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INTRODUCTION
INTRODUCTION
IN2
INTRODUCTION How to Use This Manual
REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It
identifies the components and shows how the parts fit together.
Example:
IN3
INTRODUCTION How to Use This Manual
Example:
Task heading: what to do
Specification
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is stamped on the cowl
panel.
This number has also been stamped on the vehicle identifi-
cation number plate and certification regulation label.
A. Vehicle Identification Number
B. Vehicle Identification Number Plate
C. Certification Regulation Label
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is stamped on the cowl
panel.
This number has also been stamped on the vehicle identifi-
cation number plate and certification regulation label.
A. Vehicle Identification Number
B. Vehicle Identification Number Plate
C. Certification Regulation Label
6. Precoated parts
Precoated parts are bolts and nuts, etc. that are coated with a
seal lock adhesive at the factory.
(a) If a precoated part is retightened, loosened or caused to
move in any way, it must be recoated with the specified
adhesive.
(b) Recoating of precoated parts
(1) Clean off the old adhesive from the bolt, nut or threads.
(2) Dry with compressed air.
(3) Apply the specified sea! lock adhesive to the bolt or nut
threads.
(e) Precoated parts are indicated in the. component illustra-
tions by the symbol.
7. When necessary, use a sealer on gaskets to prevent leaks.
8. Carefully observe all specifications for bolt tightening torques. Al-
ways use a torque wrench.
9. Use of special service tools (SST) and special service materials
(SSM) may be required, depending on the nature of the repair.
Be sure to use SST and SSM where specified and follow the
proper work procedure. A list of SST and
SSM can be found at the back of this manual.
10. When replacing fuses, be sure the new fuse has the correct am-
perage rating. DO NOT exceed the rating or use one with a low-
er rating.
11. Care must be taken when jacking up and supporting the vehicle.
Be sure to lift and support the vehicle at the proper locations.
(See page IN27)
(a) If the vehicle is to be jacked up only at the front or rear end,
be sure to block the wheels at the apposite end in order
to ensure safety.
(b) After the vehicle is jacked up, be sure to support it on stands.
It is extremely dangerous to do any work on a vehicle
raised on a jack alone, even for a small job that can be fin-
ished quickly.
12. Observe the following precautions to avoid damage to the parts:
(a) Do not open the cover or case of the ECU unless abso-
lutely necessary. (If the IC terminals are touched, the
IC may be destroyed by static electricity.)
(b) When replacing the internal mechanism (computer
part) of the digital meter, be careful that no
part of your body or clothing comes in contact with the
terminals of the leads from the IC, etc. of the replace-
ment part (spare part).
(c) To disconnect vacuum hoses, pull on the end, not the middle
of the hose.
M To pull apart electrical connectors, pull on the connector
itself, not the wires.
(e) Be careful not to drop electrical components, such as sen-
sors or relays. If they are dropped on a hard floor, they
should be replaced and not reused.
IN6
INTRODUCTION General Repair Instructions
FREE Position
Center Differential
Wheel
Control Indicator
Switch Light
A lifted wheel can be rotated
even if only one wheel is lifted up,
OFF OFF as long as transmission is in
neutral.
LOCK Position
Center Differential
Indicator Wheel
Control
Light
Switch
A lifted wheel cannot be rotated if
only one wheel is lifted up, even if
transmission is in neutral.
6. START ENGINE
7. PUT TRANSMISSION IN 3RD OR 4TH GEAR AND
ENGAGE CLUTCH SLOWLY, THEN GRADUALLY
INCREASE SPEED TO TEST SPEED
2. AUTOMATIC TRANSAXLE
MODELS: (Hydraulic Multiplate
Clutch Control Type Center
Differential)
BEFORE BEGINNING TEST
During tests with a brake tester or chassis dynamometer,
such as braking force tests or speedometer tests, if only the
front or the rear wheels are to be rotated, it is necessary to
first set the center differential control switch to OFF (Hydrau-
lic multiplate clutch control is released), then set the Mode
Select Lever on the automatic transaxle to the FREE (Nor-
mal) Mode or to the LOCK
Mode depending on the type of test being performed.
(4) Depress the brake pedal, shift into L range and gradu-
ally release the brake pedal.
(5) Check that the front wheels begin to rotate and that the
rear wheels do not rotate.
5. CONFIRM MODE
FREE (Normal) Mode:
A lifted wheel can be rotated even if only one wheel is lifted
up, as long as transmission is in N range.
LOCK Mode:
A lifted wheel cannot be rotated if only one wheel is
lifted up, even if transmission is in N range.
FREE MODE
(1) Do not drive off suddenly or apply the accelerator or
brakes suddenly. Always start slowly and decelerate
gradually.
(2) If either the front or the rear wheels are placed on the
tester rollers in the FREE mode, be careful not to exceed
the following limits:
Maximum speed:
Speed indicated on speedometer
19 mph(30 km/h) or
Wheel speed (Tester speed)
38 mph160 km/h)
Maximum test time: 60 sec.
Note that the actual wheel speed (tester speedy is twice the
speed indicated by the speedometer due
to center differential operation.
LOCK MODE
(1) Do not drive off suddenly or apply the accelerator or
brakes suddenly. Always start slowly and decelerate
gradually.
(2) Be sure to conduct the test with the rear propeller
shaft removed.
IN18
INTRODUCTION Precautions When Servicing FullTime 4WD Vehicles
8. START ENGINE
9. PUT TRANSMISSION IN D RANGE, THEN
GRADUALLY INCREASE SPEED TO TEST SPEED
IN25
INTRODUCTION Precautions When Servicing FullTime 4WD Vehicles
Free or
Free
Lock
(Normal
Center
Driving)
Differential AUTO
P range No
Applied 1 st Gear Control Applied
or Special
Switch OFF Operation
ON or
Necessary
OFF
Free
Center
Differential
Released Neutral Control Release N range OFF
Switch
OFF
HINT: Do not use any towing methods other than those shown above.
For example, the towing method shown below is dangerous, so do not use it
During towing with this towing method, there is a danger of the drivetrain
heating up and causing breakdown, or of the front wheels flying off the dolly.
IN27
INTRODUCTION Vehicle Lift and Support Locations
JACK POSITION
Front . . . Center of engine mounting center member
Rear . . . . Jack up support of rear suspension member
PANTOGRAPH JACK POSITION
SUPPORT POSITION
Safety stand........................................................................
IN28
INTRODUCTION Abbreviations Used in This Manual