Starter (For 1.3 Kw Type) Reassembly

Engine. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35
3Zr-Fae Starting. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

  2. INSTALL PLANET GEAR

  3. INSTALL STARTER ARMATURE ASSEMBLY

  4. INSTALL STARTER COMMUTATOR END FRAME COVER

  5. INSTALL STARTER ARMATURE PLATE

  6. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY

  7. INSTALL STARTER YOKE ASSEMBLY

  8. INSTALL REPAIR SERVICE STARTER KIT

Starter (For 1.3 Kw Type) -- Reassembly


HINT:
Use high-temperature grease to lubricate the bearings and sliding parts when assembling the starter.


1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Apply high-temperature grease to the drive lever set pin as shown in the illustration.

    Text in Illustration
    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35
    		High-temperature Grease


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.3Zr-Fae Starting.Starting System (W/ Entry And Start System).Starter (For 1.3 Kw Type) Reassembly

  1. Install the drive lever set pin to the center bearing clutch.

    Text in Illustration
    *1
    		Drive Lever Set Pin
    *2
    		Center Bearing Clutch

  1. Install the center bearing clutch together with the drive lever set pin to the drive housing.



2. INSTALL PLANET GEAR


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.3Zr-Fae Starting.Starting System (W/ Entry And Start System).Starter (For 1.3 Kw Type) Reassembly

  1. Apply high-temperature grease to the planet gears and pin parts of the planet shaft.

    Text in Illustration
    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35
    		High-temperature Grease

  1. Install the 3 planet gears to the pins of the planet shaft.



3. INSTALL STARTER ARMATURE ASSEMBLY
NOTICE:
Do not drop the starter armature.


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.3Zr-Fae Starting.Starting System (W/ Entry And Start System).Starter (For 1.3 Kw Type) Reassembly

  1. Apply high-temperature grease to the plate washer, a new snap ring, and the bearing.

    Text in Illustration
    *1
    		Snap Ring
    *2
    		Plate Washer
    *3
    		Bearing
    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35
    		High-temperature Grease


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Apply high-temperature grease to the starter armature as shown in the illustration.

    Text in Illustration
    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35
    		High-temperature Grease

  1. Install the starter armature to the commutator end frame.

  1. Install the plate washer to the starter armature shaft.

  1. Using snap ring pliers, install the snap ring.

    NOTICE:
    1. Be sure to install the snap ring in the armature shaft groove securely.
    2. Be sure to properly install the snap ring because it easily expands.


  1. Check the snap ring length.



      Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.3Zr-Fae Starting.Starting System (W/ Entry And Start System).Starter (For 1.3 Kw Type) Reassembly

    1. Using a vernier caliper, measure the snap ring length.

      Maximum length:
      5.0 mm (0.197 in.)
      Text in Illustration
      *1
      		Length
      If the length is more than the maximum, replace the snap ring.


4. INSTALL STARTER COMMUTATOR END FRAME COVER

  1. Install the commutator end frame cover to the commutator end frame.



5. INSTALL STARTER ARMATURE PLATE


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.3Zr-Fae Starting.Starting System (W/ Entry And Start System).Starter (For 1.3 Kw Type) Reassembly

  1. Align the keyway of the armature plate with the key inside the starter yoke, and install the armature plate.

    Text in Illustration
    *1
    		Key
    *2
    		Keyway


6. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.3Zr-Fae Starting.Starting System (W/ Entry And Start System).Starter (For 1.3 Kw Type) Reassembly

  1. Align the rubber part on the commutator end frame with the groove of the starter yoke.

    Text in Illustration
    *1
    		Rubber Part
    *2
    		Groove

  1. Install the commutator end frame to the starter yoke.

    NOTICE:
    The magnet of the starter yoke may attract the starter armature when the starter commutator end frame is installed, causing the magnet to break.


7. INSTALL STARTER YOKE ASSEMBLY


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.3Zr-Fae Starting.Starting System (W/ Entry And Start System).Starter (For 1.3 Kw Type) Reassembly

  1. Align the claw of the starter yoke with the groove inside the drive housing.

    Text in Illustration
    *1
    		Groove
    *2
    		Claw

  1. Install the starter yoke with the 2 through bolts.

    Torque:
    6.0 N*m{61 kgf*cm, 53 in.*lbf}


8. INSTALL REPAIR SERVICE STARTER KIT


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Apply high-temperature grease to the plunger and hook.



    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Hang the plunger hook of the repair service starter kit on the drive lever set pin.

  1. Install the plunger and return spring.

  1. Install the repair service starter kit with the 2 screws.

    Torque:
    7.5 N*m{76 kgf*cm, 66 in.*lbf}

  1. Connect the lead wire to terminal C with the nut.

    Torque:
    10 N*m{102 kgf*cm, 7 ft.*lbf}