22RE No start - COR? Confirm diagnosis.

[jgranthevagrant]

I might leave the starter relay unattached to the junction box for the future. I think it is just on there as a place for Toyota to put it. I pulled most of the dash to start testing the ignition switch. Will try to test from key right to starter. Can' t tell yet if I have the wiring where both inputs to the relay are from ST1 or not. No obvious failure points so far, but have not put the multimeter to anything.

 

[jgranthevagrant]

Dug into it pretty deep on Sunday and today. Traced the circuit from ST1 to Ignition switch. Both sides of relay do indeed get fed by the same source from the switch, if I'm looking at things correctly. I had good continuity from switch to relay, and then from relay to COR. Also good from COR to little plug on starter. I did not pull harness apart from just above the ignition switch all the way to COR. Checked the switch itself for continuity as in the FSM. Tested good. Not sure how it is supposed to "feel". Looks ok from the outside. Could contacts be bad on the inside, especially ST1? Should join pins 7 and 8 on the plug, I think. Switch is no longer available from Toyota. I looked at Amayama, Partsouq, TPD, etc. Any suggestions for finding new OEM or just wrecker? I will try to find a spare from somewhere, just to test. Picture of splice as shown in Gnob's post #14.

 

[jgranthevagrant]

Have not pulled tape off that splice to check it yet. Seems like the truck is wired with the factory fault mentioned in the Yotatech articles and elsewhere. Plan would be to run a fused wire directly from battery to one side of relay, cutting in to one side of the two black wires shown above. 20 amp fuse ok? 30 amp ? Will I cause any damage or risk anything downstream if I do this? I will try to attach a copy of the circuit with the new line drawn in red.

 

[gnob]

pretty sure im running a 30A

 

[jgranthevagrant]

So looks ok to run it like the red line I drew? I have all the materials for that sitting around the garage. New relay I would have to hunt around for or order online.

 

[gnob]

yep

 

[jgranthevagrant]

Seems like no karma risk now to say the fix worked. About 100 starts and 3 camping trips with no issues, at least as far as starting goes. Subjectively, it "feels" like it starts better. Put a 30A fuse on the firewall as suggested. Put another fuse inline that I can use as a kill mechanism if I'm worried about the truck getting stolen. Now on to other issues. Broke my radiator on latest trip. Thanks for all the advice.