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 off and the 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.
(3) Be careful not to 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 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 equipment 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, 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
(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 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 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. FOR VEHICLES EQUIPPED WITH TRACTION CONTROL (TRAC) SYSTEM
When testing with a 2-wheel drum tester such as a speedometer tester, a combination tester of the speedometer and brake, a chassis dynamometer, or when jacking up the front wheels and driving the wheels, always turn the TRAC system OFF.





(a) Confirm that the TRAC system is OFF.
(1) Ignition switch to OFF.
(2) Connect SST to terminals TS and CG of DLC3.
NOTE: Confirm that the VSC/TRAC warning light blinks.

(b) Begin testing.
(c) Disconnect SST from DLC3.





(d) Check that the VSC/TRAC warning light turns OFF.
HINT: The SLIP indicator light blinks when the TRAC system is operating.

9. FOR VEHICLES EQUIPPED WITH VEHICLE STABILITY CONTROL (VSC) SYSTEM
(a) NOTICES WHEN USING DRUM TESTER
(1) Before beginning testing, to disable the VSC, turn the ignition 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 restarted.
- 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.





10. WHEN SERVICING FULL-TIME 4WD VEHICLES
The Full-time 4WD FJ CRUISER is equipped with a mechanical lock type center differential system.
During tests using 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 test being performed.

11. WHEN TESTING BRAKES, SPEEDOMETER, ETC.





(a) When carrying out any kind of servicing or testing on a Full-time 4WD in which the front or rear wheels are to be rotated (braking test, speedometer test), be sure to observe the precautions given below.
Incorrect preparations or test procedures may cause danger 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 the system, the slip indicator light, the VSC / TRAC indicator light and the VSC OFF indicator light come on with the ignition switch turned to ON. They will go off after about a few seconds.
- Whether wheels should be touching ground or jacked up
- Transmission gear position (N position)
- Transfer gear position (H or L position)
- Maximum testing vehicle speed
- Maximum testing time





(b) Using Braking Tester:
Measure by low-speed type (Vehicle Speed: Below 0.5 km/h or 0.3 mph) brake tester and observe the following instructions before performing the test.
(1) Position the wheels to be tested (front or rear) on the tester.
(2) Put the center differential in the FREE position.
(3) If the vehicle is equipped with a Vehicle Stability Control (VSC) system, prohibit the system from activating (see previous step).
(4) Shift the transmission shift lever to the "N" position.
HINT: Do not forget to change the Vehicle Stability Control (VSC) & Traction Control (TRAC) system to an operational condition after the test. Check that the VSC 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 the FREE position.
(4) Deactivate the Vehicle Stability Control (VSC) & Traction Control (TRAC) system.
(5) Ensure that the vehicle does not move using chains.
HINT:
- Sudden shifting, braking, acceleration or deceleration is not allowed.
- Do not forget to change the Vehicle Stability Control (VSC) & Traction Control (TRAC) system to an operational condition after the test. Check that the VSC warning indicator light goes off when restarting the engine.





(d) Using Chassis Dynamometer:
Observe the following instructions and then measure with the rear wheels.
(1) Remove the front propeller shaft.
(2) Put the center differential in the LOCK position.
(3) Deactivate the Vehicle Stability Control (VSC) & Traction Control (TRAC) system.
(4) Ensure that the vehicle is securely fixed in place.
HINT:
- Sudden shifting, braking, acceleration or deceleration is not allowed.
- Do not forget to change the Vehicle Stability Control (VSC) & Traction Control (TRAC) system to an operational condition after the test. 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 a different speed and 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, lifted off of the ground completely.
(2) Put the center differential in the LOCK position.
(3) Deactivate the Vehicle Stability Control (VSC) & Traction Control (TRAC) system.
(4) The parking brake lever should be fully released.
(5) None of the brakes should be applied.
(6) The wheels should be driven on the wheel balancer with the engine running.
(7) Carry out the wheel balancing with the transmission in the D position.
HINT:
- When doing the wheel balancing, pay attention to the other wheels rotating at the same time.
- Sudden acceleration, deceleration or braking is not allowed.
- Do not forget to change the Vehicle Stability Control (VSC) & Traction Control (TRAC) system to an operational condition after the test. Check that the VSC warning indicator light goes off when restarting the engine.

12. WHEN TOWING FULL-TIME 4WD VEHICLES

- Use one of the methods shown below to tow the vehicle.
- If the vehicle has trouble in the chassis and drive train, use method 1 (flat bed truck).





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

- For example, the towing methods shown below are dangerous or may 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.