How to Replace the Starter in a Toyota Tundra

A starter cranks the engine, drawing air and fuel into the cylinders of your 2001 to 2006 Toyota Tundra and compressing them so they will ignite. It also gets the ignition and crankshaft into place so the spark plugs will fire and the fuel injectors will operate. Therefore, a failing starter will prevent the engine from starting.

Difficulty:

Moderately Challenging

Instructions

things you'll need:

• Car jack
• Drain pan
• Battery terminal puller
• Wrench
• Baby food jar
• Torque wrench

1. Remove the Malfunctioning Starter

   • 1

     Park your Toyota Tundra on a level surface, activate the emergency brake and place blocks behind the back tires for safety. Raise the front end of the car with a jack for easier access to the starter.

   • 2

     Drain the cooling system and relieve the fuel system pressure.

   • 3

     Use a battery terminal puller to disconnect the negative battery cable. Remove the engine appearance cover.

   • 4

     Detach the air intake tube and intake manifold.

   • 5

     Support the weight of the starter motor, to prevent dangle. Unscrew and remove the starter mounting bolts. Place all nuts and bolts in the jar for safe keeping until later. Continue to support the starter motor.

   • 6

     Disconnect the starter electrical connections. Label the wires prior to disconnection if there is a chance you will forget where to reconnect them later. Remove the starter from the engine.

   • 7

     Take your malfunctioning starter to the parts store with you. Aftermarket distributors remanufacture most of the starters they sell, so you can likely obtain a partial credit toward your new starter by exchanging your old one. Be sure that you take care not to damage the starter in transit, because the better condition it is in, the more you can get for it.

   • 8

     Purchase a replacement starter that has the same or higher cranking capacity (power rating) as the original starter. Also, match the bolt patterns, drive gears and electrical connections. Your owner's manual may list specifications or the auto parts technician will help you determine them.

   Install the New Starter

   • 1

     Reverse the removal process to install the new starter. Tighten the cable nuts that secure the electrical connections to 86 inch pounds (ten Nm). Torque the starter mounting bolts to 29 foot pounds (39 Nm).

   • 2

     Lower your Toyota Tundra back to the ground. Reconnect the negative battery cable.

   • 3

     Fill the cooling system. Start the engine and check for leaks and correct starter motor function.

Tips & Warnings

• Always inspect the battery, solenoid and alternator to be certain they are working properly before replacing a starter. When an engine fails to start, many do-it-yourselfers misdiagnose the problem as the starter and replace it unnecessarily, only to find that the vehicle still won't start.

• If you believe your starter is in the problem, use a bench test to see if the starter motor spins and how well the starter is performing. A bench test will check the amp load, voltage and RPMs. If the starter is good, it will draw 60 to 150 amps with no load and up to 250 amps under load.

• To remove and replace the starter in a Tundra with a 3.4L or 4.0L engine, the process is the same except that Steps 2 and 4 in Section One are unnecessary.

• If your Tundra is an older model and/or has high mileage, you should also replace the solenoid. The removal and replacement process

• The disconnection of the negative battery cable may interfere with the on board computer function. Upon reconnection, the computer may need to go through a relearning process.

• Never operate the starter for more than 30 seconds at a time. Allow the starter motor to cool for at least two minutes in between starting attempts to prevent permanent damage.

• The starter replacement process is different for later models. Consult your owner's manual or a mechanic for details.