Toyota Yaris: Stop And Start System / Starter Signal Circuit

Toyota Yaris XP210 (2020-2022) Reapir and Service Manual / Engine & Hybrid System / Stop And Start / Stop And Start System / Starter Signal Circuit

DESCRIPTION

The engine stop and start ECU uses its internal starter circuit to drive the starter drive relay (ST No. 1 relay) and operate the starter.

WIRING DIAGRAM

CAUTION / NOTICE / HINT

  • When the engine stop and start ECU is replaced, read the number of starter operations before replacement and record this number to the new engine stop and start ECU after replacement.

    Click here

  • When the engine stop ECU has been replaced, perform external backup boost converter (Eco run vehicle converter assembly) existence learning.

    Click here

  • After replacing the engine stop and start ECU or air conditioner amplifier assembly, perform initialization/learning of the air conditioner information for the engine stop and start ECU.

    Click here

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

    Click here

  • When the starter assembly is replaced, "ST NO. 1 relay" must be also replaced.
  • Inspect the fuses for circuits related to this system before performing the following procedure.

HINT:

For wire harness and connector inspection procedures and precautions, refer to

PROCEDURE

1.

CHECK CRANKING

(a) Turn the ignition switch to ON and check that the engine cranks.

Result

Proceed to

Engine cranks

A

Engine does not crank

B

B

GO TO STEP 20

A

2.

READ VALUE USING GTS (Starter(Hood Close))

Powertrain > Stop and Start > Active Test

Tester Display

Starter(Hood Close)

(a) Check whether the engine cranks while the Active Test "Starter(Hood Close)" is being performed.

NOTICE:

The Active Test "Starter(Hood Close)" is stopped automatically 3 seconds after the starter assembly begins operating.

Standard:

Engine cranks

NG

GO TO STEP 17

OK

3.

CHECK DTC OUTPUT (SFI SYSTEM)

(a) Enter the following menus: Powertrain / Engine / Trouble Codes.

Powertrain > Engine > Trouble Codes

Result

Proceed to

SFI system DTCs are not output

A

SFI system DTC (poor startability detected) output, and starter does not rotate

SFI system DTC (poor startability detected) output, and starter rotates

B

DTCs other than SFI system DTC (poor startability detected) are output

HINT:

  • According to the display on the GTS, check the freeze frame data item [Cranking Time] in the sets of freeze frame data.
  • If the value of [Cranking Time] is approximately 3 seconds, the stop and start control system or starter system may be malfunctioning.
  • If the value of [Cranking Time] is small (approximately 0.5 seconds or less: the minimum value varies depending on the model), the SFI system may be malfunctioning.
  • The Data List item [Cranking Time] indicates the length of time starter operation is requested by the engine stop and start ECU. If the engine speed exceeds the specified value, the engine stop and start ECU cancels its start request.
B

GO TO SFI SYSTEM

A

4.

CHECK FREEZE FRAME DATA

NOTICE:

The freeze frame data is cleared when DTCs are cleared. Be sure to make a note of necessary data in advance.

HINT:

Using the time-series freeze frame data, confirm the freeze frame data recorded the moment the DTC was stored and after the DTC was stored. This information can be useful when troubleshooting.

(a) According to the prompts on the GTS screen, read the time-series freeze frame data to confirm the vehicle conditions when an engine stall occurred while stop and start control was operating.

(b) Check the freeze frame data for engine stall history and engine start failure.

GTS Display

Result

Proceed to

Engine Stall History during Stop&Start (Hood Open)

Yes

A

Engine Stall History during Stop&Start (Collision or Battery Voltage Low)

Yes

B

Engine Stall History during Engine Starting (Collision)

Engine Start Fail

Yes

C

B

GO TO STEP 9

C

GO TO STEP 10

A

5.

READ VALUE USING GTS (HOOD COURTESY SWITCH)

NOTICE:

Before performing this step, check that the engine hood can be opened by pulling the hood lock control cable.

Powertrain > Stop and Start > Data List

Tester Display

Hood Courtesy Switch

(a) Check the Data List when the hood is opened and closed.

OK:

Condition

Normal Condition

Engine hood closed

ON

Engine hood open

OFF

OK

USE SIMULATION METHOD TO CHECK

NG

6.

INSPECT ENGINE HOOD COURTESY SWITCH (HOOD LOCK ASSEMBLY)

Click here

NG

REPLACE ENGINE HOOD COURTESY SWITCH (HOOD LOCK ASSEMBLY)

OK

7.

CHECK HARNESS AND CONNECTOR (ENGINE HOOD COURTESY SWITCH (HOOD LOCK ASSEMBLY) - BODY GROUND)

(a) Disconnect the A58 engine hood courtesy switch (hood lock assembly) connector.

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

A58-2 (E) - Body ground

Always

Below 1 Ω

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

8.

CHECK HARNESS AND CONNECTOR (ENGINE STOP AND START ECU - ENGINE HOOD COURTESY SWITCH (HOOD LOCK ASSEMBLY))

(a) Disconnect the A67 engine stop and start ECU connector.

(b) Disconnect the A58 engine hood courtesy switch (hood lock assembly) connector.

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

A67-7 (BNT1) - A58-1 (+)

Always

Below 1 Ω

A67-7 (BNT1) - Body ground

Always

10 kΩ or higher

A58-1 (+) - Body ground

Always

10 kΩ or higher

OK

REPLACE ENGINE STOP AND START ECU

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

9.

CHECK VEHICLE CONDITION (COLLISION HISTORY)

(a) Check if the vehicle was in a collision when the engine stalled.

Result

Proceed to

Vehicle was in collision when engine stalled

A

Vehicle was not in collision when engine stalled

B

HINT:

When "Engine Stall History during Stop & Start (Collision or Battery Voltage Low)" or "Engine Stall History during Engine Starting (Collision)" is stored: This may have been stored because the vehicle was in a collision or a collision detection signal was input while stop and start control was operating.

A

END (ENGINE STALLED BECAUSE COLLISION DETECTION SIGNAL WAS RECEIVED)

B

GO TO AIRBAG SYSTEM

10.

CHECK HARNESS AND CONNECTOR (ENGINE STOP AND START ECU - ST NO. 1 RELAY)

(a) Disconnect the H45 certification ECU (smart key ECU assembly) connector.

(b) Disconnect the A64 clutch start switch assembly connector.

(c) Disconnect the A106 ECM connector.

(d) Disconnect the A67 engine stop and start ECU connector.

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

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

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

Always

Below 1 Ω

H45-3 (STA) - Body ground

Always

10 kΩ or higher

2 (ST NO. 1 relay holder) - Body ground

Always

10 kΩ or higher

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

11.

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

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

(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 holder) - Body ground

Always

Below 1 Ω

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

12.

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

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

*1

No. 1 Engine Room Relay Block

*a

ST NO. 1 Relay Holder

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

5 (ST NO. 1 relay holder) - Body ground

Always

9.5 to 14 V

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

13.

CHECK HARNESS AND CONNECTOR (STARTER ASSEMBLY - BATTERY)

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

D108-1 (B) - Body ground

Always

9.5 to 14 V

CAUTION:

Before performing this step, check that the starter assembly connector F1 is not disconnected or loose.

*1

Starter Assembly

*a

D108-1 (B)

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

14.

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

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

(b) Disconnect the D54 starter assembly connectors.

(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 holder) - D54-1 (ST)

Always

Below 1 Ω

3 (ST NO. 1 relay holder) - D55-1 (ZYV)

Always

Below 1 Ω

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

15.

INSPECT RELAY (ST NO. 1 RELAY)

Click here

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

16.

INSPECT STARTER ASSEMBLY

Click here

OK

REPLACE ENGINE STOP AND START ECU

NG

REPLACE STARTER ASSEMBLY

17.

CHECK HARNESS AND CONNECTOR (POWER SUPPLY CIRCUIT)

(a) Disconnect the A66, A67 and H43 engine stop and start ECU connectors.

*a

Front view of wire harness connector

(to Engine Stop and Start ECU)

-

-

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

A66-3 (BIN1) - Body ground

Always

9.5 to 14 V

A66-1 (BIN2) - Body ground

Always

9.5 to 14 V

(c) Turn the ignition switch to ON.

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

Standard Resistance:

Tester Connection

Switch Condition

Specified Condition

A67-1 (+B) - Body ground

Ignition switch ON

9.5 to 14 V

H43-18 (IGP) - Body ground

Ignition switch ON

9.5 to 14 V

H43-21 (IGR) - Body ground

Ignition switch ON

9.5 to 14 V

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

18.

CHECK HARNESS AND CONNECTOR (ENGINE STOP AND START ECU - BODY GROUND)

(a) Disconnect the A66 and A67 engine stop and start ECU connectors.

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

A66-2 (GND2) - Body ground

Always

Below 1 Ω

A67-6 (DGND) - Body ground

Always

Below 1 Ω

A66-8 (GND1) - Body ground

Always

Below 1 Ω

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

19.

CHECK HARNESS AND CONNECTOR (ENGINE STOP AND START ECU - ST NO. 1 RELAY)

(a) Disconnect the H45 certification ECU (smart key ECU assembly) connector.

(b) Disconnect the A64 clutch start switch assembly connector.

(c) Disconnect the A106 ECM connector.

(d) Disconnect the A67 engine stop and start ECU connector.

(e) Remove the ST NO. 1 relay from the No. 2 engine room relay block.

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

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

Always

Below 1 Ω

A67-21 (STA) - Body ground

Always

10 kΩ or higher

2 (ST NO. 1 relay holder) - Body ground

Always

10 kΩ or higher

OK

REPLACE ENGINE STOP AND START ECU

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

20.

READ VALUE USING GTS (Starter(Hood Close))

(a) Enter the following menus: Powertrain / Stop and Start / Active Test / Starter(Hood Close)

Powertrain > Stop and Start > Active Test

Tester Display

Starter(Hood Close)

(b) Check whether the engine cranks while the Active Test "Starter(Hood Close)" is being performed.

NOTICE:

The Active Test "Starter(Hood Close)" is stopped automatically 3 seconds after the starter assembly begins operating.

Standard:

Engine cranks

Result

Proceed to

Engine cranks

A

Engine does not crank

B

B

GO TO STEP 26

A

21.

READ VALUE USING GTS (NEUTRAL SWITCH)

Powertrain > Stop and Start > Data List

Tester Display

Neutral Switch

(a) Depress the clutch pedal and read the values displayed on the GTS.

Tester Display

Result

Proceed to

Clutch Lower Switch

Fully Depressed

ON

Clutch Lower Switch

Fully Released

OFF

NG

GO TO STEP 24

OK

22.

INSPECT CLUTCH START SWITCH ASSEMBLY

Click here

NG

REPLACE CLUTCH START SWITCH ASSEMBLY

OK

23.

CHECK HARNESS AND CONNECTOR (CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) - ST NO. 1 RELAY)

(a) Disconnect the H45 certification ECU (smart key ECU assembly) connector.

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

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

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

Shift lever in P or N

Below 1 Ω

H45-3 (STA) - Body ground

Shift lever not in P or N

10 kΩ or higher

OK

PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

24.

CHECK HARNESS AND CONNECTOR (CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) - CLUTCH START SWITCH ASSEMBLY)

(a) Disconnect the A64 clutch start switch assembly connector.

(b) Disconnect the H45 certification ECU (smart key ECU assembly) connector.

(c) Disconnect the A67 engine stop and start ECU connector.

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

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

Always

Below 1 Ω

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

Always

Below 1 Ω

H45-10 (STAR) - Body ground

Always

10 kΩ or higher

A67-17 (CLL) - Body ground

Always

10 kΩ or higher

A64-2 (B) - Body ground

Always

10 kΩ or higher

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

25.

CHECK CERTIFICATION ECU (SMART KEY ECU ASSEMBLY) (STAR SIGNAL)

(a) Disconnect A67 the engine stop and start ECU connector.

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

Standard Voltage:

Tester Connection

Switch Condition

Specified Condition

A67-17 (CLL) - Body ground

Engine started using push start switch assembly (engine start)

9.5 to 14 V

OK

PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE

NG

GO TO ENTRY AND START SYSTEM (START FUNCTION)

26.

CHECK HARNESS AND CONNECTOR (STA SIGNAL)

*a

Front view of wire harness connector

(to Engine Stop and Start ECU)

-

-

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

(b) Check the waveform immediately after starting.

Standard Resistance:

Tester Connection

Condition

Specified Condition

A67-21 (STA) - A67-6 (DGND)

Ignition switch ON

6 to 14 V

Cranking commanded via Active Test item Starter(Hood Close)*1

  • *1: In the case of stop and start inspection procedure.

Result

Proceed to

OK

A

NG

B

NG*1

C

  • *1: In the case of stop and start inspection procedure.
B

GO TO STEP 37

C

GO TO PROBLEM SYMPTOMS TABLE (ENGINE DOS NOT START)

A

27.

INSPECT RELAY (ST NO. 1 RELAY)

Click here

NG

REPLACE RELAY (ST NO. 1 RELAY)

OK

28.

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

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

*1

No. 1 Engine Room Relay Block

*a

ST NO. 1 Relay Holder

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

Standard Resistance:

Tester Connection

Switch Condition

Specified Condition

5 (ST NO. 1 relay holder) - Body ground

Always

9.5 to 14 V

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

29.

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

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

(b) Disconnect the starter assembly connector.

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

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

Always

Below 1 Ω

3 (ST NO. 1 relay holder) - D55-1 (ZYV)

Always

Below 1 Ω

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

30.

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

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

(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 holder) - Body ground

Always

Below 1 Ω

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

31.

CHECK HARNESS AND CONNECTOR (ENGINE STOP AND START ECU - ST NO. 1 RELAY)

(a) Disconnect the H45 certification ECU (smart key ECU assembly) connector.

(b) Disconnect the A64 clutch switch assembly connector.

(c) Disconnect the A106 ECM connector.

(d) Disconnect the A67 engine stop and start ECU connector.

(e) Remove the ST NO. 1 relay from the No. 2 engine room relay block.

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

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

Always

Below 1 Ω

A67-21 (STA) - Body ground

Always

10 kΩ or higher

2 (ST NO. 1 relay holder) - Body ground

Always

10 kΩ or higher

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

32.

CHECK STARTER SIGNAL (OUTPUT WAVEFORM)

(a) Connect the positive (+) lead of an oscilloscope to the positive (+) battery terminal and the negative (-) lead to the negative (-) battery terminal.

(b) While cranking the engine, count the number of times the waveform drops.

Standard:

Waveform drops 2 times

Number of Times Waveform Dropped

Proceed to

0 times

A

2 times

B

B

GO TO STEP 36

A

33.

INSPECT STARTER INRUSH CURRENT REDUCTION RELAY

*1

Starter Assembly

*a

B Terminal

*b

M Terminal

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

(b) Disconnect terminals B and M of the starter inrush current reduction relay.

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

B Terminal - M Terminal

Always

Below 1 Ω

NG

GO TO STEP 35

OK

34.

INSPECT STARTER ASSEMBLY (C TERMINAL)

*1

Starter Assembly

*a

Inspect Part

*b

B Terminal

*c

C Terminal

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

(b) Disconnect terminal B of the starter inrush current reduction relay.

(c) Disconnect terminal C of the starter assembly.

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

C Terminal - B Terminal

Always

Below 1 Ω

OK

REPLACE STARTER ASSEMBLY

NG

REPAIR OR REPLACE WIRE HARNESS

35.

INSPECT STARTER ASSEMBLY (M TERMINAL)

*1

Starter Assembly

*a

Inspect Part

*b

M Terminal

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

(b) Disconnect terminal M of the starter inrush current reduction relay.

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

M Terminal - Body ground

Always

Below 1 Ω

OK

REPLACE STARTER INRUSH CURRENT REDUCTION RELAY

NG

REPLACE STARTER ASSEMBLY

36.

INSPECT STARTER ASSEMBLY

Click here

OK

USE SIMULATION METHOD TO CHECK

NG

REPLACE STARTER ASSEMBLY

37.

CHECK HARNESS AND CONNECTOR (POWER SUPPLY CIRCUIT)

(a) Disconnect the A66, A67 and H43 engine stop and start ECU connectors.

*a

Front view of wire harness connector

(to Engine Stop and Start ECU)

-

-

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

A66-3 (BIN1) - Body ground

Always

9.5 to 14 V

A66-1 (BIN2) - Body ground

Always

9.5 to 14 V

(c) Turn the ignition switch to ON.

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

Standard Resistance:

Tester Connection

Switch Condition

Specified Condition

A67-1 (+B) - Body ground

Ignition switch ON

9.5 to 14 V

H43-18 (IGP) - Body ground

Ignition switch ON

9.5 to 14 V

H43-21 (IGR) - Body ground

Ignition switch ON

9.5 to 14 V

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

38.

CHECK HARNESS AND CONNECTOR (ENGINE STOP AND START ECU - BODY GROUND)

(a) Disconnect the A66 and A67 engine stop and start ECU connectors.

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

Standard Resistance:

Tester Connection

Condition

Specified Condition

A66-2 (GND2) - Body ground

Always

Below 1 Ω

A67-6 (DGND) - Body ground

Always

Below 1 Ω

A66-8 (GND1) - Body ground

Always

Below 1 Ω

OK

REPLACE ENGINE STOP AND START ECU

NG

REPAIR OR REPLACE HARNESS OR CONNECTOR

    Lost Communication with ECM/PCM "A" Missing Message (U010087,U012687,U012987,U013187,U014087,U015187,U015587,U016487,U117087)

    DESCRIPTION The engine stop and start ECU communicates with the SFI system, electronically controlled brake system, power steering system, air conditioning system, airbag system and main body ECU (multiplex network body ECU) via CAN communication...

    Engine Hood Courtesy Switch Circuit

    DESCRIPTION The engine stop and start ECU detects whether the engine hood is open or closed based on a signal received from the engine hood courtesy switch built into the hood lock assembly...

    Other information:

    Toyota Yaris XP210 (2020-2022) Reapir and Service Manual: Starter Relay Circuit Current Above Threshold (P061519)


    DESCRIPTION When the engine is started by stop and start control, the engine stop and start ECU controls the starter assembly by activating the ST NO. 1 relay (for starter pinion operation) via voltage from terminal STA. If overcurrent is detected in the starter relay circuit, the engine stop and start ECU stores DTC P061519 and blinks the stop and start cancel indicator...

    Toyota Yaris XP210 (2020-2022) Reapir and Service Manual: Utility


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