Toyota Yaris: Sfi System / Starter Signal Circuit

Toyota Yaris XP210 (2020-2022) Reapir and Service Manual / Engine & Hybrid System / G16e-gts (engine Control) / Sfi System / Starter Signal Circuit

DESCRIPTION

While the engine is being cranked, current flows from terminal STAR of the certification ECU (smart key ECU assembly) to the clutch start switch assembly and to terminal STA of the ECM (STA signal).

WIRING DIAGRAM

Refer to DTC P061512.

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CAUTION / NOTICE / HINT

NOTICE:

Inspect the fuses for circuits related to this system before performing the following procedure.

  • Inspect the fuses for circuits related to this system before performing the following procedure.
  • After turning ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

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  • When the starter assembly is replaced, the number of starter operations stored in the engine stop and start ECU must be reset.

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  • When the starter assembly is replaced, "ST NO. 1 relay" must be also replaced.

PROCEDURE

1.

CHECK WHETHER ENGINE CAN BE CRANKED

(a) Check if the engine can be cranked.

Result

Proceed to

Engine cannot be cranked

A

Engine can be cranked

B

B

GO TO STEP 14

A

2.

READ VALUE USING GTS (STARTER SW)

(a) Fully depress the clutch pedal.

(b) Check the value displayed on the GTS when the ignition switch is turned to ON and START positions.

Powertrain > Engine > Data List

Tester Display

Starter SW

OK:

Condition

GTS Display (Starter SW)

Ignition switch ON

OFF

Engine started

ON

OK

GO TO STEP 7

NG

3.

CHECK STOP AND START SYSTEM

(a) Check the stop and start system.

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NG

REPAIR STOP AND START SYSTEM

OK

4.

INSPECT CLUTCH START SWITCH ASSEMBLY

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NG

REPLACE CLUTCH START SWITCH ASSEMBLY

OK

5.

CHECK HARNESS AND CONNECTOR (STA SIGNAL CIRCUIT)

(a) Disconnect the engine stop and start ECU connector.

(b) Disconnect the ECM connector.

(c) Remove the ST NO. 1 relay from No. 1 engine room relay block assembly.

(d) Disconnect the clutch start switch assembly connector.

(e) Disconnect the certification ECU (smart key ECU assembly) connector.

(f) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection

Condition

Specified Condition

A64-1 (L) - 2 (ST NO. 1 relay)

Always

Below 1 Ω

A106-30 (STA) - 2 (ST NO. 1 relay)

Always

Below 1 Ω

A67-21 (STA) - 2 (ST NO. 1 relay)

Always

Below 1 Ω

H45-3 (STA) - 2 (ST NO. 1 relay)

Always

Below 1 Ω

H45-3 (STA), 2 (ST NO. 1 relay), A64-1 (L) or A106-30 (STA) - Body ground and other terminals

Always

10 kΩ or higher

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

6.

CHECK HARNESS AND CONNECTOR (CERTIFICATION ECU - CLUTCH START SWITCH ASSEMBLY - ECM - ENGINE STOP AND START ECU)

(a) Disconnect the certification ECU (smart key ECU assembly) connector.

(b) Disconnect the clutch start switch assembly connector.

(c) Disconnect the ECM connector.

(d) Disconnect the engine stop and start ECU connector.

(e) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection

Condition

Specified Condition

H45-10 (STAR) - A64-2 (B)

Always

Below 1 Ω

H45-10 (STAR) - A67-17 (CLL)

Always

Below 1 Ω

A67-17 (CLL) - A106-23 (NSW)

Always

Below 1 Ω

H45-10 (STAR), A67-17 (CLL), A106-23 (NSW) or A64-2 (B) - Body ground and other terminals

Always

10 kΩ or higher

OK

GO TO ENTRY AND START SYSTEM

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

7.

INSPECT ST NO. 1 RELAY

Click here

NG

REPLACE ST NO. 1 RELAY

OK

8.

INSPECT STARTER ASSEMBLY

Click here

NG

REPLACE STARTER ASSEMBLY

OK

9.

CHECK HARNESS AND CONNECTOR (ST NO. 1 RELAY - STARTER ASSEMBLY)

(a) Remove the ST NO. 1 relay from No. 1 engine room relay block assembly.

(b) Disconnect the starter assembly connector.

(c) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection

Condition

Specified Condition

3 (ST NO. 1 relay) - D54-1 (ST)

Always

Below 1 Ω

3 (ST NO. 1 relay) or D54-1 (ST) - Body ground and other terminals

Always

10 kΩ or higher

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

10.

CHECK TERMINAL VOLTAGE (AUXILIARY BATTERY - STARTER ASSEMBLY)

(a) Disconnect the cable from the negative (-) auxiliary battery terminal.

(b) Disconnect the cable from the positive (+) auxiliary battery terminal.

(c) Disconnect the starter assembly connector.

(d) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection

Condition

Specified Condition

Positive (+) auxiliary battery terminal - D80-1 (B)

Always

Below 1 Ω

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

11.

CHECK TERMINAL VOLTAGE (POWER SOURCE OF ST NO. 1 RELAY)

*1

No. 1 Engine Room Relay Block Assembly

*2

ST NO. 1 Relay

(a) Remove the ST NO. 1 relay from No. 1 engine room relay block assembly.

(b) Measure the voltage according to the value(s) in the table below.

Standard Voltage:

Tester Connection

Condition

Specified Condition

5 (ST NO. 1 relay) - Body ground

Always

11 to 14 V

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR (AUXILIARY BATTERY - ST NO 1 RELAY)

OK

12.

CHECK HARNESS AND CONNECTOR (ST NO. 1 RELAY - BODY GROUND)

(a) Remove the ST NO. 1 relay from No. 1 engine room relay block assembly.

(b) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection

Condition

Specified Condition

1 (ST NO. 1 relay) - Body ground

Always

Below 1 Ω

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

13.

CHECK HARNESS AND CONNECTOR (ST NO. 1 RELAY - CLUTCH START SWITCH ASSEMBLY)

(a) Remove the ST NO. 1 relay from the No. 1 engine room relay block assembly.

(b) Disconnect the clutch start switch assembly connector.

(c) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection

Condition

Specified Condition

2 (ST NO. 1 relay) - A64-1 (L)

Always

Below 1 Ω

OK

REPAIR OR REPLACE HARNESS OR CONNECTOR (AUXILIARY BATTERY - STARTER ASSEMBLY)

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

14.

READ VALUE USING GTS (STARTER SW)

(a) Fully depress the clutch pedal.

(b) Check the value displayed on the GTS when the ignition switch is turned to ON and START positions.

Powertrain > Engine > Data List

Tester Display

Starter SW

OK:

Condition

GTS Display (Starter SW)

Ignition switch ON

OFF

Engine started

ON

Result

Proceed to

OK

A

NG

B

A

PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE

B

REPAIR OR REPLACE HARNESS OR CONNECTOR (ST NO. 1 RELAY - ECM)

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