96 Tacoma, Rebuild Question Continued. No Start, Possible relay and where does it go?

So tonight we finished up all the tubing and connecting wiring, mostly .
The Taco has power, but will not start. We do hear a little click when depressing the clutch to start it. It is a manual, 2.7 liter 4 cylinder. I tried using the clutch start / stop switch as well, nothing. I tried depressing the button behind the clutch pedal to try and start it. Nothing.

So, we can not get it to start or turn over. We can confirm fuel getting to the engine.

However - the one thing we could not figure out a connection for is shown in the pictures. Its the little gray flat looking piece. Ironically its near the firewall and starter, but I don't see anywhere where I can plug it in. The starter has the black box looking wire and the starter wire tight on the bottom. This gray plug is on the right side of the engine, kind of towards the back of the manifold area.

Any thoughts on the best way to troubleshoot this baby? Hopefully this plug is a quick fix that directly relates to the starting situation we have. Appreciate all of your help as always!

You Taco heads have a good night.
Jason

 

Fix the no crank issue first.

Battery charged , battery terminals clean and tight?

Connections on the starter clean and tight ? Starter stuck from sitting ?

without the EWD in front of me does this year have a starter relay?

Ground connections clean and tight?

after these steps check if your getting voltage to the starter solenoid. If no then check the starter relay if one is present.

 

Is the STA fuse getting power while cranking?
If it’s not.

Pull the starter relay
Check pin # 1 for power when cranking
Pin #5 for power at all times
Pin # 2 for Ground with clutch pushed in

 

@TnShooter: thanks for the reply. So, here is what we found.
Pin#2: Good, we have power
Pin #5 and 2: No power when cranking or power at all times.
Thoughts?

 

Hold on a sec.
Let’s clear things up.

1. Are you using a volt meter?
2. Are you using a test light?

Pin 5 should always have power.
Pin 1 should have power when cranking

To check these, place the black lead on your meter to the battery negative post, and red lead to each pin. You should see 12v (or what ever voltage the battery is currently at)
I personally like to use a test light, clip test light to Negative post, probe pins with light. Light should come on.

To test pin 2, red lead on your meter to battery Positive, black lead to pin 2. You should see 12v
If using a test light, clip light to battery Positive, probe pin 2. Light should come on.

 

Hi TNShooter,
We did buy a test light and had things hooked up the way you described it above. We were able to get the connection to show good when mashing in the clutch on the pin 2. For the rest of the connection attempts, no light or connection.
However, I'm going to go through the tests again tomorrow and ensure I follow your exact steps.
Maybe it's a killed fuse. That'd be a miracle.
I still worry about that connector in the above pic. It's just sitting there all lonely and I keep wondering what it goes too.
I did tap the starter with a hammer a few times today, and double checked all tightness in starter bolts.
Appreciate you so much! I'll be in touch.

 

The 40A AM1 fuse powers pins 1 and 5.
Check that fuse

 

Hi again TNShooter. So, no luck. We replaced both 40A fuses. I tried starting it, no click at the starter level. I also tried tapping the starter Retested the fuse box with the new 40A fuses.
- Pins 1 and 5 have no power in any condition or test.
- Pin 2 does have power when clutch is engaged.
- Here's another weird thing, pin 3 has power at all times (not 5 as you mentioned).
Any updated thoughts? Side bar, I see these other two wires under the fuse box just hanging out. Any ideas on if these two are important?
It's sat for 9 years, so who knows what the issue is I suppose.

 

It would be nice to know if you have power to the leg of the 40A AM1 fuse.
If not, you need to check the 80A Alt fuse.

As for power on 3?
Something is not right there.
If this is true, something is back feeding to that pin.
That pin can’t have power on it with out the relay in and working.
And it can’t be dpworking if you have no power to pins 5 and 1

 

We are heading on vacation until 6/20. I'll be in touch when we get back. It's a mystery for sure. The truck has a new engine put in it, but all the wires and bolts were gone. We were left to try and put all that back together. I keep wondering what we connected somewhat wrong, and if that's it.

 

I’ve been a member here for 12 years.
I’d say I’ll still be around when you get back from vacation
Until then, I’ll see what I come up with.

Have fun and enjoy the vacation.

 

Hi
when your putting together a vehicle when the battery been disconnected or dead. Check the security system with the FOB/clicker and check under dash area driver side there will be a toggle switch and usually a little red light on the dash. Lots of time the security will disable the start system when power is apply after power been lost. Older vehicle did not come with security system usually dealer installed/after market.