So, I'm driving my 98 camry 4 Cyl. with 141k miles, and I've had no problems with it what so ever, and all of a sudden the starter starts engaging and the bendix is clicking real loud. I pull over and shut it off and it won't shut off..so I disconnect the battery. I assume it's a bad starter ( the original), put a new one in and same thing. I check the relay and it's fine... I disconnect the ignition switch and still when I connect the battery the starter engages. So then I start to wonder if the burning smell wasn't the "bad starter" and maybe it's something else. I'm a Firefighter and recognize the burnt smell but didn't want to except it...so I start looking under the dash for burnt wiring and what do you know, I found one coming out of a plug plugged into the back of the fuse panel behind the driver's side lower panel. Is this the problem or a symptom of a bigger problem? I've read other postings with the same problem, but I haven't found anyone who's posted a solution. Welcoming all ideas...Please!

 

What are the colors of the burnt or effected wires?

On the starter motor solenoid disconnect the small diameter Black/Red wire (approx no 14 wire diameter). If the starter motor still runs the contacts inside the starter motor solenoid are stuck closed.

If not there is a problem with the circuit that activates the starter motor solenoid coil.

To review, the starter system is set up as follows:

A large electrical cable runs from the battery to the starter solenoid that is bolted to the starter motor. The solenoid when powered routes connects battery power to starter motor.

The starter solenoid coil is activated by the starter relay (ST Relay) located in a box left side of engine compartment.

The DC power for the starter solenoid coil comes from the 40A MAIN fuse (located in same box as ST Relay) then runs through the ST Relay (when it is activated) then to the starter solenoid coil via a small diameter Black/Red wire.

The ST Relay has its own solenoid coil that when activated closes the ST Relay switch.

To activate the ST Relay, DC power comes from the battery through the AM2 fuse (locations as above) then via a White/Red wire to the AM2 portion of the ign switch.

When the ign switch is turned to start, power runs via a Red wire to a 5A Starter fuse then a Black/White wire to the Park/Neutral (for auto trans) then a Gray or Black/Orange wire (depends on car options) to the ST Relay solenoid coil. Then through the coil to ground via a White/Black wire.

The 5A Starter fuse is located in a fuse box behind the far lower left drivers side ash tray/coin box.

Are any of the colored wires listed above burnt, damaged, etc.

 

Thanks so much for the info. I worked on it again tonite. The 5 amp starter fuse is blown. I've isolated the burnt wire. It looks like it had red with silver insulation on it at one time, it's hard to tell because it's completely burned off from the back of the fuse box (lower left driver's side) to the fuse box on the left apron near the battery. The burnt wire comes out of a five pin plug at the inside fuse box and goes into a six pin plug at the fuse block on the apron.
Could a bad relay cause this wire to fry? I'm still confused as to weather this burnt wire is the problem or over heated from something else. I'm leaning toward the latter. So far the only good news I see is the harness is only damaged for about 4 feet that I can tell.
I'm gonna have the relay checked out tomorrow so I can eliminate that as a source.
BTW..I did check the burned wire and it's not grounded, if that means anything.

 

The burn wire appears to be between the AM2 fuse and Starter fuse. A white/black wire runs from the AM2 fuse to ign switch then red wire to Starter fuse.

Suppose could be the relay but the coil on the solenoid would need to be shorted out.

Since the Starter fuse blow assume the problem is after the fuse. This leaves the park/neutral switch and a junction box which is on the passengers side of the fuse box behind the drivers side ash tray/coin box.

Take note 2 wires split off the starter circuit and run to the engine computer.