Toyota - Corolla :: Starter Motor Having Too Much Current - Crank The Engine?


Apr 20, 2012

Any explantion for how a "bad" starter motor can crank the engine, but use too many amps in the selenoid circuit?

I had this problem when I installed a rebuilt starter motor in an early 1990's Toyota Corolla recently. It was one of those offshore rebuild starter motors. When I installed it, and turned the key to start, nothing. ARRG .. I have to take it back, and it takes me about 2 hours to install it, and another 1 hour to remove it! It's not like changing a lightbulb!

Anyway, first off, before removing it, I checked the voltage (that comes in the smaller cable from the ignition switch,not the one in the thick cable direct from the battery) right at the starter selenoid, and it was only 8.6 volts. At first I thought it was a weak battery, but the battery voltage was 11.8 volts under the same load at the battery. And the voltage at the ignition switch was 11.6 volts. It was loosing 3 volts in the wiring path from the ignition switch to the starter motor! Then I noticed the wiring harness was getting warm that held that wire. Oh Oh.

For the life of me I couldn't figure out what was wrong. Unwilling to throw in the towel and remove the unit, I decided to completely bypass the ignition switch and the entire wiring harness, so I wired it up with my own switch I bough at Radio Shack and my own 16 AWG (the wire in the harness is 18 AWG) wires clipped direct from the battery to the starter selenoid. This is all from the front of the car. I just wanted to see if I could get it to turn and crank the engine. It worked, it cranked ok and everything, but the second time I tested it with this experimental configuration, it melted my 10 Amp Radio Shack switch! The switch was supposed to be able to handle 10 amps! Remember, this is the selenoid circuit, not the main power circuit from the battery.

So I then DID throw in the towel, and took it out, took the starter motor back to the auto parts place. ( I had a little dust-up with the parts place manager; he at first refused to refund my money. He wanted me to take another rebuilt one, but I'd lost trust in their rebuilt units and I just wanted my $$ back. We compromised on a voucher for future purchases.) Anyway, the parts place tested the problem starter motor I had returned to them, and they said it tested "bad". So the one they sold me was indeed no good. (Why they didn't test it before they sold it to me is another question.)

But here's the mystery: If the rebuilt starter motor tested "bad", and it indeed was "bad", how could it have cranked the engine with the experimental heavy guage wiring ? Any explantion for how a "bad" starter motor can crank the engine, but use way too many amps in the selenoid circuit?

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Car was fine, then wouldn't start one day, after driving fine a couple of minutes before. Did this a few times previously, just tried a few times then it started again. There is no cranking when I turn the key, just a click. Lights work fine, stereo etc, no dip in power when turn key. I assumed it was starter motor so took it out and tested it - fine. Also tested battery - fine. Looked at a spark plug, fine, oil level fine. Don't see a reason the engine should have seized, as it was driving just fine, then wouldn't start suddenly, but I haven't tried manually turning the crank. I then looked at the switch on the clutch pedal that gets pressed when you push the clutch in, and allows it to start. Looked ok, but pulled the wires and bypassed it with a cable. Still nothing. Can the starter test ok but still be bad? Toyota Corolla 2003 80,000 miles ...

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[URL] .....

This does not seem to apply to my vehicle although the problem seems dead on. I don't suspect battery. The car cranks hard.... Obviously it can't be the starter. I really doubt it's the fuel pump doing this. I'm going to guess ECU, injector, some funky electrical issue.

I bought this car brand new from the dealer with 2 miles on it and I can't think of anything werid that has happened to the vehicle. Before anybody says cold weather is a factor.... It was almost 40 when I cranked on my car yesterday so I doubt that is it. Also I started the car in much colder conditions. The car did sit for a week before this happened... I can't remember if the car sat for a long period of time before the other starting issues happened. I'm planning on taking the car to the dealership soon, I'm in the process of moving so I can't be without a car right now.

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When I turn it over, the started keeps going and it will pretend to turn on for half a second and then keep turning over. I also smell raw gas when I get out of the car for a few seconds before it goes away.

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