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Inspection Procedure

  1. READ VALUE USING TECHSTREAM (STARTER SIGNAL) 
    1. Connect a Techstream to the DLC3.
    2. Turn the ignition switch to ON.
    3. Turn the tester ON.
    4. Select the following menu items: Powertrain / Engine and ECT / Engine and ECT / Data List / All Data / Starter Signal.
    5. Check the result when the ignition switch is turned to ON and START positions.

      OK 

      IGNITION SWITCH CONDITION AND STARTER SIGNAL REFERENCE

      Ignition Switch Condition Starter Signal
      ON OFF
      START ON

      Result 

      RESULT REFERENCE

      Result Proceed to
      Outside standard range A
      Within standard range B

    B: Go to step 2 

    A : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE  (See PROBLEM SYMPTOMS TABLE  )

  2. INSPECT ECM (STSW TERMINAL VOLTAGE) 
    1. Disconnect the ECM connector.
    2. Perform the cranking operation.
    3. Measure the voltage according to the value(s) in the table below.

      Standard voltage 

      VOLTAGE SPECIFICATION

      Tester Connection Switch Condition Specified Condition
      A21-14 (STSW) - Body ground ON Below 1 V
      START 9 to 13 V
    4. Reconnect the ECM connector.

      HINT:

      DTCs related to the communication with other computers may be set due to this inspection. Clear those DTCs after the inspection.

    NG:  Go to step  7

    Fig 1: Identifying ECM Connector
    G05398691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  3. INSPECT ECM (STAR TERMINAL OUTPUT VOLTAGE) 
    1. Connect a Techstream to the DLC3.
    2. Turn the ignition switch to ON.
    3. Turn the tester ON.
    4. Select the following menu items: Powertrain / Engine and ECT / Active Test / Control the All Cylinders Fuel Cut.
    5. Move the shift lever to the P or N position (for automatic transaxle models).
    6. Fully depress the clutch pedal (for manual transaxle models).
    7. Measure the voltage according to the value(s) in the table below.

      Standard voltage (for automatic transaxle models) 

      VOLTAGE SPECIFICATION

      Tester Connection Switch Condition Specified Condition
      10 (Junction Connector) - Body ground Ignition switch ON (P or N position) Below 1 V
      Cranking operation 9 to 13 V

      Standard voltage (for manual transaxle models) 

      VOLTAGE SPECIFICATION

      Tester Connection Switch Condition Specified Condition
      A17-2 - Body ground Ignition switch ON (Accelerator pedal Fully depressed) Below 1 V
      Cranking operation 9 to 13 V
      Fig 2: Identifying Junction Connector Terminals
      G05398692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      • The junction connector is in the engine room relay block and junction block as the illustration above.
      • During this inspection, all connectors and relays should be connected.

    NG:  Go to step  8

    Fig 3: Identifying Clutch Start Switch Connector Terminals
    G05398693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  4. INSPECT CLUTCH START SWITCH OR PARK/NEUTRAL POSITION SWITCH 
    1. Inspect the Park/Neutral Position (PNP) switch connector (for automatic transaxle models).
      1. Disconnect the park/neutral position switch connector.
      2. Measure the resistance according to the value(s) in the table below.

        Standard resistance 

        RESISTANCE SPECIFICATION

        Tester Connection Shift Selector Lever Position Specified Condition
        2-6, 4-5 P Below 1 Ω
        1-2 R
        2-9,4-5 N
        2-7 D
        2-3 2
        2-8 L
        Except above terminals All Positions 10 kΩ or higher
      3. Reconnect the park/neutral position switch connector.
        Fig 4: Identifying Park/Neutral Position Switch Connector Terminals
        G05398572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Inspect the clutch start switch (for manual transaxle models).
      1. Disconnect the clutch start switch connector.
      2. Measure the resistance according to the value(s) in the table below.

        Standard resistance 

        RESISTANCE SPECIFICATION

        Tester Connection Switch Condition Specified Condition
        1 - 2 ON (Pushed) Below 1 Ω
        1 - 2 OFF (Not pushed) 10 kΩ or higher
      3. Reconnect the clutch start switch connector.

        Result 

        RESULT REFERENCE

        Result Proceed to
        Outside standard range A
        Within standard range (for automatic transaxle models) B
        Within standard range (for manual transaxle models) C
        Fig 5: Identifying Clutch Start Switch Connector
        G05398695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    B: Go to step 5 

    C:  Go to step  6

    A : REPLACE CLUTCH START SWITCH OR PARK/NEUTRAL POSITION SWITCH 

  5. CHECK HARNESS AND CONNECTOR (PNP SWITCH - ECM) 
    1. Disconnect the Park/Neutral Position (PNP) switch connector.
    2. Disconnect the ECM connector.
    3. Measure the resistance according to the value(s) in the table below.

      Standard resistance 

      RESISTANCE SPECIFICATION

      Tester Connection Condition Specified Condition
      C28-4 - C19-52 (STAR) Always Below 1 Ω
    4. Reconnect the PNP switch connector.
    5. Reconnect the ECM connector.

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

    Fig 6: Identifying Park/Neutral Position Switch Connector And ECM Connector
    G05398696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  6. CHECK HARNESS AND CONNECTOR (CLUTCH START SWITCH OR PNP SWITCH - ECM ST RELAY) 
    1. Check the harness and connector (for automatic transaxle models).
      1. Remove the ST relay from the engine room relay block.
      2. Disconnect the Park/Neutral Position (PNP) switch connector.
      3. Disconnect the ECM connector.
        Fig 7: Identifying Park/Neutral Position Switch Connector Terminals
        G05398568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Measure the resistance according to the value(s) in the table below.

        Standard resistance (Check for open) 

        RESISTANCE SPECIFICATION

        Tester Connection Condition Specified Condition
        C28-5 - A21-48 (STA) Always Below 1 Ω
        C28-5 - 2 (ST relay) Always Below 1 Ω
        1 (ST relay) - Body ground Always Below 1 Ω
      5. Reinstall the ST relay.
      6. Reconnect the park/neutral position switch connector.
      7. Reconnect the ECM connector.
        Fig 8: Identifying ST Relay Connector Terminals
        G05398698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check the harness and connector (for manual transaxle models).
      1. Remove the ST relay from the engine room relay block.
      2. Disconnect the clutch start switch connector.
      3. Disconnect the ECM connector.
      4. Measure the resistance according to the value(s) in the table below.

        Standard resistance (Check for open) 

        RESISTANCE SPECIFICATION

        Tester Connection Condition Specified Condition
        A17-1 - A21-48 (STA) Always Below 1 Ω
        A17-1 - 2 (ST relay) Always Below 1 Ω
        1 (ST relay) - Body ground Always Below 1 Ω
        Fig 9: Identifying Clutch Start Switch Connector Terminals
        G05398569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Reinstall the ST relay.
      6. Reconnect the clutch start switch connector.
      7. Reconnect the ECM connector.

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK : REPAIR OR REPLACE STARTER CIRCUIT (STARTER - ST RELAY) 

  7. INSPECT IGNITION SWITCH 
    1. Remove the ignition switch.
    2. Measure the resistance according to the value(s) in the table below.

      Standard resistance 

      RESISTANCE SPECIFICATION

      Tester Connection Switch Condition Specified Condition
      All terminals LOCK 10 kΩ or higher
      2 (ACC) - 4 (AM1) ACC Below 1 Ω
      1 (IG1) - 2 (ACC) - 4 (AM1) ON
      5 (AM2) - 6 (1G2)
      1 (IG1) - 3 (ST1) - 4 (AM1) START
      5 (AM2) - 6 (IG2) - 7 (ST2)
    3. Reinstall the ignition switch.

    NG: REPLACE IGNITION SWITCH  (See REMOVAL )

    Fig 10: Identifying Ignition Switch Connector Terminals
    G05398670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK : REPAIR OR REPLACE HARNESS OR CONNECTOR (IGNITION SWITCH - ECM) 

  8. INSPECT CLUTCH START SWITCH OR PARK/NEUTRAL POSITION SWITCH 
    1. Inspect the Park/Neutral Position (PNP) switch connector (for automatic transaxle models).
      1. Disconnect the park/neutral position switch connector.
      2. Measure the resistance according to the value(s) in the table below.

        Standard resistance 

        RESISTANCE SPECIFICATION

        Tester Connection Shift Selector Lever Position Specified Condition
        2-6,4-5 P Below 1 Ω
        1-2 R
        2-9, 4-5 N
        2-7 D
        2-3 2
        2-8 L
        Except above terminals All Positions 10 kΩ or higher
        Fig 11: Identifying Park/Neutral Position Switch Connector Terminals
        G05398572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Reconnect the park/neutral position switch connector.
    2. Inspect the clutch start switch (for manual transaxle models).
      1. Disconnect the clutch start switch connector.
      2. Measure the resistance according to the value(s) in the table below.

        Standard resistance 

        RESISTANCE SPECIFICATION

        Tester Connection Switch Condition Specified Condition
        1 - 2 ON (Pushed) Below 1 Ω
        1 - 2 OFF (Not pushed) 10 kΩ or higher
      3. Reconnect the clutch start switch connector.

    NG: REPLACE CLUTCH START SWITCH OR PARK/NEUTRAL POSITION SWITCH 

    Fig 12: Identifying Clutch Start Switch Connector
    G05398702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    OK: Go to next step 

  9. CHECK HARNESS AND CONNECTOR (CLUTCH START SWITCH OR PNP SWITCH IGNITION SWITCH AND ECM) 
    1. Check the harness and connector (for automatic transaxle models).
      1. Disconnect the ignition switch connector.
      2. Disconnect the Park/Neutral Position (PNP) switch connector
      3. Disconnect the ECM connector.
      4. Measure the resistance according to the value(s) in the table below.

        Standard resistance (Check for open) 

        RESISTANCE SPECIFICATION

        Tester Connection Condition Specified Condition
        F9-7 (ST2) - C28-4 Always Below 1 Ω
        C19-52 (STAR) - C28-4 Always

        Standard resistance (Check for short) 

        RESISTANCE SPECIFICATION

        Tester Connection Condition Specified Condition
        F9-7 (ST2) or C28-4 - Body ground Always 10 kΩ or higher
        C19-52 (STAR) or C28-4 - Body ground Always

        HINT:

        The wire between the park/neutral position switch and the ignition switch has a diode (refer to the WIRING DIAGRAM ). The current flowing to the park/ neutral position switch is rectified by the diode.

      5. Reconnect the ignition switch connector.
      6. Reconnect the clutch start switch connector.
      7. Reconnect the ECM connector.
    2. Check the harness and connector (for manual transaxle models).
      1. Disconnect the ignition switch connector.
      2. Disconnect the clutch start switch connector.
      3. Disconnect the ECM connector.
      4. Measure the resistance according to the value(s) in the table below.

        Standard resistance (Check for open) 

        RESISTANCE SPECIFICATION

        Tester Connection Condition Specified Condition
        F9-7 (ST2) - A17-2 Always Below 1 Ω
        C19-52 (STAR) - A17-2 Always

        Standard resistance (Check for short) 

        RESISTANCE SPECIFICATION

        Tester Connection Condition Specified Condition
        F9-7 (ST2) or A17-2-Body ground Always 10 kΩ or higher
        C19-52 (STAR) or A17-2 - Body ground Always
        Fig 13: Identifying Clutch Start Switch, PNP Switch And Ignition Switch Connector Terminals
        G05398703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT:

        The wire between the clutch start switch and the ignition switch has a diode (refer to the WIRING DIAGRAM ). The current flowing to the clutch start switch is rectified by the diode.

      5. Reconnect the ignition switch connector.
      6. Reconnect the clutch start switch connector.
      7. Reconnect the ECM connector.

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK: Go to next step 

  10. CHECK HARNESS AND CONNECTOR (CLUTCH START SWITCH OR PNP SWITCH - ECM ST RELAY) 
    1. Check the harness and connector (for automatic transaxle models).
      1. Remove the ST relay from the engine room relay block.
      2. Disconnect the Park/Neutral Position (PNP) switch connector.
      3. Disconnect the ECM connector.
        Fig 14: Identifying Park/Neutral Position Switch Connector Terminals
        G05398568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Measure the resistance according to the value(s) in the table below.

        Standard resistance (Check for short) 

        RESISTANCE SPECIFICATION

        Tester Connection Condition Specified Condition
        C28-5 or A21-48 (STA) - Body ground Always 10 kΩ or higher
        C28-5 or 2 (ST relay) - Body ground Always 10 kΩ or higher
      5. Reinstall the ST relay.
      6. Reconnect the park/neutral position switch connector.
      7. Reconnect the ECM connector.
        Fig 15: Identifying ST Relay Connector Terminals
        G05398698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check the harness and connector (for manual transaxle models).
      1. Remove the ST relay from the engine room relay block.
      2. Disconnect the clutch start switch connector.
      3. Disconnect the ECM connector.
      4. Measure the resistance according to the value(s) in the table below.

        Standard resistance (Check for short) 

        RESISTANCE SPECIFICATION

        Tester Connection Condition Specified Condition
        A17-1 or A21-48 (STA) - Body ground Always 10 kΩ or higher
        A17-1 or 2 (ST relay) - Body ground Always 10 kΩ or higher
        Fig 16: Identifying Clutch Start Switch Connector Terminals
        G05398569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Reinstall the ST relay.
      6. Reconnect the clutch start switch connector.
      7. Reconnect the ECM connector.

    NG: REPAIR OR REPLACE HARNESS OR CONNECTOR 

    OK : REPLACE ECM  (See REMOVAL  )

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