1988 Toy SR5 22RE 447K 2Wheeler

During the past two months, my pickup has developed quirky engine start.
I replaced the clutch safety switch, sanded the contacts in the starter relay, and bought a jump starter power pack.

Frequently it starts normally, occasionally it won't start normally but will start with a jump starter power pack, and sometimes it requires 30 minutes on an external battery charger before it will start.

For example, on Thursday the engine started normally twice for a short trip to the library. However, an hour later, the engine wouldn't turn over, the power pack didn't work, but it started normally after 30 minutes on the charger. I didn't leave the lights on.
Twice in the past two weeks, I stalled the engine at a stop sign on a slight grade; restart required the power pack.
After the engine starts, the alternator needle shows full charge. When it requires some time on the charger, the system acts like the battery is totally dead. That is, turning the key to accessory won't even activate the open door alert, and turning the key to start won't produce clicks from the engine.

Can any of you give me a hint where to start looking? Ignition switch? Grounds?

 

Check your alternator charging output with a multi-meter on the battery terminals with the engine running to see if it's charging. Should be ~14 volts to the battery. If it's good then your battery might be dead. How old is the battery? I had an intermittent starting issue, so did a battery test. It was ~275CCA and not the rated 650CCA. Said replace battery. Put in a new battery and now starts every time.

If the alternator output is low, the battery could still be good, but needs a full charge that it hasn't been getting.

 

Would definitely agree with battery. May also wanna run through your fuses with a multi meter too and check for a parasitic draw, maybe something is shorting out somewhere and draining the battery which could kill it over time. Had that happen on my 3VZE.

 

Don't rule out a bad starter.

My son had a 4-cylinder Honda that was doing the same as yours. Put a new battery in, and it was doing just like yours is doing. Took the starter off, and had it tested at Advance Auto. It passed the test just barely. I told him to buy a new starter anyway. Installed the new starter, and that fixed the problem.

 

Thanks for your responses. The alternator is only several years old. I checked the battery at O'Reilly two months ago when the quirks began. It was fine.
Today, I did some research to learn how to check the battery and alternator output. After I replaced the battery in the multimeter that I bought in a bag of hand tools from a yard sale three years ago, I tested the battery and alternator; the battery was about 12.6 volts, and alternator output, with engine running at idle, was 14.5 volts.

Iffen I try to pull out the key gently during engine start, I might be duplicating the problem. I will explore the ignition lock cylinder.

 

That's two less thing to worry about. If not the switch, then Snippit;'s advice would be my next choice. I have had to sand smooth eroded contacts in the starter solenoid.

 

I had to replace the ignition switch a few years ago due to an intermittent start issue.

 

Don't forget your battery cables and terminals. Visible corrosion is easy to spot and clean. I have had corrosion inside the cables. Had a voltage drop even after cleaning connections so I cut them open. Doesn't really explain the "intermittent" start but it's good maintenance to knock out while you're troubleshooting.

 

You said you checked the battery. Check the resting voltage after it sits all night. If it's down to round about 12.2 volts or lower after it sits all night it's probably time for a new battery. One weak cell can cause the problem you are having.

 

Batteries are so expensive now that $25 for a cheap load tester isn't a bad investment and takes alot of guesswork out of the equation.

 

Agree. When my truck had intermittent starting with the alternator and battery voltage checked fine with a multi-meter, I bought a not very expensive battery load tester. It showed the battery was at ~275 CCA on a 650 CCA battery- Bad Battery. Bought a Walmart Everstart Maxx 800 online on sale delivered for $139 and it has been starting every time since. A good tool to have.