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Starter relay is shown on parts scheme 28300 RELAY ASSY, STARTER, but has got no part number for SERA01 SERA02... only SERA03 /28300-10020 (12V Denso 156700-0503) for fuse and relay block /82660-10130 similar relay to check is: 85915 RELAY, MAIN /90987-02006 -> relay has no problem, because I have solenoid sound on each ignition key turn to "start" there is alternative solution to install mentioned relay on SERA01 additional: to clean ground terminals on both engine sides L\R |
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relay_starter.jpg (141,432 bytes) |
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Replaced starter to 28100-11020 (0.8kW) - original for EXY10. was 28100-16230 (0.8kW). starter /28100-10060 fits Sera 1kW Need lower starter bolt /91612-61045 and high load (80A) cord connector (from battery to alternator wire) as specified on fuse box -> this part still needs to be replaced, both wire and terminal measured: Accumulator is 12.29V and above in standby (new battery Varta 5634010613162 "silver dynamic" 63Ah gives 12.6V in installed state, and 12.8V during disconnected from car). Engine starts normally now each time - problem almost solved Real problem of starter was in wiring and oxidized terminals: install more powerful and solid connectors, hide from moist with insulating cover, apply protective paste to battery and lock contact pads as well. clean inside of starter dust see black wire from battery |
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Need tools for this work: sandpaper abrasive sponge, all-size spanner and wrench, SATA tool, long stall ratchet |
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found BREAKER ASSY, WIRING CIRCUIT, NO.1 /82650-20011 and heater relay /90987-04002 on the left board and screw 93319-15010 lost to secure COMPUTER, ENGINE CONTROL /get \GOT |
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Cannot apply screw 91612-61045 on starter -> video research |
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For more stable engine start on wet weather, need new high-voltage wire (ignition leads): CORD SET, COIL & SPARK, W/RESISTIVE /90919-21507 (or Blue Print ADT31668) , includes lost one /90919-13388 Another high-quality: Magnecor KV85 HT. Replacement OEK279, OEF378, OES1185, RC-TE52 NGK similar (variants) Old HV wire from coil was "6391-5200" with 12.4mm diameter rubber connector with 4.7mm diameter pin Basic update (after 1992, needs replacement of COIL ASSY, IGNITION /90919-02197 and CAP SUB-ASSY, DISTRIBUTOR/19101-11080): /90919-21540 CORD SET, COIL & SPARK, W/RESISTIVE (or Blue Print ADT31669 or NGK RC-TE52 or Toyota 90919-21587) includes (lost one): /19590-11020 -> Used on Toyota STARLET (EP80,NP80,EP90,NP90) 4EFTE engines CORD, COIL RESISTIVE 5E-FE engines have /90919-22325 wire 5mm^2, 34 40 52 60 mm ? Other similar cord sets: Starlet /90919-22294 /90919-22373 (EL54 with 5EFHE) -> newest, but only 4PCs - because this distributor model has ignitor on itself -> Lorcen LC1433564, Avantech IL0104 Currently installed original distributor (from 4E-FTE Denso 229100-7631) Toyota /19100-11070 (SERA01 SERA02) has one connector 4-pin: 01 -> to ECU "G-" 02 -> to ECU "G" G2 03 -> to ECU "NE-" G1 04 -> to ECU "NE" also fits distributor /19100-11080 (SERA03) |
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Purchased Spark (4pcs) Denso IK20 for replacement, engine works more or less the same on these iridium sparks as with previous ordinary spark (platinum), it does not affect wet ignition malfunction, as expected, -> 2017 done but main high-voltage cord replacement fixed problem with wet weather /19590-11020 |
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ignition-coil-spark.jpg (54,101 bytes) |
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distributor_Ne_G.jpg (30,294 bytes) |
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Igniter installed is COIL.W/IGNITER Toyota /19070-10020 (Denso 101311-6080) Vu - made by Toshiba COIL in this assembly is /90919-02198 Denso 029700-7100 12V with 2-pin connector and 1pin for high voltage wire 89620 IGNITER ASSY Toyota /89621-30010 (Denso 131300-1250) 125 (SERA01 SERA02) also fits /89621-12050 (SERA03, same as in EL44-DCPVH) replace 89621-12010 igniter has 5-pin connector: 01 -> to ignition coil 02 -> IG- to DIAGNOSIS port 03 -> to ignition coil and injector 04 -> to ECU "IGT" 05 -> to ECU "IGF" Need remake ignition parts, remove 5th wire (from coil to distributor) -> leave only 4 wire from distributor to sparks. A1. Solder coil directly to distributor B2. Get "direct" coils from EXZ10 (Raum) model with 5E-FE + position sensor "2-DIS" type C3. Get "internal" distributor coil model -> best for 5E-FHE from Cynos EL54-DCPVH, like /19101-11060 + /19235-11200 Near coil there is capacitor /90980-04079 2-pin 250/0.47.A. Other possible upgrade for Sera ignition (as found in original Toyota ??? Repair manual ???): this EL54 (Paseo ??? - Cynos ????) distributor+coil /19050-11011 (19050-11010) has no commuter inside, it is separate 5-pin igniter /89621-26010 on frame, but engine hat /11201-11030 and head /11101-19435 is the same as for EXY10 5E-FHE engine, but camshafts are "newer" than for EL44 (different part number) for the same model 5E-FHE engine (do not confuse with 5E-FE camshafts, which are smaller). C-55 igniter 5-pin connector (similar): ? 1. ECU ‘IGF’ (Grey-Black) output signal 2. ECU ‘IGT’ (Light Green-White) input signal 3. "IG2" ignition +12V from switch-relay (Black-Red) 4. Diagnostics Socket ‘IG-‘ (Black) 5. Pin 2 on ignition coil C-56 connector (Black-White) C-56 coil (under igniter or distributor) 1. "IG2" ignition +12V from switch-relay (Black-Red) 2. Pin 5 on igniter C-55 (Black-White) AC + high-voltage wire C-72 distributor 1. ECU ‘NE’ (White-Blue) + 2. ECU ‘G1’ (Orange-Blue) + 3. ECU ‘G2’ (Blue-Green) + 4. ECU ‘G-‘ (Blue-Yellow): NE- and G1- and G2- + high-voltage wire , separate |
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relay_fuse_EXY10.JPG (273,644 bytes) |
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starter_relay_SERA_.jpg (149,606 bytes) |
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starter_SERA_.png (54,336 bytes) |
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MA_D254-E_distributor.png (42,734 bytes) |
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28300-10020.jpg (33,908 bytes) |
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ME_Q236-A_wiring_ground_EXY10_.png (36,884 bytes) |
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high power wires from battery: black to starter white+blue to fuse from fuse: white white+blue white+red |
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ADT31668_90919-21507.jpg (173,094 bytes) |
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Got used starter from black Sera 0.8kW 12V Denso /28100-11020 test and clean and fix - disassembled 2021 Got normal 0.8kW starter Toyota /28100-11010 Denso /128000-8530 "69" (9 teeth) |
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Connect additional relay high load line to W-R (AM1) and B-W to starter terminal power up starter relay from R-W "ST1" line after neutral-parking start switch and GND to frame Got another Main relay Toyota /90987-02006 Denso 056700-6912 12V normally open relay from donor car it is targeted to double 30A lines .... so, must be enough
EXY10_starter_wiring_SERA1995.jpg (164,578 bytes) |
- Anonymous