[garrison]

My 2000 Sienna XLE started having key start issues...ignition switch(?)...it would start easily and then sometimes...nothing on turnover..it grew a bit worse but last Saturday...we parked to get lunch it wouldn't shut off, the engine chugged on after taking the key out. It began to smoke as the wires from the negative terminal and the battery terminal, and starter all melted enough to be rather serious. Yesterday , my mechanic pal and I drove to get a new starter, remanufactured , swapped out the Interstate battery and replaced the wire with what looks like a near new battery wire. We have no start, no lights on dash. Still at a dead halt. What's next? Stuck here at home. I greatly appreciate some help on this.
Garrison

 

[Ed's00Sienna]

Sounds like you have a probable bad ignition switch, like you thought. if it's still providing power with the key in the "off" position. Easy to replace. If it still doesn't start after replacement, check starter relay, then fuse next to it (am-2 I think it is?), then check the 5 amp fuse behind the dash panel. Let us know how it turns out!

 

[garrison]

Thank you for that likely culprit. Would a starter relay or fuses be damaged with the heat on the negative terminal. Well, next phase of repair on Tuesday hopefully. The van has been very strong overall. 133,000 miles and second owner here. 🤞...I will let you know this week🙏 and many thanks.

 

[Ed's00Sienna]

You're welcome, and yes to your questions. That's what/where I'd check. Relay AND fuse under hood. If it was my van, I'd be checking as soon as I replaced the switch, since it's free to check yourself

 

[3Wheelerguy]

I am thinking the issue was with the starter itself. Seen it a couple times. Contacts wear and stick inside the solinoid.

 

[garrison]

Thanks so much...well, new rebuilt starter, brand new battery, the wires looked pretty new too. But...completely dead. More soon! Ready to drive confidently again...