Toyota Camry 1983-1996 Repair Guide

Starter

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TESTING




WARNING
This tests must be performed within 3 to 5 seconds to avoid burning out the coil.

Pull-in

See Figure 1

Disconnect the field coil lead from the terminal C. Connect the battery to the solenoid switch as shown. See if the clutch pinion gear movement is outward. If the gear does not move perform the hold-in test.



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Fig. Fig. 1: Pull-in test terminal connections

Hold-in

See Figure 2

Attach the battery to the starter as shown and with the clutch pinion gear out, disconnect the negative lead from terminal C. Check to make sure the pinion gear stays in the outward position. If the clutch gear returns inwards, perform the clutch pinion gear return test.



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Fig. Fig. 2: Hold-in test terminal connections

Clutch Pinion Gear Return

See Figure 3

Disconnect the negative lead from the solenoid body. Check the clutch pinion gear returns inward. If not perform the no-load test.



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Fig. Fig. 3: Clutch pinion gear return terminal connections

No-load

See Figure 4

Attach a battery and ammeter to the starter. Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check the ammeter shows the correct current. 90 amps or less at 11.5 volts on gasoline engines and 180 amps or less at 11.0 volts on diesel engines. If not replace the starter.



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Fig. Fig. 4: No-load terminal connections

REMOVAL & INSTALLATION



Gasoline Engines

See Figures 5 thru 15

  1. Disconnect the cable from the negative terminal of the battery.
  2.  



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Fig. Fig. 5: Exploded view of the starter motor mounting-5S-FE engine shown, others similar

  1. On 1992-96 models with cruise control, remove the battery.
  2.  



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Fig. Fig. 6: Disconnect the negative battery cable ALWAYS first



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Fig. Fig. 7: One the cables are removed, take time to clean the terminals



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Fig. Fig. 8: Remove the battery hold-down ...



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Fig. Fig. 9: ... then lift the battery from the engine compartment

  1. Also on 1992-96 models with cruise control, remove the actuator cover and disconnect the wiring harness. Remove the three bolts and then lift out the cruise control actuator. Remove the bracket from beneath the actuator and put aside.
  2.  



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Fig. Fig. 10: Lift the cruise control, actuator cover off



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Fig. Fig. 11: To remove the assembly, loosen these bolts ...



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Fig. Fig. 12: ... and lift the actuator out of the engine compartment

  1. Peel the rubber boot away and remove the nut and disconnect the negative battery cable from the magnetic switch terminal on the starter. Disconnect the electrical connector also located on the magnetic switch.
  2.  



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Fig. Fig. 13: Remove the rubber boot and the nut retaining the starter wiring

  1. Support the starter by hand and remove the two mounting bolts.
  2.  



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Fig. Fig. 14: Remove the these two starter mounting bolts ...



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Fig. Fig. 15: ... then pull the unit from the mounting boss

  1. Remove the starter from the transaxle.
  2.  

To install:
  1. Place the starter motor in the transaxle and support by hand.
  2.  
  3. Install the two mounting bolts and tighten them to 29-31 ft. lbs. (39-42 Nm).
  4.  
  5. Connect the connector to the magnetic switch. Place the battery cable on the switch terminal and install the nut. Tighten the nut and position the rubber boot over the cable.
  6.  
  7. Using the ignition switch, "bump'' the starter over a few times and check for proper operation.
  8.  

Diesel Engines

See Figure 16

  1. Disconnect the cable from the negative terminal of the battery.
  2.  
  3. Drain the cooling system and remove the radiator.
  4.  



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Fig. Fig. 16: Exploded view of the starter motor-diesel engines


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted to the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the nut and bolt from the starter motor stay bracket and remove the bracket.
  2.  
  3. Peel the rubber boot away and remove the nut and disconnect the negative battery cable from the magnetic switch terminal on the starter. Disconnect the electrical connector also located on the magnetic switch.
  4.  
  5. Support the starter by hand and remove the two mounting bolts. Remove the lead wire from terminal 50 of the starter
  6.  
  7. Remove the starter from the transaxle.
  8.  

To install:
  1. Connect the lead wire to terminal 50 of the starter.
  2.  
  3. Place the starter motor in the transaxle and support by hand.
  4.  
  5. Install the two mounting bolts and tighten them to 29 ft. lbs. (39 Nm).
  6.  
  7. Connect the connector to the magnetic switch. Place the battery cable on the switch terminal and install the nut. Tighten the nut and position the rubber boot over the cable.
  8.  
  9. Install the starter motor stay bracket and retain with the nut and bolt.
  10.  
  11. Install the radiator and fill the cooling system.
  12.  
  13. Connect the cable to the negative terminal of the battery.
  14.  
  15. Start the engine and check for leaks. Check the automatic transaxle fluid also and top off if necessary.
  16.  

SOLENOID REPLACEMENT



The starter solenoid (magnetic switch) is an integral part of the starter assembly.

  1. Remove the starter from the car. Remove the heat insulator from the starter assembly, if equipped.
  2.  
  3. Disconnect the wire lead from the magnetic switch terminal.
  4.  
  5. Remove the two long, through bolts holding the field frame to the magnetic switch. Pull out the field frame with the armature from the magnetic switch.
  6.  
  7. On 1.0 kW starters, remove the felt seal. On 1.4 kW starters, remove the O-ring.
  8.  
  9. To remove the starter housing from the magnetic switch assembly:
    1. On 1.0 kW starters, remove the two screws and the starter housing with the idler gear and clutch assembly.
    2.  
    3. On 1.4 kW units, remove the two screws and the starter housing with the pinion gear, idler and clutch assembly.
    4.  

  10.  

To install:
  1. If necessary, install the gears and clutch assembly to the starter housing. Apply grease to the gear and clutch assemblies and:
    1. On 1.0 kW starters, place the clutch assembly, idler gear and bearing in the starter housing.
    2.  
    3. On 1.4 kW starters, place the clutch assembly, idler gear, bearing and pinion gear in the starter housing.
    4.  

  2.  
  3. Insert the spring into the clutch shaft hole and place the starter housing onto the magnetic switch. Install the two screws.
  4.  
  5. On 1.0 kW units, install the felt seal on the armature shaft. On 1.4 kW units, install the O-ring on the field frame.
  6.  
  7. Install the field frame with the armature onto the magnetic switch assembly and install the two through bolts.
  8.  

There is a protrusion or tab on each part; make sure you line them up correctly.

  1. Connect the wire to the terminal on the magnetic switch. Install the heat insulator, if equipped.
  2.  
  3. Reinstall the starter on the vehicle. Check starter system for proper operation.
  4.  

 
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