Page 2897 of 4323

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
Page 2898 of 4323
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.
Page 2899 of 4323
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
Page 2900 of 4323

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
Page 2901 of 4323

CH0K7±03
B07241
Upper Level
Lower Level
B07242
Except Maintenance±Free Battery
± CHARGINGCHARGING SYSTEM
CH±1
2893 Author: Date:
2005 SEQUOIA (RM1146U)
CHARGING SYSTEM
ON±VEHICLE INSPECTION
CAUTION:
Check that the battery cables are connected to the
correct terminals.
Disconnect the battery cables when the battery is giv-
en a quick charge.
Do not perform tests with a high voltage insulation re-
sistance tester.
Never disconnect the battery while the engine is run-
ning.
1. CHECK BATTERY ELECTROLYTE LEVEL
Check the electrolyte quantity of each cell.
If under the lower level, replace the battery (or add distilled wa-
ter if possible) and check the charging system.
2. Except Maintenance±Free Battery:
CHECK BATTERY SPECIFIC GRAVITY
Check the specific gravity of each cell.
Standard specific gravity:
1.25 to 1.29 at 20°C (68°F)
If the specific gravity is less than the specification, charge the
battery.
3. Maintenance±Free Battery:
CHECK BATTERY VOLTAGE
(a) In the case that 20 minutes have not passe4d after stop-
ping the engine, turn on the ignition switch and the electri-
cal system (headlight, blower motor, rear defogger, etc.)
for 60 seconds before removing the surface charge.
(b) Turn the ignition switch OFF and turn off the electrical sys-
tems.
Page 2902 of 4323

B07243
Voltmeter
Maintenance±Free Battery
P14937
Maintenance±Free Battery
GREEN EYE DARK EYECLEAR EYE or
CHARGED DISCHARGED ADD WATERLIGHT YELLOW
Z00030
B00807
CH±2
± CHARGINGCHARGING SYSTEM
2894 Author: Date:
2005 SEQUOIA (RM1146U)
(c) Measure the battery voltage between the negative (±)
and positive (+) terminals of the battery.
Standard voltage:
12.5 to 12.9 V at 20°C (68°F)
If the voltage is less than the specification, charge the battery.
HINT:
Check the indicator as shown in the illustration.
4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND
FUSES
(a) Check that the battery terminals are not loose or cor-
roded.
(b) Check the fusible link and fuses for continuity.
5. INSPECT DRIVE BELT
HINT:
Since the belt tensioner is used, checking the belt tension is not
necessary.
(a) Visually check the drive belt for excessive wear, frayed
cords etc.
If necessary, replace the drive belt.
HINT:
Cracks on the rib side of a drive belt are considered ac-
ceptable. If the drive belt has chunks missing from the
ribs, it should be replaced.
The drive belt tension can be released by turning the belt
tensioner counterclockwise. The pulley bolt for the belt
tensioner has a left±hand thread.
(b) Check the belt tensioner operation.
Check that the belt tensioner moves downward
when the drive belt is pressed down at the points in-
dicated in the illustration with approx. 98 N (10 kgf,
22.0 lbf) of force.
Check the alignment of the belt tensioner pulley to
make sure the drive belt does not slipped off the
pulley.
If necessary, replace the belt tensioner.
Page 2903 of 4323

B00808
B
A
AC2024
CORRECT WRONG
Z03473
Ammeter
Disconnect Wire
from Terminal B
Battery
VoltmeterB
Generator
± CHARGINGCHARGING SYSTEM
CH±3
2895 Author: Date:
2005 SEQUOIA (RM1146U)
Check that the arrow mark on the belt tensioner falls
within area A of the scale.
If it is outside area A, replace the drive belt.
HINT:
When a new belt is installed, it should lie within area B. If
not, the drive belt is not correct.
After installing a belt, check that it fits properly in the
ribbed grooves.
Check by hand to confirm that the belt does not slipped
out of the groove on the bottom of the pulley.
6. REMOVE ENGINE UNDER COVER NO.1
7. VISUALLY CHECK GENERATOR WIRING AND LIS-
TEN FOR ABNORMAL NOISES
(a) Check that the wiring is in good condition.
(b) Check that there is no abnormal noise from the generator
while the engine is running.
8. CHECK CHARGE WARNING LIGHT CIRCUIT
(a) Warm up the engine and then turn it off.
(b) Switch off all accessories.
(c) Turn the ignition switch ON, and check that the charge
warning light comes on.
(d) Start the engine, and check that the light goes off.
If the light does not go off as specified, troubleshoot the charge
light circuit.
9. INSPECT CHARGING CIRCUIT WITHOUT LOAD
HINT:
If a battery/generator tester is available, connect the tester to
the charging circuit as per manufacturer's instructions.
(a) If a tester is not available, connect a voltmeter and amme-
ter to the charging circuit as follows:
Disconnect the wire from terminal B of the genera-
tor, and connect it to the negative (±) tester probe
of the ammeter.
Connect the positive (+) tester probe of the amme-
ter to terminal B of the generator.
Connect the positive (+) tester probe of the voltme-
ter to terminal B of the generator.
Ground the negative (±) tester probe of the voltme-
ter.
(b) Check the charging circuit as follows:
With the engine running from idling to 2,000 rpm, check
the reading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage: 13.2 to 14.0 V
Page 2904 of 4323
CH±4
± CHARGINGCHARGING SYSTEM
2896 Author: Date:
2005 SEQUOIA (RM1146U)
If the voltmeter reading is more than the standard voltage, re-
place the voltage regulator.
If the voltmeter reading is less than the standard voltage, check
the voltage regulator and generator.
10. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn on the high
beam headlights and set the heater blower switch to HI.
(b) Check the reading on the ammeter.
Standard amperage: 30 A or more
If the ammeter reading is less than the standard amperage, re-
pair the generator.
HINT:
If the battery is fully charged, the indication will sometimes be
less than standard amperage.
11. REINSTALL ENGINE UNDER COVER