My 1992 2wd Previa (135K) recently started to have an intermitted starting problem. Very occasionally, you would get either nothing or just a click, similar to what you get with a dead or very low battery, but then it would start and be fine for a while. I checked, it was not the battery, and began to think maybe I might eventually need a starter.

This weekend...of course while I was out of town...my wife went to drive the van...but when she went out it would not start...a click again. After several tries the same...then 10 minutes later it moaned and labored, but started. She went inside leaving it running to warm up, but came out 5 to 10 minutes later to find it stalled. Worse yet, there was a very strong electrical/metallic burning smell all around the driver's door and inside. She called me to discuss the problem, and after hearing about the smoking, I had her disconnect the battery.

Now two days later, I am home and looking at the van searching for the problem. I wish the burning smell was fresher, but with the seat tipped up and access panel open, it seems to be coming from the area around the starter, which makes sense given the previous intermitted starting issue, and then the smell above and around the driver's door. From underneath, I can't see any obvious cooked wires, but am wondering if the starter may have melted down inside. It is a Toyota remanufactured starter...about 10+ years old. It is very clean under the van...and the starter looks nearly new from the outside...I know that cleanliness does not mean anything, but it is not covered with oil or dirt.

Now in addition to that, when I hooked the battery back up to check a few things, I am not getting any power to anything. I checked the fuseable link box, and the fuses are good, and the connections clean. The battery is only a couple of years old, and cable ends and posts are clean as well. I did get a little spark when I hooked up the battery cable...that is not normal...but it was not a particularly big spark.

This is my second Previa, and before that I had two of the 1980's Toyota vans. I know the earlier vans have a hidden fusable link, and I am wondering if the Previa has something I am missing. Also wondering if the starter totally melted down inside if that could be shorting the entire system out.

Thanks for the help in getting this old girl back on the road!