Toyota - Corolla :: 1994 - Car Intermittently Not Starting


Jan 16, 2016

Periodically my 1994 Toyota Corolla 5-speed manual will not start. Other times it seems to hesitate before starting. The rest of the time it starts fine.

When it does not start: I turn the key, and hear the fuel pump relay click, and hear the fuel pump on the gas tank energize, but the car does not try to crank. I do not know if the starter solenoid is engaging at this time, as I could not listen for it while in the car. When I did try to listen for it while under the hood with someone else starting the car, it actually started (did not exhibit the issue)

When it hesitates before starting: However, sometimes, when I turn the key I hear the fuel pump relay click and the fuel pump energize, after about 1-1/2 seconds of holding the key, it does start.

When it does start it sounds normal, not like a low battery. The battery is new. I had the charging system checked at Advance Auto and they said the battery was good as was the alternator and starter. Plenty of cranking amps.

I disconnected the main wire on the starter motor and cleaned it with a wire brush. I also cleaned up the battery terminals.

I did find that the switch on the clutch pedal that allows the car to start when pressed has some fluid leaking on it (clutch fluid I think). Could that be causing the intermittent starting issue? If so, can I just clean it with WD-40 or something like that?

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The transmission fluid level had been recently checked, and was fine. Now when this problem cropped up and it was checked, the fluid was gone! We don't notice anything on the ground where it has been parked.

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I have a 220k 1994 Corolla with I have come across a couple problems recently. It all started about a week ago when I decided to change my rear brake shoes. The old ones turned out to be all cracked and everything but were generally in pretty good shape in terms of wear. Anyways I put the new shoes in (my first brake job) and tightened up the e brake cable and went for a test drive. I walked away extremely satisfied, the e brake worked perfect which was my main reason for changing the shoes in the first place.

Basically the whole thing worked perfectly until 2 days later. I was driving for about 8 miles when my brake pedal suddenly fell through to the floor (or pretty close) at first I even thought I hit the clutch pedal! anyways after pumping the pedal a few times my pedal feel returned about 70% and after another maybe 10 seconds braking power was lost again until I pumped the pedal. So lucky for me my destination was a 1/4 mile away so I parked and checked the fluid level; it was at the max mark, then I check the wheels/drums and they were REALLY hot.

Also the driver's side drum had a faint smell of brake fluid. Anyways about an hour later I went for a short drive and the brakes worked fine so an hour after that I drove the 8 miles home and about 1/8 of a mile from home same thing happened; brake pedal basically goes almost down to the floor until pumped. My thoughts were that the new shoes were constantly rubbing and the old fluid overheated and caused failure so I flushed the system and put new fluid in and adjusted the shoes "in" with the click adjuster bolt. I had a really hard time getting the drums of to begin with. That and I loosened the e brake cable just in case.

So the next morning I drive about 5 miles without using the brakes pulled over to check that the drums were not heating up anymore (they weren't) so I thought I had fixed it. Well 3 days later (last night) I was experiencing the rear brake stickiness again. Basically when I was just moving from a stop where I had used the e brake to secure the car, I could literally feel that the rear brakes were stopping the car pretty aggressively and sure enough after a few more miles my brake pedal fell through so I poured water on the drums and they started to let off lots of steam, even after like 10 bottles!

So I limped to my friends house at 12:00 AM and jacked my car for a look. Again the drums really didn't want to come off and once we did get them off my friends dad inspected them and could find anything wrong with my installation. The conclusion that we came to was that the auto adjustor for the shoes makes the shoes too tight and they rub. So I am thinking maybe this is cause for the fluid to overheat and boil, causing the pedal to fall through. The pedal fell has gotten much worse since I bled the system 3 days ago so that may be an indicator. Did a test this morning for 5 miles and the drums were just below lukewarm.

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I can find multiple motors that "fit", but they all have different size motors and shaft sizes. What are the specs on the replacement motor? I have done a search on the Toyota nation app and cannot find any posts on this.

The part I found is Machi brand, model # FC-280PC-22125.

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I add oil regularly and do check the levels on most of my fluids on a weekly basis!

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When it has the problem, I turn key, and I only hear a click, and the dash lights are lit, but no starter motor sound.

Early on I would call for a tow truck, but it usually started when they arrived.

I got angry one time and turned the on and off rapidly, nothing. Meditated for about 10min to calm down. Nope, still angry, so turned the key rapidly again, and the starter motor engaged, but the engine didn't start.

So I did that again and gave it some gas, then a lot of gas. The engine was running very rough, like all cylinders were not firing, then it spews out a huge cloud of blue smoke, and the engine evens out. That's my usual pattern now: turn the key like crazy wait a few minutes or even an hour, and keep trying.

It is usually fine for 2 to 7 days with no problems. But a couple of times it has had the problem twice in the same day. The problem seems to happen most when the engine is cold, or after a short trip. A few times, it has had the problem even after a long trip, when the engine was still hot.

What has been replaced in the last year? In this order: starter motor, battery, hot lead to fuse box, battery terminal clamps and wires, fuel pump, mass air flow (don't know what that is), catalytic converter, and master relay. (OK the master relay probably isn't related because rain water leaked in and dripped on the fuse box in the cab.) (Also it has 133,080 miles, and a rebuilt engine put in 4 years ago.)

After the mass air flow and catalytic converter change, the truck has started with no problems for 3 months. Now the problem is back! Same symptoms.

When they last worked on the truck they did a tune-up and they said the starting problem could have been caused by the starter motor not being lined up properly so it would "jam". That would explain why the starter motor wouldn't go, but it doesn't explain the miss-firing when it does finally start going.

I also notice that after they do some work on the truck, it starts fine for about 2 weeks with no problem. So maybe something is getting wiggled into a happy position when they work on it?

If this is an "electrical" problem, what can be done to find this very intermittent problem? Also, just before the the problem started happening again, I noticed there would sometimes be about a 1/2 sec to 1 sec delay from when I turned the key, to when the starter motor would go.

Attached is an audio file of what it sounds like.

1) starting normal,
2) turning key and only clicks,
3) the rough start after many tries.

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However, yesterday getting out from work, It came back. Had to jump start and make it work again. is there something i am not doing correctly?

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I think it's probably some sensor that is busted. The car has 90000 miles now (I bought it 3 years ago with 59000), and it didn't have this problem before. In the past, it wouldn't rev high. But now, the revs wont go back to normal unless you spend a good 10-15 minutes in park until it "warms up", even though this also occurs in the summer.

Generally though the car has run great. It just revs high when starting up in the morning.

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