TOYOTA CAMRY 2000 Service Repair Manual

ST03M±03
B01224
B01225
B01226
B01227
Stop Collar
Pinion Gear
Compression
Spring
B01228
± STARTING (5S±FE)STARTER
ST±11
1718 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
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.

B01234
B01235
B01236
SST
B06419
(1)
(2)
(3)(4)(5)Long
Short
(6)
(7)
Inside
Protrusion
Identation
ST±14
± STARTING (5S±FE)STARTER
1721 Author: Date:
4. REPLACE MAGNETIC SWITCH TERMINAL KIT
PARTS
(a) Remove the 3 bolts, end cover, gasket and plunger.
(b) Using vernier calipers, measure the contact plate for
depth of wear.
Maximum wear: 0.9 mm (0.035 in.)
If the depth of wear is greater than the maximum, replace the
contact plate.
(c) Remove the terminal kit parts.
(1) Using SST, loosen the terminal nuts.
SST 09810±38140
(2) Terminal C:
Remove the terminal nut, wave washer, terminal in-
sulator (outside), O±ring, terminal bolt, contact
plate and terminal insulator (inside).
(3) Terminal 30:
Remove the terminal nut, wave washer, terminal in-
sulator (outside), packing, O±ring, terminal bolt,
contact plate, terminal insulator (inside).
(d) Temporarily install these new terminal 30 kit parts:
(1) Terminal insulator (inside)
(2) Contact plate
(3) Terminal bolt
(4) O±ring
(5) Packing and terminal insulator (outside)
Install the packing to the terminal insulator, and
install them.

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