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 (1MZ±FE)STARTER
ST±15
1742 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 (1MZ±FE)STARTER
1743 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, new gasket and end cover with the
3 bolts.
Torque: 2.5 N´m (26 kgf´cm, 23 in.´lbf)

ST01Z±01
± STARTING (1MZ±FE)STARTER
ST±17
1744 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.

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

ST021±01
± STARTING (1MZ±FE)STARTER
ST±19
1746 Author: Date:
INSTALLATION
Installation is in the reverse order of removal. (See page ST±5)

B00796
Starter
Relay
ST022±01
P07170
Ohmmeter
Ohmmeter No
ContinuityContinuity 1
3
25
P07171
Ohmmeter
Continuity1
3
25
Battery ST±20
± STARTING (1MZ±FE)STARTER RELAY
1747 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

SR06B±01
± STEERINGSTEERING SYSTEM
SR±1
2096 Author: Date:
STEERING SYSTEM
PRECAUTION

Care must be taken to replace parts properly because they could affect the performance of the
steering system and result in a driving hazard.

The CAMRY is equipped with SRS (Supplemental Restraint System) such as the driver airbag
and front passenger airbag. Failure to carry out service operation in the correct sequence could
cause the SRS to unexpectedly deployed during servicing, possibly leading to a serious acci-
dent. Before servicing (including removal or installation of parts, inspection or replacement),
be sure to read the precautionary notices in the RS section.

SR06C±01
SR±2
± STEERINGTROUBLESHOOTING
2097 Author: Date:
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in the order shown. If necessary, repair or replace these parts.
SymptomSuspect AreaSee page
Hard steering
1. Tires (Improperly inflated)
2. Power steering fluid level (Low)
3. Drive belt (Loose)
4. Front wheel alignment (Incorrect)
5. Steering system joints (Worn)
6. Suspension arm ball joints (Worn)
7. Steering column (Binding)
8. Power steering vane pump
9. Power steering gearSA±2
SR±5
SR±3
SA±4
±
SA±45
±
SR±18
SR±31
Poor return
1. Tires (Improperly inflated)
2. Front wheel alignment (Incorrect)
3. Steering column (Binding)
4. Power steering gearSA±2
SA±4
±
SR±31
Excessive play
1. Steering system joints (Worn)
2. Suspension arm ball joints (Worn)
3. Intermediate shaft, Sliding yoke (Worn)
4. Front wheel bearing (Worn)
5. Power steering gear±
SA±45
±
SA±10
SR±31
Abnormal noise
1. Power steering fluid level (Low)
2. Steering system joints (Worn)
3. Power steering vane pump
4. Power steering gearSR±5
±
SR±18
SR±31

P06717
SR06D±01
Z00038
DENSO Borroughs
P06723
CORRECT WRONG WRONG
± STEERINGDRIVE BELT
SR±3
2098 Author: Date:
DRIVE BELT
INSPECTION
INSPECT DRIVE BELT
(a) Visually check the belt for excessive wear, frayed cords
etc.
If any defect has been found, replace the drive belt.
HINT:
Cracks on the rib side of a belt are considered acceptable. If the
belt has chunks missing from the ribs, it should be replaced.
(b) Using a belt tension gauge, measure the belt tension.
Belt tension gauge:
DENSO BTG±20 (95506±00020)
Borroughs No. BT±33±73F
5S±FE Engine:
Drive belt tension:
New belt: 95 ± 145 lbf
Used belt: 60 ± 100 lbf
1MZ±FE Engine:
Drive belt tension:
New belt: 150 ± 185 lbf
Used belt: 95 ± 135 lbf
If the belt tension is not as specified, adjust it.
HINT:

ºNew beltº refers to a belt which has been used less than
5 minutes on a running engine.

ºUsed beltº refers to a belt which has been used on a run-
ning engine for 5 minutes or more.

After installing a belt, check that it fits properly in the
ribbed grooves.

Check with your hand to confirm that the belt has not
slipped out of the groove on the bottom of the pulley.

After installing a new belt, run the engine for about 5 min-
utes and recheck the belt tension.

SR06E±01
R09599
Normal Abnormal SR±4
± STEERINGPOWER STEERING FLUID
2099 Author: Date:
POWER STEERING FLUID
BLEEDING
1. CHECK FLUID LEVEL
(See page SR±5)
2. JACK UP FRONT OF VEHICLE AND SUPPORT IT
WITH STANDS
3. TURN STEERING WHEEL
With the engine stopped, turn the wheel slowly from lock to lock
several times.
4. LOWER VEHICLE
5. START ENGINE
Run the engine at idle for a few minutes.
6. TURN STEERING WHEEL
(a) With the engine idling, turn the wheel to left or right full
lock and keep it there for 2±3 seconds, then turn the
wheel to the opposite full lock and keep it there for 2±3 se-
conds.
(b) Repeat (a) several times.
7. STOP ENGINE
8. CHECK FOR FOAMING OR EMULSIFICATION
If the system has to be bled twice specifically because of foam-
ing or emulsification, check for fluid leaks in the system.
9. CHECK FLUID LEVEL
(See page SR±5)