cm, 13 ft.lb). After cleaning contact surfaces the technician must reinstall the plunger with a new gasket in the end cover by tightening three bolts to 2.5 N.m (26 kg.cm, 23 in.lb).