UPDATE: Here is what I have done so far...
Previously on Cruiser ER:
1. Cleaned and inspected the wires and plug connecting to the neutral safety switch.
2. Replaced the fusible link.
3. Replaced the starter.
4. Replaced both the positive battery cable (connects to starter) and the negative battery cables (connects to engine block + a smaller wire connecting to the body)
5. Replaced the ignition switch.
New:
6. Pulled the neutral safety switch. Used a jumper to bypass the switch to see if this is the problem. No luck.
7. Pulled, inspected, and re-installed all fuses. No luck.
8. Used a jumper from the positive terminal on the battery directly to the small wire on the starter.
Details. Essentially, I hot-wired the Cruiser, bypassing the entire ignition circuit.
THIS WORKS! It cranks strongly and instantly.
This means the problem is NOT:
- battery
- starter
- battery cables
- grounds
Problem is somewhere in the ignition circuit. Here's a description of the circuit on Mud:
The current in the starter circuit starts at the
battery,
passes through
fusible links and
fuses,
then through the
ignition switch (switch is closed when the key is at the START position) and
then takes a tour over to the
glovebox
before coming into the
NSS as the black-with-white-tracer wire.
From there, assuming the transmission is in neutral or park, the current leaves the NSS as the black-with-red-tracer wire and goes to the starter solenoid.
Next suspects:
- I noticed a piezo chirper in the engine bay. It's a Floyd Bell SP-609. It's connected to a Glass Breakage Sensor Electronic Control Unit, Toyota Part No. 08192-00970. Not sure how I diagnose the sensor to see if it's good. Is the sensor and alarm system even part of the ignition circuit? I'd be glad to remove the whole thing, but I'd love to keep the keyless remote. See attached photos.
- Wondering what the deal is with the ignition circuit going to the glovebox.
9. If all else fails, I can install a relay and bypass the ignition system, as several people on Mud have done.
10. Give up, buy a Camry.