clutch TOYOTA CAMRY 1999 Service Repair Manual

B01229
Starter Housing
Starter
ClutchCompression
Spring
Clutch
Shaft
B01230
B01231B01670
Spring
Compression PinionStop
Collar
Gear
Spring
Retainer
B01232
B01233
ST±12
± STARTING (5S±FE)STARTER
1719 Author: Date:
(b) Assemble the starter housing and the clutch assembly
(1) Assemble these parts:

Starter housing

Starter clutch

Compression spring

Clutch shaft
(2) Mount a brass bar in a vise, install the starter hous-
ing and clutch assembly to the brass bar.
(3) Push down the starter housing, and install these
parts:

Spring retainer

Compression spring

Pinion gear

Stop collar
(4) Push down the pinion gear.
(5) Using snap ring pliers, install a new snap ring.
(6) Using pliers, compress the snap ring.
(7) Check that the snap ring fits correctly.

B01165
P10595
SST
P10596
SSTUpward
Downward
P10593
SST
P10594
± STARTING (5S±FE)STARTER
ST±13
1720 Author: Date:
(8) Remove the starter housing and clutch assembly
from the brass bar.
(9) Using a plastic±faced hammer, tap the clutch shaft
and install the stop collar onto the snap ring.
2. REPLACE FRONT BEARING
(a) Using SST, remove the bearing.
SST 09286±46011
(b) Using SST and a press, press in a new bearing.
NOTICE:
Be careful of the bearing installation direction.
SST 09820±00030
3. REPLACE REAR BEARING
(a) Using SST, remove the bearing.
SST 09286±46011
(b) Using a press, press in a new bearing.

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

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:

ST01W±01
B01156
B01157
ProtrusionIdentation
B01158
B01160
(1)
(4)
(3)
(2)
B01159
ST±6
± STARTING (1MZ±FE)STARTER
1733 Author: Date:
DISASSEMBLY
1. REMOVE DUST PROTECTOR
2. REMOVE FIELD FRAME AND ARMATURE
(a) Remove the nut, and disconnect the lead wire from the
magnetic switch terminal.
Torque: 5.9 N´m (60 kgf´cm, 52 in.´lbf)
(b) Remove the 2 through bolts.
Torque: 5.9 N´m (60 kgf´cm, 52 in.´lbf)
(c) Pull out the field frame together with the armature.
HINT:
Align the protrusion of the field frame with the groove of the
magnetic switch.
(d) Remove the O±ring from the field frame.
HINT:
At the time of installation, please refer to the following items.
Use a new O±ring.
3. REMOVE STARTER HOUSING, CLUTCH
ASSEMBLY AND GEAR
(a) Remove the 2 screws.
Torque: 5.9 N´m (60 kgf´cm, 52 in.´lbf)
(b) Remove these parts from the magnetic switch:
(1) Starter housing and clutch assembly
(2) Return spring
(3) Idler gear
(4) Bearing
4. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch
shaft hole.

P13481
No Continuity Ohmmeter
B01162
Lock
Free
B01163
Ohmmeter
Terminal 50Terminal C
Continuity
B01164
Ohmmeter
Terminal 50Continuity
ST±10
± STARTING (1MZ±FE)STARTER
1737 Author: Date:
6. INSPECT BRUSH HOLDER
Check the brush holder insulation.
Using an ohmmeter, check that there is no continuity be-
tween the positive (+) and negative (±) brush holders.
If there is continuity, repair or replace the brush holder.
7. INSPECT CLUTCH AND GEAR
(a) Check the gear teeth on the pinion gear, idler gear and
clutch assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the ring gear of the flywheel/drive plate
for wear or damage.
(b) Check the clutch pinion gear.
Hold the starter clutch and rotate the pinion gear counter-
clockwise, and check that it turns freely. Try to rotate the
pinion gear clockwise and check that it locks.
If necessary, replace the clutch assembly.
8. INSPECT MAGNETIC SWITCH
(a) Check the pull±in coil for open circuit.
Using an ohmmeter, check that there is continuity be-
tween terminals 50 and C.
If there is no continuity, check and replace the magnetic switch.
(b) Check the hold±in coil for open circuit.
Using an ohmmeter, check that there is continuity be-
tween terminal 50 and the switch body.
If there is no continuity, replace the magnetic switch.
9. INSPECT BEARING
Turn the bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
(See page ST±11)

ST01Y±03
B01224
B01225
B01226
B01227
Stop Collar
Pinion Gear
Compression
Spring
B01228
± STARTING (1MZ±FE)STARTER
ST±11
1738 Author: Date:
REPLACEMENT
1. REPLACE CLUTCH ASSEMBLY
(a) Disassemble the starter housing and the clutch assembly.
(1) Mount a brass bar in a vise, and install the starter
housing and clutch assembly to the brass bar.
(2) Push down the pinion gear.
(3) Using a plastic±faced hammer, tap down the stop
collar.
(4) Using a screwdriver, pry out the snap ring.
(5) Remove these parts:

Stop collar

Pinion gear

Compression spring
(6) Push down the starter housing, and remove the
spring retainer.
(7) Disassemble these parts:

Starter housing

Starter clutch

Compression spring

Clutch shaft

B01229
Starter Housing
Starter
ClutchCompression
Spring
Clutch
Shaft
B01230
B01231B01670
Spring
Retainer Pinion
GearStop
Collar
Compression
Spring
B01232
B01233
ST±12
± STARTING (1MZ±FE)STARTER
1739 Author: Date:
(b) Assemble the starter housing and the clutch assembly
(1) Assemble these parts:

Starter housing

Starter clutch

Compression spring

Clutch shaft
(2) Mount a brass bar in a vise, install the starter hous-
ing and clutch assembly to the brass bar.
(3) Push down the starter housing, and install these
parts:

Spring retainer

Compression spring

Pinion gear

Stop collar
(4) Push down the pinion gear.
(5) Using snap ring pliers, install a new snap ring.
(6) Using pliers, compress the snap ring.
(7) Check that the snap ring fits correctly.

B01165
P10595
SST
P10596
SSTUpward
Downward
P10593
SST
P10594
± STARTING (1MZ±FE)STARTER
ST±13
1740 Author: Date:
(8) Remove the starter housing and clutch assembly
from the brass bar.
(9) Using a plastic±faced hammer, tap the clutch shaft
and install the stop collar onto the snap ring.
2. REPLACE FRONT BEARING
(a) Using SST, remove the bearing.
SST 09286±46011
(b) Using SST and a press, press in a new bearing.
NOTICE:
Be careful of the bearing installation direction.
SST 09820±00030
3. REPLACE REAR BEARING
(a) Using SST, remove the bearing.
SST 09286±46011
(b) Using a press, press in a new bearing.

ST020±01
B01242Terminal 50Terminal C
Battery
B01243
Terminal C
Battery
Disconnect
B01244
Disconnect
Battery
B01245Terminal 50
Terminal 30
Battery
Ammeter
ST±18
± STARTING (1MZ±FE)STARTER
1745 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
(a) Disconnect the negative (±) lead from the switch body.
(b) 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