This procedure covers the replacement of the starter solenoid assembly on a 2019-2024 Toyota RAV4 with the 2.5L I4 gas engine, requiring removal of the starter motor to access the solenoid.

Warnings

Tools required

Parts

• Starter solenoid assembly × 1 — Use OEM Toyota specification
• Starter mounting bolt thread sealant (if specified by service manual) × 1 — Toyota Genuine Thread Sealant

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Allow engine to cool completely if recently operated
4. Raise front of vehicle and secure on jack stands rated for vehicle weight
5. Remove engine splash shield/under cover if equipped (multiple 10mm bolts and push clips)
6. Disconnect negative battery terminal and secure cable away from battery post

Procedure

1. 1

   Access starter motor from below
   Position yourself under the front driver's side of the vehicle with adequate lighting. Locate the starter motor mounted to the lower rear section of the engine block, between the engine and transmission bellhousing. The starter is accessible from underneath on the FWD model without removing other components.
2. 2

   Disconnect electrical connections
   Locate the two electrical connections on the starter solenoid: the battery cable terminal (larger connection with protective cover) and the signal wire connector (smaller push-type connector). Remove the rubber protective cover from the battery cable terminal. Using a 12mm or 14mm wrench (depending on terminal nut size), remove the nut securing the battery cable to the solenoid terminal. Remove the battery cable and secure it away from the starter. Press the release tab and disconnect the signal wire connector from the solenoid.
3. 3

   Remove upper starter mounting bolt
   Locate the upper starter mounting bolt accessible from above or through the wheel well area. This bolt secures the starter to the engine block/transmission bellhousing. Use a 14mm socket with extension to remove the upper mounting bolt. Keep the bolt in a secure location as it will be reused.
4. 4

   Remove lower starter mounting bolt
   From underneath the vehicle, locate the lower starter mounting bolt. Use a 14mm socket with appropriate extension to remove this bolt. Support the starter motor with one hand while removing the final bolt to prevent it from falling.
5. 5

   Remove starter assembly
   Carefully lower and remove the starter motor assembly from the engine. Maneuver it past any obstructions and bring it to your workbench. The complete starter assembly weighs approximately 8-10 pounds. Inspect the mounting surface on the engine block for debris or damage.
6. 6

   Remove solenoid from starter
   On your workbench, locate the two or three bolts securing the solenoid to the starter motor body (typically 10mm bolts). Remove these bolts and carefully separate the solenoid from the starter housing. Note the position of the plunger engagement mechanism. Inspect the starter motor gear teeth and bushing condition while the unit is removed.
7. 7

   Install new solenoid
   Position the new solenoid onto the starter motor body, ensuring the plunger mechanism properly engages with the shift fork. Align the mounting holes and install the solenoid mounting bolts. Tighten bolts in a cross pattern to ensure even seating.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
8. 8

   Reinstall starter assembly
   Position the starter motor with new solenoid back into the mounting location on the engine block. Align the starter nose housing with the bellhousing opening. Insert both mounting bolts hand-tight first to ensure proper alignment.
9. 9

   Torque starter mounting bolts
   Using a torque wrench, tighten both starter mounting bolts to specification in an alternating pattern (tighten upper partially, then lower partially, then both to final torque). This ensures the starter seats properly against the mounting surface.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
10. 10

    Reconnect electrical connections
    Reconnect the signal wire connector to the solenoid, ensuring it clicks into place. Position the battery cable terminal onto the solenoid stud. Install the terminal nut and tighten to specification using appropriate wrench. Replace the rubber protective cover over the battery cable terminal.
    Torque spec

    Battery Cable Nut14 Nm (10 lb-ft)
11. 11

    Reinstall under covers and lower vehicle
    If removed, reinstall the engine splash shield/under cover and secure all fasteners. Remove jack stands and carefully lower the vehicle to the ground. Remove wheel chocks.
12. 12

    Reconnect battery and test
    Reconnect the negative battery terminal and tighten to specification. Do not overtighten as this can damage the battery terminal. Ensure the connection is clean and secure.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Ensure all electrical connections are secure and protective covers are in place
2. Verify starter mounting bolts are torqued to specification - improper torque can cause starter noise or failure to engage
3. Double-check that no tools or parts were left in the engine compartment or under the vehicle
4. Confirm the engine splash shield is properly secured if it was removed

Verification

• Turn the ignition key to the START position (or press start button) and verify the engine cranks normally without unusual grinding or clicking noises
• Verify the starter disengages immediately when the key is released or the engine starts
• Listen for smooth engagement without excessive noise or gear grinding
• Check for any electrical burning smell or smoking from the starter area
• Perform 3-5 start cycles allowing the starter to cool between attempts to verify consistent operation
• Inspect underneath the vehicle for any fluid leaks or loose components after test starts
• Verify all warning lights on the dashboard function normally after reconnecting battery

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