Part 2

INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

PRECAUTION (Continued)

3. ELECTRONIC CONTROL





(a) REMOVAL AND INSTALLATION OF BATTERY TERMINAL

NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

(1) Before performing electronic work, disconnect the cable from the negative (-) battery terminal to prevent component and wire damage caused by accidental short circuits.
(2) When disconnecting the cable, turn the ignition switch and headlight dimmer switch off and loosen the cable nut completely. Perform these operations without twisting or prying the cable. Then disconnect the cable.
(3) Clock settings, radio settings, audio system memory, DTCs and other data are erased when the cable is disconnected from the negative (-) battery terminal. Write down any necessary data before disconnecting the cable.





(b) HANDLING OF ELECTRONIC PARTS
(1) Do not open the cover or case of the ECU unless absolutely necessary. If the IC terminals are touched, the IC may be rendered inoperative by static electricity.
(2) Do not pull the wires when disconnecting electronic connectors. Pull the connector itself.
(3) Do not drop electronic components, such as sensors or relays. If they are dropped on a hard surface, they should be replaced.
(4) When cleaning the engine with steam, protect the electronic components, air filter and emission-related components from water.
(5) Never use an impact wrench to remove or install temperature switches or temperature sensors.
(6) When measuring the resistance between terminals of a wire connector, insert the tester probe carefully to prevent terminals from bending.

4. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
(a) PLACE FOR REMOVING AND INSTALLING FUEL SYSTEM PARTS
(1) Work in a location with good air ventilation that does not have welders, grinders, drills, electric motors, stoves, or any other ignition sources.
(2) Never work in a pit or near a pit as vaporized fuel will collect in those places.
(b) REMOVING AND INSTALLING FUEL SYSTEM PARTS
(1) Prepare a fire extinguisher before starting the operation.
(2) To prevent static electricity, install a ground wire to the fuel changer, vehicle and fuel tank, do not spray the surrounding area with water. Be careful when performing work in this area, as the work surface will become slippery. Do not clean up gasoline spills with water, as this may cause the gasoline to spread, and possibly create a fire hazard.
(3) Avoid using electric motors, working lights and other electric equipments that can cause sparks or high temperatures.
(4) Avoid using iron hammers as they may create sparks.
(5) Dispose of fuel-contaminated cloth separately using a fire resistant container.





5. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS
(a) If any metal particles enter inlet system parts, this may damage the engine.
(b) When removing and installing inlet system parts, cover the openings of the removed parts and engine openings. Use gummed tape or other suitable materials.
(c) When installing inlet system parts, check that no metal particles have entered the engine or the installed parts.





6. HANDLING OF HOSE CLAMPS
(a) Before removing the hose, check the clamp position so that it can be reinstalled in the same position.
(b) Replace any deformed or dented clamps with new ones.
(c) When reusing a hose, attach the clamp on the clamp track portion of the hose.
(d) For a spring type clamp, you may want to spread the tabs slightly after installation by pushing in the direction of the arrows as shown in the illustration.





7. FOR VEHICLES EQUIPPED WITH MOBILE COMMUNICATION SYSTEMS
(a) Install the antenna far away from the ECU and sensors of the vehicle electronic systems as possible.
(b) Install an antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle electronic systems. For details about ECU and sensors locations, refer to the section on the applicable components.
(c) Keep the antenna and feeder separate from other wirings as much as possible. This will prevent signals sent from the communication equipment from affecting vehicle equipment and vice-versa.
(d) Check that the antenna and feeder are correctly adjusted.
(e) Do not install any high-powered mobile communication system.





8. FOR VEHICLES EQUIPPED WITH VEHICLE STABILITY (VSC) SYSTEM
(a) NOTICES WHEN USING DRUM TESTER
(1) Before beginning testing, disable the VSC. To disable the VSC, turn the engine switch off and connect SST to terminals TS and CG of the DLC3.
SST: 09843-18040

NOTICE:
- Confirm that the VSC warning light blinks.
- VSC system will be reset when the engine is started.
- For safety, secure the vehicle with restraint chains while using a wheel dynamometer.

(b) NOTICES OF RELATED OPERATIONS TO VSC
(1) Do not carry out unnecessary installation and removal as it might affect the adjustment of VSC related parts.
(2) Be sure to follow the instructions for work preparation and final confirmation of proper operation of the VSC system.

9. WHEN SERVICING FULL-TIME 4WD VEHICLES

CAUTION: When servicing or disconnecting the 4WD ECU, be sure to disconnect all power by removing the 20A 4WD fuse or the negative battery terminal. Failure to disconnect power for the 4WD ECU before performing diagnostic procedures may cause the transfer case actuator to be activated, resulting in damage to the transfer case actuator.

(a) The Full-time 4WD 4RUNNER is equipped with the mechanical lock type center differential system.




During tests that require the use of a brake tester or chassis dynamometer, such as braking force tests or speedometer tests, if only the front or rear wheels are to be rotated, it is necessary to set the position of the center differential to FREE or LOCK depending on the type of the test being performed.





Center differential FREE condition:





Center differential LOCK condition:





NOTE:
Center differential LOCK > FREE selecting procedures:
- Operate the switch only when all 4 wheels are stopped or driving in a straight line.
- Never operate the switch when any wheel is slipping.
- Never operate the switch when any wheel is spinning freely.
- Never operate the switch when swerving or cornering.




(1) Refer to HINT below.

HINT:
- Center differential LOCK > FREE selecting procedures:
Move the vehicle forward or backward slightly if the indicator light does not operate correctly when the center differential lock switch is turned ON or OFF. - 4WD switch H4 > L4 position switching procedures:
When switching, always put the shift lever of the transmission in N position. In other positions, the transfer gear cannot be changed.

10. WHEN TESTING BRAKES, SPEEDOMETER, ETC.
(a) When carrying out any kind of servicing or testing on a Full-time 4WD 4RUNNER in which the front or rear wheels are to be rotated (braking test, speedometer test), be sure to observe the precautions listed below.




Incorrect preparations or test procedures may cause damage as well as unsuccessful test results.
Before starting any such servicing or test, be sure to check the following items:
- Center differential mode position (FREE or LOCK)
- Vehicle Stability Control (VSC) system:





If the vehicle is equipped with this system, the slip indicator light, the VSC/TRAC warning light and the VSC OFF indicator light come on with the ignition switch turned ON. They will go off in a few seconds.
- Whether wheels should be touching the ground or jacked up
- Transmission gear position (N position)
- 4WD switch position (H4 or L4 position)
- Maximum testing vehicle speed
- Maximum testing time





(b) Using Braking Tester:
Test by low-speed type brake tester (Vehicle Speed: Below 0.5 km/h or 0.3 mph) and observe the following instructions before the test.
(1) Position the wheels to be tested (front or rear) on the tester.
(2) Put the center differential in FREE position.
(3) Deactivate the Vehicle Stability Control (VSC) system.
(4) Shift the transmission shift lever to N position.

HINT: Do not forget to change the Vehicle Stability Control (VSC) & Traction Control (TRAC) system to operational condition after the test. Check that the VSC/TRAC warning indicator light goes off when restarting the engine.





(c) Using Speedometer Tester:
Observe the following instructions and then test with the rear wheels.
(1) Position the rear wheels on the tester roller.
(2) Position the front wheels on the free roller or jack them up.
(3) Put the center differential in FREE position.
(4) Deactivate the Vehicle Stability Control (VSC) & Traction Control (TRAC) system.
(5) Ensure that the vehicle does not move using chains.

NOTE: The maximum speed should be less than 60 km/h (37 mph) and maximum driving time should be 1 minute.

HINT:
- Do not suddenly shift gears, brake, accelerate or decelerate.
- Do not forget to reactivate the Vehicle Stability Control (VSC) & Traction Control (TRAC) system. Check that the VSC warning light goes off when restarting the engine.





(d) Using Chassis Dynamometer:
Observe the following instructions and then test with the rear wheels.
(1) Remove the front propeller shaft.
(2) Put the center differential in LOCK position.
(3) Deactivate the Vehicle Stability Control (VSC) & Traction Control (TRAC) system.
(4) Make sure that the vehicle is securely fixed.

HINT:
- Do not suddenly shift gears, brakes, accelerate or decelerate.
- Do not forget to reactivate the Vehicle Stability Control (VSC) & Traction Control (TRAC) system. Check that the VSC warning indicator light goes off when restarting the engine.





(e) On-Vehicle Wheel Balancing:
When doing on-vehicle wheel balancing on a full-time 4WD vehicle, to prevent each wheel from being rotated at different speed in different directions (which could damage the center differential), always be sure to observe the following precautions.
(1) All 4 wheels should be jacked up, so they do not touch the ground at all.
(2) Put the center differential in LOCK position.
(3) Deactivate the Vehicle Stability Control (VSC) & Traction Control (TRAC) system.
(4) Fully release the parking brake lever.
(5) None of the brakes should be applied.
(6) Drive the wheels on the wheel balancer with the engine running.
(7) Carry out the wheel balancing with the transmission position in D position.

HINT:
- When balancing, pay attention to the other wheels rotating at the same time.
- Do not suddenly shift gears, brake, accelerate or decelerate.
- Do not forget to reactivate the Vehicle Stability Control (VSC) & Traction Control (TRAC) system to operational condition after the test. Check that the VSC warning indicator light goes off when restarting the engine.

11. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER

CAUTION: If a large amount of unburned gasoline or gasoline vapors flow into the converter, it may cause over heating and create a fire hazard. To prevent this, observe the following precautions.

(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.
Avoid idling the engine for more than 20 minutes.
(c) Avoid a spark jump test.
(1) Perform a spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
(2) While testing, never race the engine.
(d) Avoid a prolonged engine compression measurement.
Engine compression measurements must be performed as rapidly as possible.
(e) Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter.
12. WHEN TOWING FULL-TIME 4WD VEHICLES
- Use one of the methods shown below to tow the vehicle.
- If the vehicle has trouble with the chassis or drive train, use method 1 (flat bed truck).





NOTE: Do not use any towing method other than those shown above.

- The towing methods shown below are dangerous and can damage the vehicle, so do not use them.





13. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER

CAUTION: If a large amount of unburned gasoline or gasoline vapors flow into the converter, it may cause overheating and create a fire hazard. To prevent this, observe the following precautions.

(a) Use only unleaded gasoline.
(b) Avoid idling the engine for more than 20 minutes.
(c) Avoid performing unnecessary spark jump tests.
(1) Perform a spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
(2) While testing, never race the engine.
(d) Avoid a prolonged engine compression measurement. Engine compression measurements must be performed as rapidly as possible.
(e) Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter.