Page 2257 of 3066

GI-4
PRECAUTIONS
General Precautions
EAS000FQ
lDo not operate the engine for an extended period of time without
proper exhaust ventilation.
Keep the work area well ventilated and free of any inflammable
materials. Special care should be taken when handling any
inflammable or poisonous materials, such as gasoline, refriger-
ant gas, etc. When working in a pit or other enclosed area, be
sure to properly ventilate the area before working with hazard-
ous materials.
Do not smoke while working on the vehicle.
lBefore jacking up the vehicle, apply wheel chocks or other tire
blocks to the wheels to prevent the vehicle from moving. After
jacking up the vehicle, support the vehicle weight with safety
stands at the points designated for proper lifting before working
on the vehicle.
These operations should be done on a level surface.
lWhen removing a heavy component such as the engine or tran-
saxle/transmission, be careful not to lose your balance and drop
them. Also, do not allow them to strike adjacent parts, especially
the brake tubes and master cylinder.
lBefore starting repairs which do not require battery power:
Turn off ignition switch.
Disconnect the negative battery terminal.
lIf the battery terminals are disconnected, recorded memory of
radio and each control unit is erased.
lTo prevent serious burns:
Avoid contact with hot metal parts.
Do not remove the radiator cap when the engine is hot.
lDispose of drained oil or the solvent used for cleaning parts in
an appropriate manner.
lDo not attempt to top off the fuel tank after the fuel pump nozzle
shuts off automatically.
Continued refueling may cause fuel overflow, resulting in fuel
spray and possibly a fire.
lClean all disassembled parts in the designated liquid or solvent
prior to inspection or assembly.
lReplace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new
ones.
lReplace inner and outer races of tapered roller bearings and needle bearings as a set.
lArrange the disassembled parts in accordance with their assembled locations and sequence.
lDo not touch the terminals of electrical components which use microcomputers (such as ECM).
Static electricity may damage internal electronic components.
lAfter disconnecting vacuum or air hoses, attach a tag to indicate the proper connection.
SGI285
SGI231
SEF289H
SGI233
Page 2258 of 3066

PRECAUTIONS
GI-5
lUse only the fluids and lubricants specified in this manual.
lUse approved bonding agent, sealants or their equivalents when required.
lUse tools and recommended special tools where specified for safe and efficient service repairs.
lWhen repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks.
lBefore servicing the vehicle:
Protect fenders, upholstery and carpeting with appropriate cov-
ers.
Take caution that keys, buckles or buttons do not scratch paint.
WA RN ING:
To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness
connectors which are related to the engine control system and TCM (transmission control module)
system. The connectors should be disconnected only when working according to the WORK FLOW of
TROUBLE DIAGNOSES in EC and AT sections.
Precautions for All Mode 4´4 SystemEAS000GQ
Even if the 2WD mode is selected, the All mode 4´4 system occasionally changes from 2WD to 4WD auto-
matically depending on the driving conditions.
When spinning the front wheels by running the engine with the front wheels jacked up or mounted on the free
rollers / or a chassis dynamometer, be careful because the vehicle may suddenly move due to the driving
force from the rear wheels.
To avoid personal injury and vehicle damage, use one of the following methods when working with the front
wheels drive force and spinning freely.
lRemove the propeller shaft.
lUse free rollers / chassis dynamometer designed for 4WD vehicles.
Precautions for Three Way CatalystEAS000FR
If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To
prevent this, follow the instructions.
lUse unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst.
lWhen checking for ignition spark or measuring engine compression, make tests quickly and only when
necessary.
lDo not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to
the catalyst.
Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the three
way catalyst.
Precautions for FuelEAS000FS
Use unleaded gasoline with an octane rating of at least 95 (RON).
CAUTION:
Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Using a fuel
other than that specified could adversely affect the emission control devices and systems, and could
also affect the warranty coverage validity.
SGI234
Page 2259 of 3066

GI-6
PRECAUTIONS
Precautions for Multiport Fuel Injection System or Engine Control System
EAS000FT
lBefore connecting or disconnecting any harness connector for
the multiport fuel injection system or ECM:
Turn ignition switch to “OFF” position.
Disconnect negative battery terminal.
Otherwise, there may be damage to ECM.
lBefore disconnecting pressurized fuel line from fuel pump to
injectors, be sure to release fuel pressure.
lBe careful not to jar components such as ECM and mass air
flow sensor.
Precautions for Turbocharger (If Equipped)EAS000FU
The turbocharger turbine revolves at extremely high speeds and
becomes very hot. Therefore, it is essential to maintain a clean sup-
ply of oil flowing through the turbocharger and to follow all required
maintenance instructions and operating procedures.
lAlways use the recommended oil. Follow the instructions for
proper time to change the oil and proper oil level.
lAvoid accelerating engine to a high rpm immediately after start-
ing.
lIf engine had been operating at high rpm for an extended period
of time, let it idle for a few minutes prior to shutting if off.
Precautions for HosesEAS000FV
HOSE REMOVAL AND INSTALLATION
lTo prevent damage to rubber hose, do not pry off rubber hose
with tapered tool or screwdriver.
lTo reinstall the rubber hose securely, make sure that hose inser-
tion length and orientation is correct. (If tube is equipped with
hose stopper, insert rubber hose into tube until it butts up
against hose stopper.)
SGI787
SGI292
SMA019D
SMA020D
Page 2260 of 3066

PRECAUTIONS
GI-7
HOSE CLAMPING
lIf old rubber hose is re-used, install hose clamp in its original
position (at the indentation where the old clamp was). If there is
a trace of tube bulging left on the old rubber hose, align rubber
hose at that position.
lDiscard old clamps; replace with new ones.
lAfter installing plate clamps, apply force to them in the direction
of the arrow, tightening rubber hose equally all around.
Precautions for Engine OilsEAS000FW
Prolonged and repeated contact with used engine oil may cause skin cancer. Try to avoid direct skin contact
with used oil.
If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible.
HEALTH PROTECTION PRECAUTIONS
lAvoid prolonged and repeated contact with oils, particularly used engine oils.
lWear protective clothing, including impervious gloves where practicable.
lDo not put oily rags in pockets.
lAvoid contaminating clothes, particularly underpants, with oil.
lHeavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regu-
larly.
lFirst aid treatment should be obtained immediately for open cuts and wounds.
lUse barrier creams, applying them before each work period, to help the removal of oil from the skin.
lWash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Prepa-
rations containing lanolin replace the natural skin oils which have been removed.
lDo not use gasoline, kerosine, diesel fuel, gas oil, thinners or solvents for cleaning skin.
lIf skin disorders develop, obtain medical advice without delay.
lWhere practical, degrease components prior to handling.
lWhere there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face
shields; in addition an eye wash facility should be provided.
ENVIRONMENTAL PROTECTION PRECAUTIONS
Dispose of used oil and used oil filters through authorized waste disposal contractors to licensed waste dis-
posal sites, or to the waste oil reclamation trade. If in doubt, contact the local authority for advice on disposal
facilities.
It is illegal to pour used oil on to the ground, down sewers or drains, or into water sources.
The regulations concerning pollution vary between regions.
SMA021D
SMA022D
Page 2261 of 3066
GI-8
PRECAUTIONS
Precautions for Air Conditioning
EAS000FX
Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to
ATC/MTC section “HFC-134a (R-134a) Service Procedure”, “REFRIGERANT LINES” for specific instructions.
Page 2262 of 3066

HOW TO USE THIS MANUAL
GI-9
HOW TO USE THIS MANUALPFP:00008
DescriptionEAS000FY
This volume explains “Removal, Disassembly, Installation, Inspection and Adjustment” and “Trouble Diag-
noses”.
Te r m sEAS000FZ
lThe captionsWA RN INGandCAUTIONwarn you of steps that must be followed to prevent personal
injury and/or damage to some part of the vehicle.
WAR NIN Gindicates the possibility of personal injury if instructions are not followed.
CAUTIONindicates the possibility of component damage if instructions are not followed.
BOLD TYPED STATEMENTSexceptWA RN INGandCAUTIONgive you helpful information.
Standard value:Tolerance at inspection and adjustment.
Limit value:The maximum or minimum limit value that should not be exceeded at inspection and adjust-
ment.
UnitsEAS000G0
lTheUNITSgiven in this manual are primarily expressed as the SI UNIT (International System of Unit),
and alternatively expressed in the metric system and in the yard/pound system.
“Example”
ContentsEAS000G1
lALPHABETICAL INDEXis provided at the end of this manual so that you can rapidly find the item and
page you are searching for.
lA QUICK REFERENCE INDEX, a black tab (e.g. ) is provided on the first page. You can quickly find
the first page of each section by matching it to the section's black tab.
lTHE CONTENTSare listed on the first page of each section.
lTHE TITLEis indicated on the upper portion of each page and shows the part or system.
lTHEPAGENUMBERof each section consists of two or three letters which designate the particular sec-
tion and a number (e.g. “BR-5”).
lTHE SMALL ILLUSTRATIONSshow the important steps such as inspection, use of special tools, knacks
of work and hidden or tricky steps which are not shown in the previous large illustrations.
Assembly, inspection and adjustment procedures for the complicated units such as the automatic tran-
saxle or transmission, etc. are presented in a step-by-step format where necessary.
ComponentsEAS000G2
lTHE LARGE ILLUSTRATIONSare exploded views (See the following) and contain tightening torques,
lubrication points, section number of thePARTS CATALOG(e.g. SEC.440) and other information neces-
sary to perform repairs.Tightening torque :59 - 78 N-m (6.0 - 8.0 kg-m, 43 - 58 ft-lb)
Page 2263 of 3066
GI-10
HOW TO USE THIS MANUAL
The illustrations should be used in reference to service matters only. When ordering parts, refer to the
appropriatePA R T S C ATA L O G.
SYMBOLS
How to Follow Trouble DiagnosesEAS000G3
DESCRIPTION
NOTICE:
Trouble diagnoses indicate work procedures required to diagnose problems effectively. Observe the following
instructions before diagnosing.
SBR364AC
SYMBOL DESCRIPTION
Tightening torque
Should be lubricated with grease. Unless otherwise indicated, use recommended multi-purpose grease.
Shouldbelubricatedwithoil.
Sealing point
Checking point
Always replace after every disassembly.
PApply petroleum jelly.
Apply ATF.
Select with proper thickness.
Adjustment is required.
Page 2264 of 3066

HOW TO USE THIS MANUAL
GI-11
1.Before performing trouble diagnoses, read the “Preliminary Check”, the “Symptom Chart” or the
“Work Flow”.
2.After repairs, re-check that the problem has been completely eliminated.
3.Refer to Component Parts and Harness Connector Location for the Systems described in each
section for identification/location of components and harness connectors.
4.Refer to the Circuit Diagram for quick pinpoint check.
If you need to check circuit continuity between harness connectors in more detail, such as when a
sub-harness is used, refer to Wiring Diagram in each individual section and Harness Layout in PG
section for identification of harness connectors.
5.When checking circuit continuity, ignition switch should be OFF.
6.Before checking voltage at connectors, check battery voltage.
7.After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure
that all harness connectors are reconnected as they were.
HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES
1.Work and diagnostic procedure
Start to diagnose a problem using procedures indicated in enclosed test groups.
2.Questions and required results
Questions and required results are indicated in bold type in test group.
The meaning of are as follows:
3.Symbol used in illustration
SAIA0256E
a. Battery voltage®11 - 14V or approximately 12V
b. Voltage : Approximately 0V®Less than 1V