Part 2
INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION - Continued
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.
(3) Avoid using electric motors, working lights and other electric equipment that can cause sparks or high temperatures.
(4) Avoid using iron hammers as they may create sparks.
(5) Dispose of fuel-contaminated cloths separately using a fire resistant container.
5. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS
(a) If any metal particles enter inlet system parts, they 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
Text in Illustration
(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 as far away from the ECU and sensors of the vehicle electronic systems as possible.
(b) Install the 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 of the applicable components.
(c) Keep the antenna and feeder separate from other wiring as much as possible. This will prevent signals 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 a high-powered mobile communication system.
8. WHEN INSPECTING HEADLIGHT
(a) When the headlights are illuminated, do not cover the headlights for 3 minutes or more.
Text in Illustration
NOTICE:
* When the headlight dimmer switch assembly is set to HEAD, do not touch the high-voltage socket area of the discharge headlight.
* As the outer lens of the headlight is made of resin, the resulting heat created when covering the headlight for an extended period of time may deform the headlight.
9. FOR VEHICLES EQUIPPED WITH AIR SUSPENSION SYSTEM
(a) Be sure to turn the height control OFF switch on to switch the height control system off and cancel the auto leveling function when:
* Jacking up the vehicle.
* A trailer etc. is attached to the vehicle.
(b) When replacing the suspension control ECU, be sure to replace it with a new one. If the suspension control ECU is replaced with a normally functioning one from another vehicle, the vehicle identification information will not match, which may cause the air suspension system to stop operating or have undesirable effects on other systems.
10. 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 speedometer and brake tester, or a chassis dynamometer, or when jacking up the front wheels and turning the wheels, perform the following procedure to enter inspection mode and disable the TRAC and VSC systems.
HINT
* The vehicle may slip unexpectedly out of the dynamometer because of TRAC and VSC operation.
* Pressing the VSC OFF switch (for vehicles with a VSC OFF switch) does not disable TRAC and VSC operation completely.
NOTICE:
* Make sure that the VSC warning light is blinking.
* Secure the vehicle with chains for safety.
(a) Activating Inspection Mode (When Using the Techstream)
(1) Ensure that the engine switch is off and the engine is stopped.
(2) Make sure that the shift lever is in P.
(3) Connect the Techstream to the DLC3.
(4) Start the engine.
(5) Turn the Techstream on.
(6) Enter the following menus: Chassis / ABS/VSC/TRAC / Utility / Inspection Mode.
(7) Check that the slip indicator light will come on.
HINT
* If the slip indicator light does not come on, repeat the steps.
* Turning the engine switch off ends Inspection Mode.
(b) Activating Inspection Mode (When not Using the Techstream)
HINT
Perform steps "C" to "H" within 30 seconds.
(1) Ensure that the engine switch is off and the engine is stopped (Step "A").
(2) Make sure that the shift lever is in P (Step "B").
(3) Start the engine (Step "C").
(4) Apply the parking brake by depressing the parking brake pedal (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 will come on (Step "H").
HINT
* If the slip indicator light does not come on in step "H", repeat steps "A" to "H".
* Turning the engine switch off ends Inspection Mode.
11. WHEN SERVICING FULL-TIME 4WD VEHICLES
(a) WHEN USING A SPEEDOMETER TESTER
NOTICE:
* Inspection should be done using the front wheels.
* Do not brake or accelerate suddenly.
* Maximum vehicle speed must be less than 60 km/h (37 mph) (when using free rollers to support the rear wheels, vehicle speed must be less than 50 km/h (31 mph)).
* Driving time should be less than 1 minute.
* Follow all usage and safety procedures in the operator's manual for the speedometer tester.
(1) Place the front wheels onto the rollers.
(2) Enter inspection mode to disable TRAC and VSC control.
(3) Place the rear wheels on free rollers or use safety stands to allow the rear wheels to rotate freely.
(4) Secure the vehicle with suitable chains or straps.
(5) Start the engine, and then measure the vehicle speed while increasing the speed gradually with the shift lever in D.
(6) After the test is finished, decrease the speed gradually, and then stop the vehicle.
(b) WHEN USING A BRAKE TESTER
NOTICE:
* A high-speed type brake tester cannot be used.
* Vehicle speed should be less than 0.5 km/h (0.3 mph).
* Follow all usage and safety procedures in the operator's manual for the brake tester.
(1) Place the wheels to be tested (front or rear) onto the rollers.
(2) Move the shift lever to N.
(3) Start the engine to allow normal brake booster operation.
(4) Operate the brakes to perform the test.
(c) WHEN USING A CHASSIS DYNAMOMETER
(1) Enter inspection mode to disable TRAC and VSC control.
(2) Follow the instructions shown in the illustration.
NOTICE:
* Do not brake or accelerate suddenly.
* Confirm that the vehicle is securely immobilized.
* Follow all usage and safety procedures in the operator's manual for the chassis dynamometer.
* Be sure to follow the instructions specified in the illustration. Failure to do so may cause deterioration of 4WD system function, malfunction of drivetrain components and risk of the vehicle jumping off the dynamometer.
Text in Illustration
(d) WHEN USING AN ON-VEHICLE BALANCER
(1) Raise the vehicle until all 4 wheels are off the ground.
(2) Support the vehicle with safety stands at an appropriate height. Make sure that vehicle does not lean in any direction, and that the tires are completely clear of the floor.
(3) Place the vibration pick-up unit into position for the wheel to be measured*1.
(4) Release the parking brake.
(5) Check that no dragging force exists when turning each wheel by hand.
(6) Put the wheel balancer in position.
(7) Wheel balance measurement should be done by using both the engine and the wheel balancer drive roller to spin the wheels.
HINT
*1: Different on-vehicle wheel balancers have different requirements for mounting the vibration pick-up unit(s). Refer to the operator's manual for the wheel balancer to confirm requirements for use.
NOTICE:
* Start the engine and then increase the vehicle speed gradually with the shift lever in D.
* Do not accelerate or decelerate suddenly.
* Deceleration should be done by braking gradually.
* Make sure that no one is standing in-line with the spinning wheels.
* Measurement should be done quickly.
* Confirm that the vehicle is securely immobilized.
* Follow all usage and safety procedures in the operator's manual for the wheel balancer.
12. PRECAUTIONS FOR TOWING ALL WHEEL DRIVE VEHICLES
(a) Use one of the following methods to tow the vehicle.
(b) If the vehicle has trouble with the chassis or drivetrain, use method 1 (flatbed truck).
NOTICE:
Do not use any towing method other than those shown above.
(c) If a tow truck is not available, in an emergency the vehicle may be temporarily towed using a cable or chain secured to the emergency towing eyelet(s).
This should only be attempted on hard surfaced roads for distances of less than 80 km, and at speeds below 30km/h (19 mph).
A driver must be in the vehicle to steer and operate the brakes. The vehicle's wheels, drivetrain, axles, steering and brakes must be in good condition.
NOTICE:
If the towing speed or distance exceeds the above limits, or the vehicle is towed in a backward direction with any of the wheels on the ground, the drivetrain may be damaged.
(1) Emergency towing procedure
1 Turn the engine switch to ON.
2 Depress the brake pedal and move the transmission shift lever to N.
3 Release the parking brake.
4 Release the brake pedal slowly.
NOTICE:
* Use extreme caution when towing the vehicle. Avoid sudden starts or erratic driving maneuvers which place excessive stress on the emergency towing eyelet and the cables or chains.
* Do not turn off the engine switch. Turning off the engine switch may result in engagement of the steering lock, resulting in a hazardous situation or accident.
(d) The towing methods shown below are dangerous and can damage the vehicle, so do not use them.
(1) Do not tow the vehicle with only 2 wheels on the ground.
NOTICE:
If the vehicle is towed with only the 2 wheels on the ground, the drivetrain may overheat and be damaged or the wheels may come off the dollies.
(2) Do not use a sling-type towing method either from the front or rear.
NOTICE:
If a sling-type tow truck is used, damage may occur to the vehicle body.
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 converter 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 tests.
(1) Perform a spark test only when absolutely necessary. Perform this test as rapidly as possible.
(2) While testing, never race the engine unless instructed.
(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.