TOYOTA CAMRY 1999 Service Repair Manual

B01238
(1)(2)
(3) (4)
(5) (6)
(7)
Long
Short
(7)
InsideLead Terminal
B01239
40 mm
Wooden Block
Contact Plate
20 mm37 mm
(kgf/cm2) =100 kgf
Ram diameter (cm)
2x 3.14 (p)2
Ram diameter (in.)
2x 3.14 (p)2(psi) =221 lbf
(kPa) = x 98.1
x 6.9 (kgf/cm2)
(kPa) = (psi)
± STARTING (5S±FE)STARTER
ST±15
1722 Author: Date:
HINT:
Match the protrusion of the insulator with the indentation of the
housing.
(6) Wave washer
(7) Terminal nut
NOTICE:
Be careful to install the terminal insulators
(inside) and wave washers in the correct direction.
(e) Temporarily install these new terminal C kit parts:
(1) Terminal insulator (inside)
(2) Contact plate
(3) Terminal bolt
(4) O±ring
(5) Terminal insulator (outside)
(6) Wave washer
(7) Terminal nut
NOTICE:
Be careful to install the terminal insulators
(inside) and wave washers in the correct direction.
(f) Temporarily tighten the terminal nuts.
(g) Tighten terminal nuts.
(1) Put a wooden block on the contact plate and press
it down with a hand press.
Dimensions of wooden block:
20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
Press force:
981 N (100 kgf, 221 lbf)
NOTICE:

Check the diameter of the hand press ram. Then cal-
culate the gauge pressure of the press when 981 N
(100 kgf, 221 lbf) of force is applied.
Gauge pressure:

B01240
SST
B01241
ST±16
± STARTING (5S±FE)STARTER
1723 Author: Date:

If the contact plate is not pressed down with the spe-
cified pressure, the contact plate may tilt due to coil
deformation or the tightening of the nut.
(2) Using SST, tighten the nuts to the specified torque.
SST 09810±38140
Torque: 17 N´m (173 kgf´cm, 13 ft´lbf)
NOTICE:
If the nut is over tightened, it may cause cracks on the in-
side of the insulator.
(h) Clean the contact surfaces of the remaining contact plate
and plunger with a dry shop rag.
(i) Reinstall the plunger, a new gasket and the end cover
with the 3 bolts.
Torque: 2.5 N´m (26 kgf´cm, 23 in.´lbf)

ST03N±02
± STARTING (5S±FE)STARTER
ST±17
1724 Author: Date:
REASSEMBLY
Reassembly is in the reverse order of disassembly. (See page ST±6)
HINT:
Use high±temperature grease to lubricate the bearings, springs, steel ball and gears when assembling the
starter.

ST03O±01
B01242Terminal 50Terminal C
Battery
B01243
Terminal C
Battery
Disconnect
B01244
Disconnect
Battery
B01245Terminal 50
Terminal 30
Battery
Ammeter
ST±18
± STARTING (5S±FE)STARTER
1725 Author: Date:
TEST
NOTICE:
These tests must be done within 3 to 5 seconds to avoid
burning out the coil.
1. DO PULL±IN TEST
(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the clutch pinion gear moves outward.
2. DO HOLD±IN TEST
With battery connected as above with the clutch pinion gear
out, disconnect the negative (±) lead from terminal C. Check
that the pinion gear remains out.
3. INSPECT CLUTCH PINION GEAR RETURN
Disconnect the negative (±) lead from the switch body.
Check that the clutch pinion gear returns inward.
4. DO NO±LOAD PERFORMANCE TEST
(a) Connect the battery and ammeter to the starter as shown.
(b) Check that the starter rotates smoothly and steadily with
the pinion gear moving out. Check that the ammeter
shows the specified current.
Specified current: 90 A or less at 11.5 V

ST03P±01
± STARTING (5S±FE)STARTER
ST±19
1726 Author: Date:
INSTALLATION
Installation is in the reverse order of removal. (See page ST±5)

B00796
Starter
Relay
ST03Q±01
P07170
Ohmmeter
Ohmmeter No
ContinuityContinuity 1
3
25
P07171
Ohmmeter
Continuity1
3
25
Battery ST±20
± STARTING (5S±FE)STARTER RELAY
1727 Author: Date:
STARTER RELAY
INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE STARTER RELAY (Marking: ST)
3. INSPECT STARTER RELAY
(a) Inspect the relay continuity.
(1) Using an ohmmeter, check that there is continuity
between terminals 1 and 2.
If there is no continuity, replace the relay.
(2) Check that there is no continuity between terminals
3 and 5.
If there is continuity, replace the relay.
(b) Inspect the relay operation.
(1) Apply battery positive voltage across terminals 1
and 2.
(2) Using an ohmmeter, check that there is continuity
between terminals 3 and 5.
If there is no continuity, replace the relay.
4. REINSTALL STARTER RELAY
5. REINSTALL RELAY BOX COVER

ST01T±01
± STARTING (1MZ±FE)STARTING SYSTEM
ST±1
1728 Author: Date:
STARTING SYSTEM
ON±VEHICLE INSPECTION
NOTICE:
Before changing the starter, check the following items again:

Connector connection

Accessory installation, e.g.: theft deterrent system

ST01U±04
B01274
Throttle Cable
Clamp (A/T)Battery Tray
Cruise
Control
Actuator
Connector
Cruise Control Actuator Cruise Control
Cover
Clamp Hold Down Clamp
Starter Wire
Starter Connector
Starter
Battery
ST±2
± STARTING (1MZ±FE)STARTER
1729 Author: Date:
STARTER
COMPONENTS

B01154

Snap Ring
Starter Housing
Starter Clutch
Compression Spring
Clutch Shaft
Starter Housing and
Clutch Assembly
Idler Gear
Bearing Stop Collar
Pinion Gear
Compression Spring
Spring Retainer
Steel Ball
Return
Spring

Front Bearing
Armature

O±Ring
Field Frame
(Field Coil)
End Cover Brush Holder
Rear Bearing

Dust Protector

Non±reusable part
Magnetic Switch
Assembly

O±Ring
± STARTING (1MZ±FE)STARTER
ST±3
1730 Author: Date:

B06418
Magnetic Switch Assembly
Terminal Nut
Wave Washer
Terminal Insulator
O±RingContact Plate
Terminal
Bolt
Terminal Insulator
Terminal C Kit part
Plunger

Gasket
End Cover
Lead Terminal
O±Ring
Packing
Terminal Insulator
Wave Washer
Terminal Nut Terminal Bolt

Terminal 30 Kit PartContact PlateTerminal Insulator
N´m (kgf´cm, ft´lbf)

Non±reusable part: Specified torque
17 (173, 13)
17 (173, 13)
ST±4
± STARTING (1MZ±FE)STARTER
1731 Author: Date: