TOYOTA SEQUOIA 2001 Service Repair Manual

P10588
Ohmmeter
Continuity
P00299
OhmmeterContinuity
S02267
Ohmmeter(B)
(A)
Z00037
ST0019
± STARTINGSTARTER
ST±9
2883 Author: Date:
2005 SEQUOIA (RM1146U)
7. INSPECT FIELD COIL FOR OPEN CIRCUIT
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.
8. INSPECT SHUNT COIL FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
field coil end and field frame.
If there is no continuity, repair or replace the field frame.
9. INSPECT SHUNT COIL FOR OPEN CIRCUIT
Using an ohmmeter, measure the resistance between shunt
coil terminals (A) and (B).
Resistance: 1.5 to 1.9 W at 20 °C (68 °F)
If the resistance is not as specified, replace the field frame.
10. INSPECT BRUSH LENGTH
Using vernier calipers, measure the brush length.
Standard length: 15.0 mm (0.591 in. )
Minimum length: 9.0 mm (0.354 in. )
If the length is less than minimum, replace the brush holder and
field frame.
11. INSPECT BRUSH SPRING LOAD
Using a pull scale, measure the spring load by pulling the spring
from the brush until they are separated.
Standard spring installed load: 21.5 to 27.5 N ( 2.2 to
2.8 kgf, 4.8 to 6.2 lbf )
Minimum installed load: 12.7 N (1.3 kgf, 2.9 lbf )
If the installed load is less than minimum, replace the brush
springs.

P21088
Ohmmeter
No Continuity
P10821
Free
Lock
B12319
Terminal CTerminal 50
ContinuityOhmmeter
B12320ContinuityOhmmeter
Terminal 50
ST±10
± STARTINGSTARTER
2884 Author: Date:
2005 SEQUOIA (RM1146U)
12. INSPECT BRUSH HOLDER INSULATION
Using an ohmmeter, check that there is no continuity between
the positive (+) and negative (±) brush holders.
If there is continuity, repair or replace the brush holder.
13. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idle gear and the clutch
assembly for wear or damage.
If any damage is found, replace the gear or clutch assembly,
and also check the drive plate ring gear for wear or damage.
14. INSPECT CLUTCH PINION GEAR
Rotate the pinion gear clockwise, and check that it turns freely.
Check that it locks by rotating the pinion gear counterclockwise.
If necessary, replace the clutch assembly.
15. INSPECT FRONT AND REAR BEARING
Turn the bearing by hand as applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
16. DO PULL±IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minals 50 and C.
If there is no continuity, replace the magnetic switch.
17. DO HOLDING COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minal 50 and the switch body.
If there is no continuity, replace the magnetic switch.

ST092±07
S00058
SST
S00059
S00060
SST
S00061
SST Upward
Downward
B12321
± STARTINGSTARTER
ST±11
2885 Author: Date:
2005 SEQUOIA (RM1146U)
REPLACEMENT
1. REPLACE REAR BEARING
(a) Using SST, remove the bearing.
SST 09286±46011
(b) Using a press, press in a new bearing.
2. REPLACE FRONT BEARING
(a) Using SST, remove the bearing.
SST 09286±46011
(b) Using SST and a press, press in a new bearing.
NOTICE:
Be careful of the bearing installation direction.
SST 09820±00031
3. REPLACE MAGNETIC SWITCH TERMINAL KIT
PARTS
(a) Remove the magnetic switch end cover.
Remove the 3 nuts, the end cover, the gasket and the
plunger.
NOTICE:
Do not loosen the 3 stud bolts.

B12322
Wear
B12323
SST
B12324
(2)
(1)(3)
(5)
(4)
B12325
(2)
(3) (4) (5)(1)
ST±12
± STARTINGSTARTER
2886 Author: Date:
2005 SEQUOIA (RM1146U)
(b) Inspect 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.
(c) Remove terminal kit parts.
(1) Put a wooden block on the plate, and press it down
with a hand press.
Dimensions of wooden block:
20 X 33 X 40 mm (0.79 X 1.30 X 1.57 in.)
(2) Using SST, loosen the terminal nuts.
SST 09810±38140
(3) Terminal C:
Remove the terminal nut, wave washer, terminal in-
sulator (outside), O±ring, terminal bolt, contact
plate and terminal insulator (inside).
(4) Terminal 30:
Remove the terminal nut, wave washer, terminal in-
sulator (outside), O±ring, terminal bolt, contact
plate, terminal insulator (inside) and insulation pa-
per.
(d) Temporarily install these new terminal 30 kit parts:
(1) Contact plate
(2) Terminal bolt
(3) O±ring
(4) Wave washer
(5) Terminal nut
(e) Temporarily install these new terminal C kit parts:
(1) Contact plate
(2) Terminal bolt
(3) O±ring
(4) Wave washer
(5) Terminal nut
(f) Temporarily tighten the terminal nuts.

B12323
33 mm20 mm
Contact
Plate
40 mm
(kgf/cm2)
(psi)
(kPa) = (psi) x 6.9100 kgf
2 Ram diameter (cm)
(kPa) = (kgf/cm
2) x 98.1 ==
x 3.14 (p)
2
221lbf
2 Ram diameter (in.)
x 3.14 (p)
2
B13044
SST
B12326
± STARTINGSTARTER
ST±13
2887 Author: Date:
2005 SEQUOIA (RM1146U)
(g) Tighten terminal nuts.
(1) Put a wooden block on the contact plate and press
it down with a hand press.
Dimensions of wooden block:
20 x 33 x 40 mm (0.79 x 1.30 x 1.57 in.)
Press force:
981 N (100 kgf, 221 lbf)
NOTICE:

Check the diameter of the hand press ram. Then cal-
culate the gauge pressure of the press when
981 N (100 kgf, 221 lbf) of force is applied.
Gauge pressure:

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.
(2) Using SST, tighten the nuts to the specified torque.
SST 09810±38140
Torque: 17 N´m (170 kgf´cm, 13 ft´lbf)
NOTICE:
If the nut is over tightened, it may cause cracks on the plas-
tic frame.
(h) Clean contact surfaces of the contact plate and the plung-
er.
Clean the contact surfaces of the remaining contact plate
and plunger with a dry shop rag.
(i) Reinstall the magnetic switch end cover.
Install the plunger, the new gasket and the end cover with
the 3 nuts.
Torque: 3.6 N´m (37 kgf´cm, 32 in.´lbf)

ST093±03
ST±14
± STARTINGSTARTER
2888 Author: Date:
2005 SEQUOIA (RM1146U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page ST±6).
HINT:
At the time of assembly, use high±temperature grease to lubricate the bearing and gears when assembling
the starter.

ST094±06
B02289
Terminal 50
Battery Terminal C
B02290
Battery Terminal CDisconnect
B02291
Disconnect
Battery
B02292
Terminal 30
Battery Ammeter Terminal 50
± STARTINGSTARTER
ST±15
2889 Author: Date:
2005 SEQUOIA (RM1146U)
TEST
NOTICE:
These tests must be done within 3 to 5 seconds to avoid the
coil to be burned ± out.
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.
Check that the pinion gear moves outward.
2. DO HOLDING TEST
While connected as above with the pinion gear out, disconnect
the negative (±) lead from terminal C. Check that the pinion gear
remains out.
3. INSPECT CLUTCH PINION GEAR RETURN
Disconnect the negative (±) lead from the starter body. Check
that the pinion gear returns inward.
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
shows the specified current.
Specified current:
At 11.5 V: 100 A or less

ST095±06
B04549
Starter
Connector
Engine Wire Protector
B04548
ST±16
± STARTINGSTARTER
2890 Author: Date:
2005 SEQUOIA (RM1146U)
INSTALLATION
1. INSTALL STARTER
(a) Install the engine wire protector to the starter with the bolt.
Torque: 9.81 N´m (100 kgf´cm, 84 in.´lbf)
(b) Connect the starter wire with the nut.
Torque: 9.81 N´m (100 kgf´cm, 84 in.´lbf)
(c) Connect the starter connector.
(d) Connect the starter to the cylinder block.
(e) Connect the engine wire with the bolt.
(f) Install the starter with the 2 bolts.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
2. INSTALL AIR PUMP ASSEMBLY (See page EC±26)
3. INSTALL INTAKE MANIFOLD ASSEMBLY
(See page EM±60)
4. CONNECT THROTTLE BODY ASSEMBLY TO INTAKE
MANIFOLD (See page SF±43)
5. INSTALL INTAKE AIR CONNECTOR
6. INSTALL THROTTLE BODY COVER
7. CONNECT CABLE TO NEGATIVE (±) BATTERY TER-
MINAL
8. PERFORM INITIALIZATION (See page IN±20)
Some system need initialzation when disconnecting the cable
from the battery terminal.

ST0PJ±01
A00968
Continuity
No continuity12
5
3 OhmmeterOhmmeter
A00969
Ohmmeter
Battery 1
2
5
3
Continuity
± STARTINGSTARTER RELAY
ST±17
2891 Author: Date:
2005 SEQUOIA (RM1146U)
STARTER RELAY
INSPECTION
1. REMOVE STARTER RELAY
Remove the relay box cover and starter relay.
2. INSPECT STARTER RELAY CONTINUITY
(a) Using an ohmmeter, check that there is continuity be-
tween terminals 1 and 2.
If there is no continuity, replace the relay.
(b) Check that there is no continuity between terminals 3 and
5.
If there is continuity, replace the relay.
3. INSPECT STARTER RELAY OPERATION
(a) Apply battery positive voltage across terminals 1 and 2.
(b) Using an ohmmeter, check that there is continuity be-
tween terminals 3 and 5.
If there is no continuity, replace the relay.
4. REINSTALL STARTER RELAY

ST0OT±02
S04972ContinuityNo continuity 12
5
3 Ohmmeter
Ohmmeter Continuity
4
S04971
OhmmeterBattery12
5
3
ContinuityOhmmeter
No Continuity4 ST±18
± STARTINGACC CUT RELAY
2892 Author: Date:
2005 SEQUOIA (RM1146U)
ACC CUT RELAY
INSPECTION
1. REMOVE ACC CUT RELAY
Remove the cowl side trim board LH and ACC cut relay.
2. INSPECT ACC CUT RELAY CONTINUITY
(a) Using an ohmmeter, check that there is continuity be-
tween terminals 1 and 2.
If there is no continuity, replace the relay.
(b) Check that there is no continuity between terminals 3 and
5.
If there is continuity, replace the relay.
(c) Check that there is continuity between terminals 3 and 4.
If there is no continuity, replace the relay.
3. INSPECT ACC CUT RELAY OPERATION
(a) Apply battery positive voltage across terminals 1 and 2.
(b) Using an ohmmeter, check that there is no continuity be-
tween terminals 3 and 4.
If there is continuity, replace the relay.
(c) Using an ohmmeter, check that there is continuity be-
tween terminals 3 and 5.
If there is no continuity, replace the relay.
4. REINSTALL ACC CUT RELAY