MA-4
DESCRIPTION
DESCRIPTION
PFP:00000
Pre-delivery Inspection ItemsELS000AK
Shown below are Pre-delivery Inspection Items required for the new vehicle. It is recommended that
necessary items other than those listed here be added, paying due regard to the conditions in each
country.
Perform applicable items on each model. Consult text of this section for specifications.
UNDER HOOD — engine off
Radiator coolant level and coolant hose connections for leaks
Battery fluid level, specific gravity and conditions of battery terminals
Drive belts tension
Fuel filter for water or dusts (Diesel only), and fuel lines and connections for leaks
Engine oil level and oil leaks
Clutch and brake reservoir fluid level and fluid lines for leaks
Windshield and rear window washer and headlamp cleaner reservoir fluid level
Power steering reservoir fluid level and hose connections for leaks
ON INSIDE AND OUTSIDE
Remove front spring/strut spacer (If applicable)
Operation of all instruments, gauges, lights and accessories
Operation of horn(s), wiper and washer
Steering lock for operation
Check air conditioner for gas leaks
Front and rear seats, and seat belts for operation
All moldings, trims and fittings for fit and alignment
All windows for operation and alignment
Hood, trunk lid, door panels for fit and alignment
Latches, keys and locks for operation
Weatherstrips for adhesion and fit
Headlamp aiming
Tighten wheel nuts (Inc. inner nuts if applicable)
Tire pressure (Inc. spare tire)
Check front wheels for toe-in
Install clock/voltmeter/room lamp fuse (If applicable)
Install deodorizing filter to air conditioner (If applicable)
Remove wiper blade protectors (If applicable)
UNDER BODY
Manual transmission/transaxle, transfer and differential gear oil level
Brake and fuel lines and oil/fluid reservoirs for leaks
Tighten bolts and nuts of steering linkage and gear box, suspension, propeller shafts and drive shafts
Tighten rear body bolts and nuts (Models with wooden bed only)
ROAD TEST
Clutch operation
Parking brake operation
Service brake operation
Automatic transmission/transaxle shift timing and kickdown
Steering control and returnability
Engine performance
Squeaks and rattles
ENGINE OPERATING AND HOT
Adjust idle speed
Automatic transmission/transaxle fluid level
TROUBLE DIAGNOSIS
MTC-7
C
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F
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MTC
Operational CheckEJS001FE
The purpose of the operational check is to confirm that the system operates properly.
CHECKING BLOWER
1. Turn fan switch to 1-speed. Blower should operate on low
speed.
2. Then turn fan switch to 2-speed, and continue checking blower
speed until all speeds are checked.
3. Leave blower on 4-speed.
If NG, go to trouble diagnosis procedure for blower motorMTC-13
.
If OK, continue with next check.
CHECKING DISCHARGE AIR
1. Set the mode control dial to each position.
2. Confirm that discharge air comes out according to the air distri-
bution table.Refer to Discharge Air FlowMTC-5
.
Intake door position is checked in the next step.
If NG, go to trouble diagnosis procedure for mode door motor.
If OK, continue with next check.
CHECKING RECIRCULATION
1. Press REC switch one time. Recirculation indicator should illu-
minate.
2. Listen for intake door position change (you should hear blower
sound change slightly).
If NG, go to trouble diagnosis procedure for intake doorMTC-10
.
If OK, continue with next check.Conditions :Engine running and at
normal operating temper-
ature
RJIA0587E
RJIA0588E
RJIA0492E
RJIA0589E
PS-6
STEERING WHEEL
STEERING WHEEL
PFP:48430
On-Vehicle Inspection and ServiceEGS0004E
PLAY INSPECTION
1. Turn steering wheel to straight-ahead position. Start engine and lightly turn steering wheel clockwise and
counter clockwise until front wheels start moving. Measure travel to starting point on circumference of
steering wheel.
2. If play is outside specifications, check following parts for proper installation: steering gear assembly, front
suspension, axles, and steering column
lCheck steering wheel for vertical, horizontal, or axial play.
lLift vehicle and check steering gear mounting bolts and nuts for looseness.
NEUTRAL POSITION INSPECTION
lAfter the wheel alignment inspection, carry out the neutral position inspection. Refer toWT-4.
lBefore removing steering wheel, check steering gear neutral position.
1. Set vehicle to straight-ahead position, and check that steering wheel is in neutral position.
2. If it is not in neutral position, remove steering wheel, and install again in properly.
3. If it is not adjusted within two teeth from center of gear, loosen tie rod lock nut. Then turn it to opposite
direction to adjust until amount of left and right becomes equal.
STEERING TORQUE CHECK
1. Stop vehicle on a dry flat paved road and apply parking brake.
2. Start engine and wait until power steering fluid warms up. Using
a preload gauge, check rotational torque of steering wheel.
3. If torque is outside specifications, check rack sliding torque and
oil pump relief pressure.
STEERING ANGLE INSPECTION
lAfter toe-in inspection, check steering angle. Place front wheels
on turning radius gauges and rear wheels on stands. Level the
vehicle. Check maximum inner and outer wheel steering angles
for LH and RH road wheels.Steering wheel play inspection standard : 0 - 35 mm (0 - 1.38 in)
Steering wheel axial endplay: : 0 mm (0 in)
Tightening torque : 140 - 160 N·m (14.2 - 16.4 kg·m,103-118 ft·lb)
Steering torque : 706 N·cm (72 kg·cm) or less
Rack sliding torque : 153 - 240N (15.5 - 24.5 kg,
34.3-54.2 lb)
Oil pump relief hydraulic
pressure: 8.3 + 0.4 - 0.2 MPa
(85+4-2kg/cm
2)
STA0005D
FAA0016D
TF-42
TROUBLE DIAGNOSIS
NOTE:
1. Light tight-corner braking symptom may occur depending on driving conditions in AUTO mode. This is not
malfunction.
2. Heavy tight-corner braking symptom occurs when vehicle is driven in the following conditions: LOCK
mode, steering wheel is turned fully to either sides, and accelerator pedal was depressed.
3. When the difference of revolution speed between the front and the rear wheels is large, the 4WD mode
does not change to other mode.this is not a malfunction.
4WD control unit input/output signal standardEDS000H9
4WD CONTROL UNIT CONNECTOR TERMINAL ARRANGEMENT
When ignition switch is turned to ON with connectors of 4WD control unit connected.
While driving, 4WD warning lamp
flashes rapidly. (when it flashes for
approx. one minute, then does not illu-
minate.) Rapid flashing: Two times
flashing per 1 secondEngine running
(to other than 2WD
mode)Protection function was activated due to heavy
load to electronically controlled coupling. (4WD
system is not malfunctioning.)TF-57, "
WHILE
DRIVING, 4WD
WARN ING
LAMP
FLASHES RAP-
IDLY. (WHEN IT
FLASHERS
FOR APPROX.
ONE MINUTE,
THEN DOES
NOT ILLUMI-
NATE.)"
While driving, 4WD warning lamp
flashes slowly. (when it flashes for
approx. one minute, then does not illu-
minate.)Slow flashing: One flashing
per 2 secondslEngine running
lDriving at vehicle
speed 20km/
h(12MPH)Tire size is different for front and rear of vehicle.TF-58, "
WHILE
DRIVING, 4WD
WARN ING
LAMP
FLASHES
SLOWLY.
(WHEN IT
CONTINUES
TO ILLUMI-
NATE UNTIL
ENGINE
TURNS OFF.)"
Vehicle does not enter 4WD mode
even though 4WD warning lamp is off.Engine runningMechanical malfunction of electronically con-
trolled coupling (Mechanical engagement of
clutch is not possible.)TF-58, "
VEHI-
CLE DOES
NOT ENTER
4WD MODE
EVEN
THOUGH 4WD
WARN ING
LAMP IS OFF."
Symptom Condition Check items Reference page
SDIA0120E
TROUBLE DIAGNOSIS
TF-49
C
E
F
G
H
I
J
K
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MA
B
TF
4WD solenoid valve
Under the vehicle stopped with engine ON, touch UP, DOWN on
screen. Adjust 4WD solenoid command current.
Check the monitor current at that time. If monitor current is within
approx.±10%, light switch is normal.
CAUTION:
Do not continuously energize solenoid for long period of time.
ECU PART NUMBER
Ignore the ECU part number displayed in the ECU PART NUMBER MODE.
Refer to parts catalog to order the ECU.
Component InspectionEDS000HC
4WD SOLENOID VALVE
lDisconnect connector B15 and measure resistance between ter-
minals 1(L/W) and 2.(LG)
System InspectionEDS000IO
CONTROL UNIT POWER SUPPLY SYSTEM
Inspection procedure
Disconnect 4WD control unit connector. Check for continuity and voltage between each terminal of vehicle-
side connector and body ground.
SDIA0626E
Resistance : Approx. 2.45W
SDIA0136E
Terminal No. Signal name Measuring condition Measurement value
3, 4, 6, 16, 17, 18, 24, 109 Power supply Ignition switch ON Battery voltage
104, 106, 108, 111, 113, 115 Ground Ignition switch OFF Continuity should exist.
SDIA0129E
TROUBLE DIAGNOSIS
TF-57
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TF
3.INSPECTION USING 4WD MODE CHANGE-OVER SWITCH
lOn data monitor screen of the CONSULT-II, check 4WD mode switch.
lCheck if the display changes from ## to 2WD mode when the 2WD switch is pressed.
lCheck if the display changes from ## to AUTO mode when the AUTO switch is pressed.
lCheck if the display changes from ## to LOCK mode when the LOCK switch is pressed.
OK or NG
OK >> No malfunction detected.
NG >>
lNot in AUTO mode. (in 2WD or LOCK mode)
Countermeasure: Slightly depress the accelerator pedal and check that the operation mode
changes to LOCK mode.
lCheck circuit between 4WD mode switch harness connector M39 terminal No.1 (BR) and
4WD control unit harness connector E122 terminal No. 27 (BR).
(AUTO mode is not available because a malfunction is present in the 2WD mode harness.)
NOTICE:
Mechanism of 4WD mode change-over
l2WD mode: Operation changes to 2WD mode when 4WD control unit harness connector E122
terminal No. 27 (BR) is shorted to ground.
lAUTO mode: Operation changes to AUTO mode when 4WD control unit harness connector
E122 terminals No. 27 (BR) and No. 26 (L) is shorted to ground.
lLOCK mode: Operation changes to LOCK mode when 4WD control unit harness connector
E122 terminal No. 26 (L) is shorted to ground.
4WD MODES CANNOT BE SWITCHED AFTER ENGINE IS STARTED
1.INSPECTION USING 4WD MODE CHANGE-OVER SWITCH
lDrive modes cannot be switched after the engine is started.
lOn data monitor screen of the CONSULT-II, check 4WD mode switch.
lCheck if the display changes from ## to 2WD mode when the 2WD switch is pressed.
lCheck if the display changes from ## to AUTO mode when the AUTO switch is pressed.
lCheck if the display changes from ## to LOCK mode when the LOCK switch is pressed.
OK or NG
OK >> No malfunction detected.
NG >>
lCONSULT-II display does not change from ## when the 2WD switch is pressed. Check harness
of the 2WD switch.
lCONSULT-II display does not change from ## when the AUTO switch is pressed. Check har-
ness of the 2WD switch and LOCK switch.
lCONSULT-II display does not change from ## when the LOCK switch is pressed. Check har-
ness of the LOCK switch.
lPerform 4WD mode change-over switch inspection.
WHILE DRIVING, 4WD WARNING LAMP FLASHES RAPIDLY. (WHEN IT FLASHERS FOR
APPROX. ONE MINUTE, THEN DOES NOT ILLUMINATE.)
lWhile driving, 4WD warning lamp flashes rapidly. (when it flashes for approx. one minute, then does not
illuminate.)
Rapid flashing: 2 times/second
This phenomenon protects drivetrain parts when a heavy load is applied to the electronically controlled
coupling and multiple disc clutch temperature increases. It is not a malfunction.
When the difference of diameters by or with the front and rear wheel with AUTO mode the shift switch
occasionally changes to LOCK mode automatically. This is not a malfunction.
When the difference of revolution speed between the front and rear wheel with AUTO mode, the shift
switch occasionally changes to LOCK mode automatically. This is not a malfunction.