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Might be dirty or oxidized alternator connections.
First disconnect the negative battery terminal from the battery.
Get a small, fine wire brush, remove the alternator plug and clean it with the brush. Also get a spray can of electrical contact cleaner and spray both alternator plug and socket .... On the alternator there is a ground wire connection ... a threaded bolt and nut as I recall. Clean these and spray with contact cleaner... snug up nut on bolt, but don't over tighten.
It is important for electrical connections to have bright, shiny surfaces... If they are dirty or loose, the electrical current can't get from one side to the other of a plug or terminal. ... Sometimes moisture is a factor, or maybe road salt, or just a lot of road miles.
Starter problem might be due to internal contact plate within the starter ... probably have to rebuild or get a new one. Not sure about starter relay... I would guess problem is actually in the starter, where it handles the high magnitude motor current. ... Might be worth removing the starter cable terminals and cleaning the connections .... remove negative battery cable first though.
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98 Camry LE, 2.2L, automatic
50k miles, drop in K&N A/F
 recent timing belt, water pump
Last edited by dc_98_cam; 01-02-2008 at 11:22 AM.
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