OEM 2003 Toyota RAV4 Starter Motor

2003 Toyota RAV4 Starter Motor Parts Q&A

• Q: How to service and repair the starter motor on 2003 Toyota RAV4?

  A: Start by removing the dust protector followed by disconnection of the lead wire from the magnetic switch terminal by unscrewing the nut to 5.9 N.m (60 kg.cm, 52 in.lb). The service starts with removing two through bolts using the same torque yet you must pull out the field frame together with the armature. Keep the field frame protrusion facing toward the magnetic switch indentation while replacing all parts. The O-ring must be taken out of the field frame before placing a new ring during assembly. You can remove the starter housing and clutch assembly when you unscrew both screws at 5.9 N.m (60 kg.cm, 52 in.lb) torque and take out the starter housing followed by the clutch assembly (1) and return spring (2) and idler gear (3) and bearing from the magnetic switch. Using a magnetic finger extract the steel ball that is located inside the clutch shaft hole. The brush holder repair begins by removing the two screws together with the field frame end cover at 1.5 N.m (15 kg.cm, 13 in.lb) torque while also removing the O-ring. This step precedes disconnecting the brush holder's four brushes with a screwdriver when holding the spring in place. Pay attention to keep the positive (+) lead wires free from touching any ground while restoring the device. High-temperature grease should be used to lubricate bearings, springs, steel ball and gears during a reverse assembly procedure. A complete clutch assembly replacement requires use of a brass bar between vise jaws to disassemble starter housing with clutch assembly. The pinion gear must then be lowered followed by stop collar hammer strikes with plastic-faced hammer while prying out snap ring. Stop collar and pinion should be removed with compression spring afterward. After removing the spring retainer, clutch shaft and compression spring and starter clutch from the starter housing assemble these parts by inserting the starter clutch and compression spring before adding the clutch shaft and spring retainer along with the pinion gear and stop collar while ensuring correct placement of the snap ring. The SST 09286-46011 tool should be used for removing the front bearing and the SST 09820-00030 to press a new bearing into place while observing the correct installation direction. Perform the same steps for the replacement of the rear bearing. Begin the magnetic switch terminal kit part replacement process by eliminating three bolts, the end cover, gasket, and plunger. Measure the contact plate wear depth before replacing it if the measurement reaches or exceeds 0.9 mm (0.035 in.). Use SST 09810-38140 to loosen terminal nuts before you remove the required components from terminal C and terminal 30. Install new terminal kit parts with correct direction placement for terminal insulators and wave washers. The technician will apply force of 981 N (100 kg, 221 lb) using a hand press with wooden block to tighten the terminal nuts while using SST 09810-38140 to achieve 17 N.m (173 kg.cm, 13 ft.lb) torque. Following cleaning with a dry shop rag, reinstall the plunger and new gasket while tightening three bolts to 2.5 N.m (26 kg.cm, 23 in.lb) torque.