Part 2

INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

PRECAUTION

Part 2 of 2

3. ELECTRONIC CONTROL





(a) REMOVAL AND INSTALLATION OF BATTERY TERMINAL
NOTE: Certain systems need to be initialized after reconnecting the cable to 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, and 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 adhesive tape or other suitable materials.
(c) When installing inlet system parts, check that no metal particles have entered the engine or 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 sensor 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. WHEN SERVICING FULL-TIME 4WD VEHICLES
(a) MEASURING POINTS FOR SPEEDOMETER TESTER
NOTICE:
- Tester with a function of load setting for only two wheels cannot be used.
- Inspection should be done in the front wheels.
- Do not start, accelerate nor decelerate the vehicle suddenly.
- Maximum vehicle speed must be below 60 km/h (37 mph) (when using free roller, it must be below 50 km/h (31 mph)).
- Driving time should be within 1 minute.




(1) Place the front wheels onto the rollers.
(2) Set the rear wheels free by free rollers or rigid racks.
(3) Fasten the vehicle with the lock chain.
(4) Enter inspection mode to disable TRAC and VSC control.
(5) Start the engine, and then measure the vehicle speed by increasing the speed gradually in the D range.
(6) After the measurement completion, decrease the vehicle speed by braking gradually, and then stop the vehicle.
(b) MEASURING POINTS FOR BRAKE TESTER
NOTICE:
- Tester with a function of load measurement cannot be used.
- High-speed braking cannot be performed.
(1) Place the wheels to be measured (front or rear) onto the rollers.
(2) Enter inspection mode to disable TRAC and VSC control.
(3) Shift the lever into neutral.
(4) Perform the measurement by driving the tester rollers.
(c) MEASURING POINTS FOR ON-VEHICLE BALANCER
(1) Jack up all 4 wheels with 2 post lifts.
(2) Fasten the vehicle by setting 2 pick-up stands in the bottom of suspension arm's tip of the front wheels or rear wheels to be measured.
(3) Support the vehicle with rigid racks so that vehicle will not lean in any direction.
(4) Release the parking brake.
(5) Check that there is no dragging force exists when turning each wheel by hand.
(6) Set the wheel balancers.
(7) Measurement should be done by using both of engine drive and wheel balancer roller drive.
NOTICE:
- Start the engine, and then increase the vehicle speed gradually in the D range.
- Do not accelerate nor decelerate suddenly.
- Deceleration should be done by braking gradually.
- Take special care that the vehicle does not move.
- Measurement should be done quickly.

9. FOR VEHICLES EQUIPPED WITH TRACTION CONTROL (TRAC) AND VEHICLE STABILITY CONTROL (VSC) SYSTEMS
When testing with a 2-wheel drum tester such as a speedometer tester, a combination tester for the speedometer and brake, a chassis dynamometer, or when jacking up the front wheels and turning the wheels, perform the following procedure to enter the inspection mode and stop the TRAC and VSC systems.
Enter inspection mode to disable TRAC and VSC control when using a chassis dynamometer.
HINT:
- The vehicle may move unexpectedly out of the dynamometer because of TRAC and VSC operations.
- Pressing the VSC OFF switch does not disable TRAC and VSC operation completely.
NOTICE:
- Make sure that the SLIP indicator light is blinking.
- Secure the vehicle with the lock chain for safety.

(a) Activating inspection mode (Not using Techstream)
HINT:
- Perform steps "D" to "H" within 30 seconds.
- Perform steps "F" and "G" within 15 seconds each.
(1) Ensure that the ignition switch is off and the engine is stopped (Step "A").
(2) Make sure that the shift lever is in the P position (Step "B").
(3) Start the engine (Step "C").
(4) Apply the parking brake by pulling the parking brake lever (Step "D").
(5) Depress and release the brake pedal twice (Step "E").
(6) While holding the brake pedal down, release and apply the parking brake twice (Step "F").
(7) With the parking brake applied, depress and release the brake pedal twice (Step "G").




(8) Check if the SLIP indicator light comes on (Step "H").

HINT :
- If the SLIP indicator light does not come on in step "H", repeat the steps from "A" to "H".
- Turning the ignition switch off ends inspection mode.

(b) Activating inspection mode (Using Techstream)
(1) Ensure that the ignition switch is off and the engine is stopped (Step "A").
(2) Make sure that the shift lever is in the P position (Step "B").
(3) Connect Techstream to the DLC3 (Step "C").
(4) Start the engine (Step "D").
(5) Turn the Techstream main switch on (Step "E").
(6) Select the following menu items: ABS/INSPECTION MODE (Step "F").




(7) Check that the SLIP indicator light come on (Step "G").

HINT :
- If the SLIP indicator light does not come on in step "G", repeat the steps from "A" to "G".
- Turning the ignition switch off ends inspection mode.

10. WHEN TOWING FULL-TIME 4WD VEHICLES
(a) Use one of the following methods to tow the vehicle.
(b) 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.

(c) The following towing methods shown are dangerous and can damage the vehicle, so do not use them.





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 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.
12. EXPRESSIONS OF IGNITION SWITCH
(a) The type of ignition switch used on this model differs according to the specifications of the vehicle.
The expressions listed in the following table.






13. INSPECTION AND ADJUSTMENT OF JOINT ANGLE DURING REMOVAL AND INSTALLATION OF PROPELLER SHAFT (4WD)
(a) When performing operations which involve the removal and installation of the propeller shaft, always check the joint angle. Make adjustments if necessary Installation.