Hi all,

If I drive the car for a while (1hr+) on the highway and then stop and turn the engine off, the car won't wind over and start again. I hear a click noise when I turn the key but that is it.
The car starts fine when it is cold or hasn't been driven much, this leads me to think that it has a lot to do with the starter motor heating up..

My solution after repairing and replacing the starter motor to no avail, I lift the bonnet and let the engine cool down. This can take between 15-45 minutes depending on how hot the day is and so forth.

I have seen that this is a common problem amongst other 4Runner owners. No one has replied back to other threads and explained how they fixed this problem.
Can someone point me in the direction of a thread I have missed or give me some trouble shooting points?

I read somewhere that I might need to install a solenoid heat shield?
Does the solenoid stick when hot because of heat expansion?

The car with the problem is a 91, 3.0L, V6, Automatic, 4x4, 4Runner.

I hope I have written enough detail and look forward to hearing feedback to my problem

Throttle Positioning Sensor

I don't understand how the Throttle Positioning Sensor would cause the car not to turn over after a long period of driving the car when everything works fine.

My google search on Throttle Positioning Sensor gave me this link below..

Heres the issue I had with mine, I would drive 20-30 minutes, stop for gas or whatever, she wouldn't crank. I was stumped, finally I would wiggle the sensor, she'd fire right up. I think the heat of the engine was making it expand and not making a good connection. As soon as I swapped in a new one, havent had the problem since.

I had the same problem for nearly 8 years. Replaced starters and batteries. Upgraded cables. Nothing worked. Several months ago I finally took it to a true Toyota expert in Austin (it took that long to find the shop). They installed a relay between the battery and the starter. It has started reliably ever since - even in 100+ degree days we have been having lately. BTW this is an unusual, but not uncommon problem of other older Toyotas including 4Runners and Camrys.

Thank you for the explanation combatmedic. I will give it a wiggle and see how I go.
Thank you pkinfinity for your response as well. Do you know what installing this relay achieves?
In the mean time I shall wiggle the TPS and see how I go.
I'll be back to report on any findings ;)

Good luck brother.

I'm not an expert. But I gathered that the relay takes a charge directly from the battery to the starter instead of routing it through the wiring harness. This ensures that the starter receives a full electrical signal rather than a weak one that might not fully engage the starter. In my case, I had replaced my starter just three weeks prior to experiencing several heat related "no-starts" like you described. So when I spoke with the Toyota expert he knew that the starter was not the issue.

Wow! I can't believe this thread is so new! I'm having the same issue. Just purchased it. I live in Seattle and the weather has been hot these last few days, and I've been experiencing the same - won't start when hot. Then today, the clouds and cool weather rolled back in and the 4runner starts every time I turn the key. Threw me for a loop. I was literally getting ready to replace the starter... This makes me think I should re-think that. I replaced the relay up in the fuse box to no avail, myself.

Anyways, I'll be waiting for your update. I'll throw in my own two cents when I figure it out...

I have a 1990, V6, automatic, 4x4 myself.

Okay, it has been 2 weeks since I last replied to this post and about 1 week since I installed a relay between the battery and the starter as pkinfinity mentioned:

I'm very happy to report that installing this relay has fixed my problem. The car starts every time. Crossed fingers

Sounds to me like the solenoid wire to the starter has an intermittent open caused by heat. If you wanted to confirm it, do a voltage draw test while cranking. Put one lead at each end of the solenoid wire, and crank the engine. The voltage should be low (.5 volts or so). If it's any higher, the resistance in that wire is drawing too much power.

The relay that you installed probably just bypassed that wire. You could also cut an splice new wires, but the relay sounds like a simpler, more reliable repair.

That's what the starter solenoid does. The heavy gauge wire on the starter/solenoid goes straight to the battery.

I'm from Vancouver, WA and same thing with my 98 runner. Its a manual 4 cylinder. I'm not a mechanic so I took it to mine and he has had it twice in the last month and could not figure out wth was wrong. Of course it would always start for him because he would start it when the engine was cold. I'm calling him tomorrow. I will keep you posted.

Thanks for the advice folks and Fish On!

Point him at Toyota/Chrysler/Mitsubishi - Nippon Denso Starter Solenoid Repair , and have him run the tests detailed while it's working fine and again when it's doing the click-no-start thing. Do NOT let him replace the starter on suspicion - unless he gets the thing on his bench and can demonstrate exactly how it's bad, it isn't bad.

Click-no-start is a common problem with these trucks as they get old, and I have yet to see installation of additional starter relay not solve the problem. They're easy to install, if you want to do it yourself. Good luck!

i used to have this issue with my 88 after driving it for a while and shut it off wouldnt start had to replace about 4 starters in that truck all but one i think was warranty what a pain in the ass they are to do but all i would do would be just walk out side tap it and then the truck started fine every time after that till it got hott again or it go shut off