Repair Instruction: Precaution

1. HINTS ON OPERATIONS
   Fig 1: Precaution For Repair Instructions

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2. JACKING UP AND SUPPORTING VEHICLE
   1. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations.
3. PRECOATED PARTS
   1. Precoated parts are bolts and nuts that are coated with a seal lock adhesive at the factory.
   Fig 2: Identifying Seal Lock Adhesive
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   2. If a precoated part is retightened, loosened or moved in any way, it must be recoated with the specified adhesive.
   3. When reusing a precoated part, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriate to that part.
   4. Some seal lock agents harden slowly. You may have to wait for the seal lock adhesive to harden.
4. GASKETS
   1. When necessary, use a sealer on gaskets to prevent leaks.
5. BOLTS, NUTS AND SCREWS
   1. Carefully follow all the specifications for tightening torques. Always use a torque wrench.
6. FUSES
   1. When inspecting a fuse, check that the wire of the fuse is not broken.
   Fig 3: Identifying Fuses Correct And Incorrect Position
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   2. When replacing fuses, be sure that the new fuse has the correct amperage rating. Do not exceed the rating or use one with a lower rating.
      FUSE SPECIFICATION
      
      

      Illustration	Symbol	Part Name	Abbreviation
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	FUSE	FUSE
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	MEDIUM CURRENT FUSE	M-FUSE
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	HIGH CURRENT FUSE	H-FUSE
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	FUSIBLE LINK	FL
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	CIRCUIT BREAKER	CB

7. clips
   1. The removal and installation methods of typical clips used for vehicle body parts are shown in the table below.

      HINT:

      If clips are damaged during a procedure, always replace the damaged clip with a new clip.

      CLIPS SPECIFICATION
      
      

      Shape (Example)	Illustration	Procedures
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	1. Remove the clips with a clip remover or pliers.
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	1. Remove the clips with a clip remover or screwdriver.
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	1. Remove the clips with a wide scraper to prevent panel damage.
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	1. Remove the clips by pushing the center pin through and prying out the shell.
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	1. Remove the clips by unscrewing the center pin and prying out the shell.
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	1. Remove the clips by prying out the pin and then prying out the shell.

8. CLAWS
   1. The removal and installation methods of typical claws used for vehicle body parts are shown in the table below.

      HINT:

      If claws are damaged during a procedure, always replace the damaged claws with new caps or covers.

      CLAWS SPECIFICATION
      
      

      Shape (Example)	Illustration	Procedures
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	1. Using a screwdriver, detach the claws and remove the cap or covers.
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	1. Using a screwdriver, detach the claws and remove the cap or covers.
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	1. Using a screwdriver, detach the claws and remove the cap or covers.

9. HINGE, GUIDE, CLAMP AND PIN ETC.
   1. The removal and installation methods of typical hinge, guide, clamp and pin used for vehicle body parts are shown in the table below.

      HINT:

      If clamps are damaged during a procedure, always replace the cap or cover that has damaged clamps with a new one.

      HINGE, GUIDE, CLAMP AND PIN SPECIFICATION
      
      

      Shape (Example)	Removal/Installation
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

10. REMOVAL AND INSTALLATION OF VACUUM HOSES
    1. To disconnect a vacuum hose, pull and twist from the end of the hose. Do not pull from the middle of the hose as this may cause damage.
       Fig 4: Precaution For Vacuum Hosse

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    2. When disconnecting vacuum hoses, use tags to identify where they should be reconnected.
    Fig 5: Identifying Vacuum Hoses With Tags
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    3. After completing any hose related repairs, double check that the vacuum hoses are properly connected. The label under the hood shows the proper layout.
    4. When using a vacuum gauge, never force the hose onto a connector that is too large. If a hose has been stretched, it may leak air. Use a step-down adapter if necessary.
11. TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL
    Fig 6: Identifying Torque Wrench With Extension Tool

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    1. Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with a torque wrench.

       Formula: T' = L2 / (L1 + L2) * T 

       Fig 7: Identifying SST Dimension

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       FORMULA VALUES
       
       

       T'	Reading of torque wrench {N*m (kgf*cm, ft.*lbf)}
       T	Torque {N*m (kgf*cm, ft.*lbf)}
       L1	Length of SST or extension tool {cm (in.)}
       L2	Length of torque wrench {cm (in.)}

       NOTE: If an extension tool or SST is combined with a torque wrench and the wrench is used to tighten to a torque specification in this manual, the actual torque will be excessive and parts will be damaged.

The FJ CRUISER is equipped with a Supplemental Restraint System (SRS).

1. GENERAL NOTICE
   1. As malfunctions of the SRS are difficult to confirm, the Diagnostic Trouble Codes (DTCs) become the most important source of information when troubleshooting. When troubleshooting the SRS, always check the DTCs before disconnecting the battery.
   2. Work must be started at least 90 seconds after the ignition switch is turned OFF and after the cable is disconnected from the negative (-) battery terminal.

      (The SRS is equipped with a backup power source. If work is started within 90 seconds after turning the ignition switch OFF and disconnecting the cable from the negative (-) battery terminal, the SRS may deploy. When the cable is disconnected from the negative (-) battery terminal, clock and audio system memory is erased. Before starting work, make a note of the settings of each memory system. When work is finished, reset the clock and audio system as before.

      CAUTION: Never use a backup power source (battery or other) to avoid erasing system memory. The backup power source may inadvertently power the SRS and cause it to deploy.
   3. Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, front seat side airbag assembly, curtain shield airbag assembly and seat belt pretensioner should be inspected
   4. In minor collisions where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, front seat side airbag assembly, curtain shield airbag assembly and seat belt pretensioner should be inspected before further use of the vehicle.
   5. Never use SRS parts from another vehicle. When replacing parts, use new parts.
   6. Before repairs, remove the airbag sensor assemblies if impacts are likely to be applied to the sensor during repairs.
   7. Never disassemble and attempt to repair the steering wheel pad, front passenger airbag assembly, side airbag assembly, curtain shield airbag assembly and seat belt pretensioner.
   8. Replace the steering wheel pad, front passenger airbag assembly, front seat side airbag assembly, curtain shield airbag assembly and seat belt pretensioner if: 1) damage has occurred from being dropped, or 2) cracks, dents or other defects in the case, bracket or connector are present.
   9. Do not directly expose the airbag sensor assemblies or airbag assemblies to hot air or flames.
   10. Use an ohmmeter / voltmeter with high impedance (10 kΩ/V minimum) for troubleshooting electrical circuits.
   11. Information labels are attached to the SRS components. Follow the instructions on the labels.
   12. After work on the SRS is completed, check the SRS warning light.
2. SPIRAL CABLE
   1. The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, as cable disconnection and other problems may occur. Refer to the information about correct installation of the steering wheel.
   Fig 8: Aligning Spiral Cable Marks

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3. STEERING PAD
   1. Always place a removed or new steering pad surface upward as shown in the illustration. Placing the horn button with the pad surface facing down could cause a serious accident if the airbag inflates. Also, do not place anything on top of the horn button.
      Fig 9: Caution For Steering Pad

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   2. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury.
      Fig 10: Caution - Never Measure Resistance Of Airbag Squib

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   3. Grease or detergents of any kind should not be applied to the horn button.
   4. Store the horn button assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.
   5. When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (4 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring.
   6. When disposing of the vehicle or the horn button assembly by itself, the airbag should be deployed using SST before disposal. Activate the airbag in a safe place away from electrical noise.
4. FRONT PASSENGER AIRBAG ASSEMBLY
   1. Always place a removed or new front passenger airbag assembly with the pad surface facing upward as shown in the illustration. Placing the airbag assembly with the airbag inflation direction facing down could cause a serious accident if the airbag inflates.
      Fig 11: Caution For Passenger Airbag Assembly

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   2. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury.
      Fig 12: Caution - Never Measure Resistance Of Airbag Squib

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   3. Grease or detergents of any kind should not be applied to the front passenger airbag assembly.
   4. Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.
   5. When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (4 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring.
   6. When disposing of the vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal. Activate the airbag in a safe place away from electrical noise.
5. CURTAIN SHIELD AIRBAG ASSEMBLY
   1. Always place a removed or new curtain shield airbag assembly in a clear plastic bag, and keep it in a safe place.
      Fig 13: Identifying Curtain Shield Airbag Correct Assembly

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