Toyota Tacoma 2002-06

Starter

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Removal & Installation



1GR-FE Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine undercover assembly.
  6.  
  7. On 2WD and PreRunner, remove the number two manifold stay.
  8.  
  9. On 4WD vehicles, remove the number two exhaust front pipe assembly. Remove the five clips and then remove the front fender splash shield, left side. Remove the number two steering intermediate shaft.
  10.  
  11. Disconnect the starter electrical connectors.
  12.  
  13. Disconnect the positive battery cable.
  14.  
  15. Remove the starter retaining bolts. Remove the starter from the vehicle.
  16.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Tighten the retaining bolts to 27 ft. lbs.
  4.  

2.4L Engine


Click image to see an enlarged view

Fig. Starter motor location-2.4L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Accelerator cable and intake air connector
     
    Intake manifold assembly
     
    Starter motor
     
    Starter electrical connectors
     

  4.  

To install:

  1. Install or connect the following:

    Starter. Tighten both bolts to 29 ft. lbs. (39 Nm).
     
    Intake manifold
     
    Accelerator cable and intake air connector
     
    Engine cover
     
    Negative battery cable
     

  2.  

2TR-FE Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the terminal cap. Disconnect the electrical connections.
  6.  
  7. Disconnect the positive battery cable.
  8.  
  9. Remove the starter retaining bolts. Remove the starter from the vehicle.
  10.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Tighten the retaining bolts to 27 ft. lbs.
  4.  

Except 2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Starter electrical connectors
     
    Starter
     

  4.  

To install:

  1. Install or connect the following:

    Starter. Tighten the fasteners to 29 ft. lbs. (39 Nm).
     
    Electrical connections
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Starter motor location-except 2.4L, 2.7L (TR-FE/X) and 4.0L engines

     

  2.  

Testing & Troubleshooting



The starter should crank the engine smoothly and steadily. If the starter engages, but cranks the engine erratically, remove it, and inspect the starter drive gear and torque converter ring gear for damage. Check the drive gear overrunning clutch for binding or slipping when the armature is rotated with the drive gear held. If damaged, replace the gears.

 
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