ST–1

STARTING (5VZ–FE) – STARTING SYSTEM

STARTING SYSTEM
ST08A–01

ON–VEHICLE INSPECTION
NOTICE:
Before changing the starter, check these items again:

Connector connection

Accessory installation, e.g.: theft deterrent system

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2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1425

ST–2
STARTING (5VZ–FE) – STARTER

STARTER
ST036–05

COMPONENTS

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Starter

Starter Connector
Starter Wire

P20589

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1426

 ST–3
STARTING (5VZ–FE) – STARTER

Bearing
Field Frame (Field Coil)

Brush Spring
End Frame

O–Ring
Through Bolt Armature

Bearing

Brush Holder

O–Ring
Steel ball
Through Bolt

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Retainer
Roller Starter Housing
Idler Gear

Starter Clutch Assembly

Return Spring
Magnetic Switch Assembly

Magnetic Switch Assembly

Terminal Insulator
Terminal Nut
Terminal 30 Kit Part
17 (170, 13)
Contact
Plate
Terminal
Bolt
Waver Washer
Terminal Insulator
Packing
O–Ring

Terminal C Kit Part

Plunger

Gasket
1.8 kW Lead Clamp

O–Ring
Terminal Insulator
Waver Washer

Contact Plate
End Cover Terminal Insulator Terminal Nut
17 (170, 13)
Terminal Bolt

N·m (kgf·cm, ft·lbf) : Specified torque

Non–reusable part
B07950

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1427

ST–4
STARTING (5VZ–FE) – STARTER
ST037–05

REMOVAL
REMOVE STARTER
(a) Disconnect the starter connector.
(b) Remove the nut, and disconnect the starter wire.
(c) Remove the 2 bolts and starter.

P20440

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2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1428

 ST–5
STARTING (5VZ–FE) – STARTER
ST038–05

DISASSEMBLY
1. REMOVE FIELD FRAME AND ARMATURE
(a) Remove the nut, and disconnect the lead wire from the
magnetic switch terminal.
Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)

P20446

(b) Remove the 2 through bolts.

Torque:
1.2 kW, 1.4 kW type: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
1.8 kW type: 9.3 N·m (95 kgf·cm, 82 in.·lbf)

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P20444

(c) Pull out the field frame with the armature from the magnet-
ic switch assembly.
NOTICE:
At the time of assembly, align the protrusion of the field
frame with cutout of the magnetic switch.
(d) Remove the O–ring.
HINT:
At the time of assembly,use a new O–ring.
P20443

2. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY

AND GEAR
(a) Remove the 2 screws.
Torque:
1.2 kW, 1.4 kW type: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
1.8 kW type: 9.3 N·m (95 kgf·cm, 82 in.·lbf)

P20441

Bearing (b) Remove the starter housing, return spring, bearing, idler
gear and clutch assembly from the magnetic switch as-
Idler Gear
sembly.

Return Spring

Starter Housing
Clutch Assembly B07116

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1429

ST–6
STARTING (5VZ–FE) – STARTER

3. REMOVE STEEL BALL

Using a magnetic finger, remove the steel ball from the clutch
shaft hole.

Magnetic Finger
P04515

4. REMOVE BRUSH HOLDER

(a) Remove the 2 screws and end cover from the field frame.
Torque:
1.2 kW, 1.4 kW type: 1.5 N·m (15 kgf·cm, 13 in.·lbf)
1.8 kW type: 3.8 N·m (38 kgf·cm, 34 in.·lbf)
(b) Remove the O–ring from the field frame.
HINT:

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At the time of assembly,use a new O–ring.
P20445

(c) Using a screwdriver, hold the spring back and disconnect

the brush from the brush holder.
Disconnect the 4 brushes, and remove the brush holder.
5. REMOVE ARMATURE FROM FIELD FRAME

P04525

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1430

 ST–7
STARTING (5VZ–FE) – STARTER
ST0GH–02

INSPECTION
1. INSPECT ARMATURE COIL FOR OPEN CIRCUIT
Continuity
Using an ohmmeter, check that there is continuity between the
segments of the commutator.
If there is no continuity between any segment, replace the ar-
Ohmmeter mature.

P10584

2. INSPECT ARMATURE COIL FOR GROUNDED

Using an ohmmeter, check that there is no continuity between
No Continuity the commutator and armature coil core.
If there is continuity, replace the armature.
3. INSPECT COMMUTATOR FOR DIRTY AND BURNT
Ohmmeter SURFACES
If the surface is dirty or burnt, clean it with sandpaper (No.400)

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or on a lathe.
P10585

4. INSPECT COMMUTATOR CIRCLE RUNOUT

(a) Place the commutator on V–blocks.
(b) Using a dial indicator, measure the circle runout.
Maximum circle runout: 0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on a lathe.

P10586

5. INSPECT COMMUTATOR DIAMETER

Using vernier calipers, measure the commutator diameter.
Standard diameter:
1.2 kW, 1.4 kW type 30 mm (1.18 in.)
1.8 kW type 35 mm (1.38 in.)
Minimum diameter:
1.2 kW, 1.4 kW type 29 mm (1.14 in.)
1.8 kW type 34 mm (1.34 in.)
P10587
If the diameter is less than minimum, replace the armature.
6. INSPECT UNDERCUT DEPTH OF SEGMENT
Check that the undercut depth is clean and free of foreign mate-
rial. Smooth out the edge.
Standard undercut depth:
1.2 kW, 1.4 kW type 0.6 mm (0.024 in.)
1.8 kW type 0.7 mm (0.028 in.)
Minimum undercut depth: 0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a
ST0040
hacksaw blade.
2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1431

ST–8
STARTING (5VZ–FE) – STARTER

7. INSPECT FIELD COIL FOR OPEN CIRCUIT

Continuity Using an ohmmeter, check that there is continuity between the
lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
Ohmmeter

P00300

8. INSPECT THAT FIELD COIL IS NOT GROUNDED

No continuity Using an ohmmeter, check that there is no continuity between
the field coil end and field frame.
If there is continuity, repair or replace the field frame.
Ohmmeter

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P00299

1.8 kW Type Ohmmeter 9. 1.8 kW type:

INSPECT SHUNT COIL FOR OPEN CIRCUIT
Using an ohmmeter, measure the resistance between shunt
coil terminals (A) and (B).
(A) Resistance: 1.5 – 1.9 Ω at 20°C (68°F)
(B)
If the resistance is not as specified, replace the field frame.

B07121

Brush Holder Side 10. INSPECT BRUSH LENGTH

Using vernier calipers, measure the brush length.
Standard length:
1.2 kW, 1.4 kW type 15.5 mm (0.610 in.)
1.8 kW type 15.0 mm (0.591 in.)
Minimum length:
1.2 kW, 1.4 kW type 10.0 mm (0.394 in.)
1.8 kW type 9.0 mm (0.354 in.)
Length
If the length is less than minimum, replace the brush holder and
Field Frame Side
field frame.

Length
Z10079

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1432

 ST–9
STARTING (5VZ–FE) – STARTER

11. INSPECT BRUSH SPRING LOAD

Take the pull scale reading the instant the brush spring sepa-
rates from the brush.
Standard installed load:
1.2 kW type 13.7 – 19.6 N (1.40 – 2.00 kgf, 3.1 – 4.4 lbf)
1.4 kW type 17.6 – 23.5 N (1.80 – 2.40 kgf, 4.0 – 5.3 lbf)
1.8 kW type 21.5 – 27.5 N (2.20 – 2.80 kgf, 4.9 – 6.2 lbf)

Minimum installed load:

ST0019
1.2 kW type 9.8 N (1.00 kgf, 2.2 lbf)
1.4 kW type 11.8 N (1.20 kgf, 2.6 lbf)
1.8 kW type 12.7 N (1.30 kgf, 2.7 lbf)
If the installed load is less than minimum, replace the brush
springs.
HINT:
Take the pull scale reading the instant the brush spring sepa-
rates from the brush.

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12. INSPECT INSULATION OF BRUSH HOLDER
Using an ohmmeter, check that there is no continuity between
No continuity
the positive (+) and negative (–) brush holders.
If there is continuity, repair or replace the brush holder.
13. INSPECT GEAR TEETH
Ohmmeter
Check the gear teeth on the pinion gear, idler gear and clutch
assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
P00303 If damaged, also check the flywheel or drive plate ring gear for
wear or damage.
14. INSPECT CLUTCH
Hold the starter clutch and rotate the clutch pinion gear clock-
Free
wise and check that it turns freely. Try to rotate the clutch pinion
counterclockwise and check that it locks. If necessary, replace
the clutch assembly.
15. INSPECT BEARINGS
Lock
Turn the bearing by hand while applying inward force.
If the resistance is felt or if the bearing sticks, replace the bear-
P04514 ing.

Ohmmeter 16. DO PULL–IN COIL OPEN CIRCUIT TEST

Using an ohmmeter, check that there is continuity between ter-
Terminal C
minals 50 and C.
If there is no continuity, check and replace the magnetic switch.

Terminal 50 Continuity
P25578

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1433

ST–10
STARTING (5VZ–FE) – STARTER

Ohmmeter 17. DO HOLD–IN COIL CIRCUIT TEST

Using an ohmmeter, check that there is continuity between ter-
Terminal C
minal 50 and the switch body.
If there is no continuity, replace the magnetic switch assembly.

Terminal 50 Continuity
P25578

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2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1434

 ST–11
STARTING (5VZ–FE) – STARTER
ST0GI–03

REPLACEMENT
SST 1. REPLACE REAR BEARING
(a) Using SST, remove the bearing.
SST 09286–46011

P10593

(b) Press in a new bearing.

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P10594

2. REPLACE FRONT BEARING

(a) Using SST, remove the bearing.
SST
SST 09286–46011

P10595

Upward (b) Using SST and a press, press in a new bearing.

SST 09820–00031
SST NOTICE:
Be careful of the bearing installation direction.

Downward P10596

3. REPLACE MAGNETIC SWITCH TERMINAL KIT

PARTS
(a) Remove magnetic switch end cover
Remove the 3 bolts, lead clamp (1.8 kW type), end cover,
gasket and plunger.

P25592

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1435

ST–12
STARTING (5VZ–FE) – STARTER

(b) Inspect the contact plate for wear.

Using vernier calipers, measure the contact plate for
depth of wear.
Maximum wear: 0.9 mm (0.035 in.)
If the depth of wear is greater than the maximum, replace the
contact plate.
Wear

P25599

(c) Remove the terminal kit parts.

(1) Using SST, loosen the terminal nuts.
SST
SST 09810–38140
(2) Terminal C:
Remove the terminal nut, wave washer, terminal in-
sulator (outside), O–ring, terminal bolt, contact
plate and terminal insulator (inside).

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(3) Terminal 30:
P25600 Remove the terminal nut, wave washer, terminal in-
sulator (outside), packing, O–ring, terminal bolt,
contact plate, terminal insulator (inside) and insula-
tion paper.

(d) Install new terminal 30 kit parts.

Long
(1) Temporarily install new terminal insulator (inside).
Short
(4) NOTICE:
(3) (5) Be careful to install the terminal insulator in the correct
(2) (6)
direction.
(1) (7)
(2) Temporarily install new contact plate.
(3) Temporarily install new terminal bolt.
Indentation (4) Temporarily install new O–ring.
Protrusion B07951 (5) Temporarily install new packing and new terminal
insulator (outside).
Install new packing to new terminal insulator, and
install them.
HINT:
Match the protrusion of the insulator with the indentation of the
housing.
(6) Temporarily install new wave washer.
(7) Temporarily install new terminal nut.

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1436

 ST–13
STARTING (5VZ–FE) – STARTER

(7) (6) Long (e) Install new terminal C kit parts.

(5) Short (1) Temporarily install new terminal insulator (inside).
(4) (2) (2) Temporarily install new contact plate.
(1) (3) Temporarily install new terminal bolt.
(3) (4) Temporarily install new O–ring.
(5) Temporarily install new terminal insulator (outside).
(6) Temporarily install new wave washer.
(7) Temporarily install new terminal nut.
Lead Terminal NOTICE:
B07118

Be careful to install the terminal insulator (inside) in the

correct direction.
(f) Temporarily tighten the terminal nuts.

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Wooden Block (g) Tighten the terminal nuts.
(1) Put a wooden block on the contact plate and press
40 mm it down with a hand press.
Dimensions of wooden block:
20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
37 mm
20 mm Contact Press force: 981 N (100 kgf, 221 lbf)
Plate
NOTICE:

Check the diameter of the hand press ram. Then cal-
P25602 culate the gauge pressure of the press when
981 N (100 kgf, 221 lbf) of force is applied.
Gauge pressure:
100 kgf
(kgf/cm2) = 2
Ram diameter (cm)
x 3.14 (π)
2
221lbf
(psi) = 2
Ram diameter (in.)
x 3.14 (π)
2
(kPa) = (kgf/cm2) x 98.1
(kPa) = (psi) x 6.9

If the contact plate is not pressed down with the spe-

cified pressure, the contact plate may tilt due to coil
deformation or the tightening of the nut.

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1437

ST–14
STARTING (5VZ–FE) – STARTER

(2) Using SST, tighten the nuts to the specified torque.

SST 09810–38140
SST
Torque: 17 N·m (170 kgf·cm, 13 ft·lbf)
NOTICE:
If the nut is over tightened, it may cause cracks on the in-
side of the insulator.
(h) Clean the contact surfaces of the remaining contact plate
and plunger with a dry shop rag.
P25601 (i) Reinstall the plunger, new gasket, end cover and lead
clamp (1.8 kW type) with the 3 bolts.
Torque:
1.2 kW, 1.4 kW type: 2.5 N·m (25 kgf·cm, 22 in.·lbf)
1.8 kW type: 3.6 N·m (35 kgf·cm, 30 in.·lbf)

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2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1438

 ST–15
STARTING (5VZ–FE) – STARTER
ST03B–04

REASSEMBLY
Reassembly is in the reverse order of disassembly (See page ST–5).
HINT:
At the time of assembly,use high–temperature grease to lubricate the bearings, gears, return spring and
steel ball when assembling the starter.

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2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1439

ST–16
STARTING (5VZ–FE) – STARTER
ST03C–04

TEST
NOTICE:
These tests must be done within 3 to 5 seconds to avoid
burning out the coil.
1. DO PULL–IN TEST
(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Terminal C
Check that the clutch pinion gear moves outward.
Battery Terminal 50 P20438

Terminal C 2. DO HOLD–IN TEST

With battery connected as above with the clutch pinion gear
out, disconnect the negative (–) lead from terminal C. Check
that the pinion gear remains out.

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Battery Disconnect P20449

3. INSPECT CLUTCH PINION GEAR RETURN

Disconnect the negative (–) lead from the switch body.
Disconnect Check that the clutch pinion gear returns inward.

Battery P20448

Terminal 30
4. DO NO–LOAD PERFORMANCE TEST
(a) Connect the battery and ammeter to the starter as shown.
(b) Check that the starter rotates smoothly and steadily with
the pinion gear moving out. Check that the ammeter
reads the specified current.
Specified current:
1.2 kW, 1.4 kW type 90 A or less at 11.5 V
1.8 kW type 100 A or less at 11.5 V
Battery Ammeter Terminal 50
P20447

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1440

 ST–17
STARTING (5VZ–FE) – STARTER
ST0GJ–02

INSTALLATION
INSTALL STARTER
(a) Install the starter with the 2 bolts.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Connect the starter wire with the nut.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
(c) Connect the starter connector.

P20440

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2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1441

ST–18
STARTING (5VZ–FE) – STARTER RELAY

Starter
STARTER RELAY ST08J–06

Relay INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE STARTER RELAY (Marking: ST)

B16377

3. INSPECT STARTER RELAY

Ohmmeter Ohmmeter
(a) Inspect the relay continuity.
2
1 (1) Using an ohmmeter, check that there is continuity
between terminals 1 and 2.
5 If there is no continuity, replace the relay.
(2) Check that there is no continuity between terminals
3 and 5.
3

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If there is continuity, replace the relay.
Continuity No Continuity B16388

(b) Inspect the relay operation.

Ohmmeter
(1) Apply battery voltage across terminals 1 and 2.
2
1 (2) Using an ohmmeter, check that there is continuity
between terminals 3 and 5.
5 If there is no continuity, replace the relay.
4. REINSTALL RELAY BOX COVER
5. REINSTALL STARTER RELAY
3
Battery Continuity
B16389

2003 TOYOTA TUNDRA (RM956U)

Author: Date: 1442