Toyota Celica 1986-1993 Repair Guide

Starter

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TESTING



Before condemning a starter, make sure the battery clamps are clean and tight, the negative battery cable is connected solidly to ground and the positive battery cable has a solid connection at the starter. Also, make sure the battery is in good condition. In rare cases, the engine itself or an engine accessory can be tight, making the engine crank slowly.

A good way to check the starter itself is to remove it, then check the amperage draw under no load. Before doing the test, check the teeth on the pinion gear and on the flywheel for damage or wear.

  1. Remove the starter, using the proper procedures.
  2.  
  3. Connect the battery and ammeter to the starter, using the proper procedures.
  4.  
  5. Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check the reading on the ammeter. The draw should be 90 amps or less at 11.5 volts.
  6.  



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Fig. Fig. 1 Performing no-load starter test Celica



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Fig. Fig. 2 Troubleshooting the starting system Celica

REMOVAL & INSTALLATION




CAUTION
On models with an air bag, wait at least 30 seconds from the time that the ignition switch is turned to the lock position and the battery is disconnected before performing any further work.

2S-E and 3S-FE Engines

For these engines, starter removal is straightforward.

  1. Disconnect the negative battery cable.
  2.  
  3. Label and disconnect all wiring leading from the starter.
  4.  
  5. Unscrew the two starter mounting bolts.
  6.  



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Fig. Fig. 3 Removing the starter 2S-E engine



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Fig. Fig. 4 Removing the starter 3S-FE engine

  1. Using two hands if possible, remove the starter. It is a heavy unit.
  2.  

To install:

  1. Installation is in the reverse order of removal. Tighten the two mounting bolts to 29 ft. lbs. (39 Nm).
  2.  

3S-GE Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Label and disconnect all wiring leading from the starter.
  4.  
  5. Disconnect the exhaust pipe. First, loosen the bolt and nut and disconnect the clamp from the bracket at the first exhaust joint under the car.
  6.  



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Fig. Fig. 5 Disconnecting exhaust for starter removal3S-GE engine



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Fig. Fig. 6 Removing the starter3S-GE engine

  1. At the exhaust manifold, remove the three nuts holding the pipe and carefully remove the pipe.
  2.  
  3. Remove the two starter mounting bolts and remove the starter. It is a fairly heavy unit; be careful.
  4.  
  5. Remove the starter cover.
  6.  

To install:

  1. When reinstalling, the cover must be in place before installation. Place the starter into the engine and tighten the bolts to 29 ft. lbs. (39 Nm).
  2.  
  3. Install a new gasket and connect the exhaust pipe to the manifold; tighten the nuts to 46 ft. lbs. (62 Nm).
  4.  
  5. Install the exhaust pipe clamp and tighten the hardware.
  6.  
  7. Connect the starter wiring.
  8.  
  9. Connect the negative battery cable.
  10.  

5S-FE Engine
  1. Disconnect the negative battery cable. Wait 30 seconds before performing any other work.
  2.  



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Fig. Fig. 7 Starter removal components5S-FE engine



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Fig. Fig. 8 Preparing for starter removal5S-FE engine shown



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Fig. Fig. 9 Be careful not to damage this lock-type connector when removing the starter5S-FE engine shown

  1. Disconnect the intake air temperature sensor connector.
  2.  
  3. Disconnect the air cleaner hose from the throttle body and remove the air cleaner top and filter element.
  4.  



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Fig. Fig. 1 0Removing starter terminal5S-FE engine shown



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Fig. Fig. 1 1Removing the starter5S-FE engine

  1. Remove the 3 bolts and remove the air cleaner case.
  2.  
  3. Remove the two nuts holding the relay box and remove the relay box from the battery.
  4.  
  5. Remove the lower cover from the relay box.
  6.  
  7. Disconnect the fusible link cassette (tray) and the two engine harness connectors from the relay box.
  8.  
  9. Remove the cruise control actuator. If the car is not equipped with Anti-lock Brake System (abs), proceed as follows:
    1. Remove the actuator cover.
    2.  
    3. Disconnect the actuator vacuum hose from the air intake chamber.
    4.  
    5. Disconnect the actuator connector.
    6.  
    7. Disconnect the cable from the actuator.
    8.  
    9. Remove the 3 retaining bolts and the actuator.
    10.  

  10.  
  11. If the car is equipped with abs, proceed as follows:
    1. Disconnect the actuator connector.
    2.  
    3. Remove the 4 retaining bolts and remove the actuator.
    4.  

  12.  
  13. Disconnect the starter connector and the starter wire. Remove the two bolts, wire clamp and the starter. The starter is heavy; be careful.
  14.  

To install:

  1. Reinstall the starter and tighten the bolts to 29 ft. lbs. (39 Nm).
  2.  
  3. Connect the starter wiring and connectors.
  4.  
  5. Install the cruise control actuator by reversing the removal procedures.
  6.  
  7. Reinstall the relay box, remembering to connect the engine harnesses and secure the cassette in the box. Reinstall the lower cover and mount the relay box in position.
  8.  
  9. Install the air cleaner case, the filter element and top and the various hoses and ducts. Connect the wiring to the air flow sensor.
  10.  
  11. Connect the negative battery terminal.
  12.  

1989 3S-GTE Engine
  1. Disconnect the battery (negative terminal first) and remove the battery from the car.
  2.  
  3. Remove the air cleaner assembly:
    1. Disconnect the air flow meter connector.
    2.  
    3. Disconnect the two air hoses. Release the 4 clamps holding the top of the air cleaner.
    4.  
    5. Loosen the hose clamps and disconnect the air cleaner hose from the turbocharger. Remove the air cleaner cap (top) together with the air cleaner hoses, connector pipe and air flow meter.
    6.  
    7. Remove the air cleaner element.
    8.  
    9. Remove the 3 bolts and remove the air cleaner case.
    10.  

  4.  
  5. Disconnect and remove the connectors and wiring from the starter.
  6.  
  7. Remove the two starter mounting bolts and remove the starter. It is a fairly heavy unit; be careful.
  8.  

To install:

  1. Reinstall the starter and tighten the retaining bolts to 29 ft. lbs.
  2.  
  3. Connect the wiring to the starter terminals.
  4.  
  5. Install the air cleaner assembly. Start with the case and install the filter element. Install the top section, the air flow meter, connector pipe and air cleaner hoses. Connect the air flow meter harness connector.
  6.  
  7. Install the battery and connect the cables (negative cable last).
  8.  

1990-93 3S-GTE Engine
  1. Disconnect the battery, negative terminal first. Wait at least 30 seconds before performing any other work. Disconnect the positive cable.
  2.  
  3. Remove the air cleaner assembly:
    1. Disconnect the air flow meter connector.
    2.  
    3. Disconnect the PCV hose from the valve cover and the air hose from the air tube. Release the 4 clamps holding the top of the air cleaner.
    4.  
    5. Loosen the hose clamps and disconnect the air cleaner hose from the turbocharger. Remove the air cleaner cap (top) together with the air cleaner element and the air flow meter.
    6.  
    7. Remove the 3 bolts and remove the air cleaner case.
    8.  

  4.  



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Fig. Fig. 1 2Starter removal components3S-GTE engine



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Fig. Fig. 1 3Removing air cleaner for starter removal3S-GTE engine



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Fig. Fig. 1 4Removing relay box for starter removal3S-GTE engine



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Fig. Fig. 1 5Removing the starter3S-GTE engine

  1. Remove the two nuts holding the relay box and remove the relay box from the battery.
  2.  
  3. Remove the lower cover from the relay box.
  4.  
  5. Disconnect the fusible link cassette (tray) and the two engine harness connectors from the relay box.
  6.  
  7. Remove the battery.
  8.  
  9. Disconnect and remove the connectors and wiring from the starter.
  10.  
  11. Remove the two starter mounting bolts and remove the starter. It is a fairly heavy unit; be careful.
  12.  

To install:

  1. Reinstall the starter and tighten the retaining bolts to 29 ft. lbs.
  2.  
  3. Connect the wiring to the starter terminals.
  4.  
  5. Install the battery.
  6.  
  7. Install the engine relay box. Remember to connect the engine harnesses and secure the cassette within the box. Install the lower cover and mount the box with the two nuts.
  8.  
  9. Install the air cleaner base and the filter element. Connect the air cleaner hose to the turbocharger, the PCV hose to the valve cover and the air hose to the air pipe. Install the air cleaner top and air flow meter; connect the wiring for the air flow meter.
  10.  
  11. Connect the battery cables to the battery, negative cable last.
  12.  

4A-FE Engine
  1. Disconnect the negative battery cable. Wait 30 seconds before performing any other work.
  2.  



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Fig. Fig. 1 6Starter removal components4A-FE engine



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Fig. Fig. 1 7Removing the suspension lower crossmember for starter removal4A-FE engine



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Fig. Fig. 1 8Removing air cleaner for starter removal4A-FE engine



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Fig. Fig. 1 9Removing the starter4A-FE engine

  1. Elevate and safely support the car on jackstands.
  2.  
  3. Remove the 4 bolts and 2 nuts holding the lower crossmember. Remove the crossmember.
  4.  


CAUTION
Support the crossmember while removing the final hardware; do NOT allow it to fall free.

  1. Disconnect the intake air temperature sensor connector.
  2.  
  3. Disconnect the accelerator cable from the bracket on the top of the air cleaner.
  4.  
  5. Loosen the 4 clips holding the top of the air cleaner. Remove the air hose from the air pipe.
  6.  
  7. Disconnect the air cleaner hose from the throttle body and remove the air cleaner top and filter element.
  8.  


WARNING
The starter is removed from under the car.

  1. Loosen the two bolts holding the starter to the transaxle. Disconnect starter wiring connectors.
  2.  
  3. Remove the retaining bolts and remove the starter. Use two hands; it's heavy.
  4.  

To install:

  1. Reinstall the starter and tighten the retaining bolts to 29 ft. lbs.
  2.  
  3. Connect the starter wiring.
  4.  
  5. Install the air cleaner cap; connect the various lines and hoses.
  6.  
  7. Install the lower crossmember. Tighten the nuts and bolts to 152 ft. lbs.
  8.  
  9. Lower the car to the ground.
  10.  
  11. Connect the battery cables, negative cable last.
  12.  

STARTER RELAY REPLACEMENT



A starter relay is used on vehicles equipped with manual transaxles. The relay is located on the left hand cowl on 1986-89 models and behind the right kick panel on 1990-93 models.



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Fig. Fig. 2 0Do NOT bend the starter relay pins when reinstalling the relay1986-89 with manual transaxle



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Fig. Fig. 2 1Location of starter relay1990-93 with manual transaxle


CAUTION
On models with an air bag, wait at least 30 seconds from the time that the ignition switch is turned to the lock position and the battery is disconnected before performing any further work.

  1. Disconnect the negative battery terminal.
  2.  
  3. On 1990-93 vehicles remove the right kick panel.
  4.  
  5. Pull the relay straight out to remove.
  6.  

To Install:

  1. Installation is the reverse of removal. Do NOT bend the prongs of the relay when installing.
  2.  

 
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