| Last Modified: 01-30-2024 | 6.11:8.1.0 | Doc ID: RM1000000020MOB |
| Model Year Start: 2022 | Model: RAV4 | Prod Date Range: [12/2021 - ] |
| Title: A25A-FKS (STARTING): STARTER (w/ Stop And Start System): INSPECTION; 2022 - 2024 MY RAV4 [12/2021 - ] | ||
INSPECTION
PROCEDURE
1. INSPECT STARTER ASSEMBLY
CAUTION:
As a large electric current passes through the cable during this inspection, a thick cable must be used. If not, the cable may become hot and cause injury.
NOTICE:
Perform each of the following tests within 3 to 5 seconds to prevent the coil from burning out.
(a) Perform a pull-in test.
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(1) Remove the nut, and disconnect the lead wire from terminal M. |
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(2) Connect a battery to the magnet starter switch assembly as shown in the illustration. Check that the clutch pinion gear moves outward.
If the clutch pinion gear does not move outward, replace the magnet starter switch assembly.
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*a |
Starter Body |
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*b |
Terminal 50 |
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*c |
Terminal C |
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Moves outward |
(b) Perform a hold-in test.
(1) While maintaining the battery connections of the pull-in test, disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear does not return inward.
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*a |
Starter Body |
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*b |
Terminal 50 |
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*c |
Terminal C |
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Disconnect |
If the clutch pinion gear returns inward, replace the magnet starter switch assembly.
(c) Perform a return test.
(1) Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns inward.
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*a |
Starter Body |
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*b |
Terminal 50 |
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Disconnect |
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Returns inward |
If the clutch pinion gear does not return inward, replace the magnet starter switch assembly.
(d) Perform a no-load performance test.
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(1) Connect the lead wire to terminal M with the nut. Make sure that the lead wire is not grounded. Torque: 9.0 N·m {92 kgf·cm, 80 in·lbf} |
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(2) Secure the starter assembly in a vise between aluminum plates.
NOTICE:
Ensure that the starter assembly is secured in the vise to prevent it from falling out.
(3) Connect the battery and an ammeter to the starter assembly as shown in the illustration.
NOTICE:
Do not allow any lead to get caught as the clutch pinion gear operates.
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*a |
Starter Body |
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*b |
Terminal 30 |
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*c |
Terminal 50 |
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Rotates |
(4) Check that the starter assembly operates smoothly and steadily while the clutch pinion gear is moving outward.
Measure the current according to the value(s) in the table below.
Standard Current:
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Tester Connection |
Condition |
Specified Condition |
|---|---|---|
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Battery positive (+) terminal - Terminal 30 - Terminal 50 |
11.5 V |
Below 100 A |
If the result is not as specified, replace the starter assembly.
2. INSPECT STARTER ARMATURE ASSEMBLY
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(a) Check the commutator for an open circuit. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance:
If the result is not as specified, replace the starter armature assembly. |
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(b) Check the commutator for a short circuit. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance:
If the result is not as specified, replace the starter armature assembly. |
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(c) Check the commutator appearance.
If the surface is dirty or burnt, replace the stater armature assembly.
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(d) Check the commutator for runout. (1) Place the armature shaft on V-blocks. (2) Using a dial indicator, measure the runout. Maximum Runout: 0.05 mm (0.00197 in.) If the runout is more than the maximum, replace the starter armature assembly. |
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(e) Using a vernier caliper, measure the commutator diameter. Standard Diameter (convex part): 29 mm (1.1417 in.) Minimum Diameter (convex part): 28 mm (1.1024 in.) If the diameter is less than the minimum, replace the starter armature assembly. |
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(f) Check that the undercut portion between the segments is free of foreign matter and measure its depth. Standard Undercut Depth (convex part): 0.7 mm (0.0276 in.) Minimum Undercut Depth (convex part): 0.4 mm (0.0157 in.) If the undercut depth is less than the minimum, replace the starter armature assembly. |
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3. INSPECT STARTER BRUSH HOLDER ASSEMBLY
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(a) Check the brush length. (1) Using a vernier caliper, measure the brush length. Standard Length (convex part): 14.4 mm (0.567 in.) Minimum Length (convex part): 9.0 mm (0.354 in.) If the length is less than the minimum, replace the starter brush holder assembly. |
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(b) Check the brush holder resistance. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance:
If the result is not as specified, replace the starter brush holder assembly. |
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(c) Check the brush spring load.
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(1) Take a pull scale reading the instant the brush spring separates from the brush. Standard Spring Load: 22.3 to 27.3 N (2.27 to 2.78 kgf, 5.01 to 6.14 lbf) Minimum Spring Load: 13.8 N (1.41 kgf, 3.1 lbf) If the spring load is less than the minimum, replace the starter brush holder assembly. |
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4. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
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*a |
Free |
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*b |
Lock |
(a) Check the clutch pinion gear.
(1) While holding the starter center bearing clutch sub-assembly, rotate the clutch pinion gear clockwise, and check that it turns freely. Try to rotate the clutch pinion gear counterclockwise and check that it locks.
If the clutch pinion gear does not operate as specified, replace the starter center bearing clutch sub-assembly.
5. INSPECT MAGNET STARTER SWITCH ASSEMBLY
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(a) Check the plunger. (1) Push in the plunger and check that it returns quickly to its original position. If the plunger does not operate as specified, replace the magnet starter switch assembly. |
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(b) Check the pull-in coil for an open circuit. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance:
If the result is not as specified, replace the magnet starter switch assembly. |
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(c) Check the holding coil for an open circuit. (1) Measure the resistance according to the value(s) in the table below. Standard Resistance:
If the result is not as specified, replace the magnet starter switch assembly. |
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