W/Harness Inspection
1.

Many malfunctions in the electrical system are caused by poor harness and terminals.

Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.

2.

Thoroughly check all connectors (and connections) for looseness, bending, corrosion, contamination, deterioration, and/or damage.

3.

Has a problem been found?

▶ Repair as necessary and then go to "Verification of Vehicle Repair" procedure.

▶ Go to next procedure.

Charging System Inspection
1.

Engine "ON"

2.

headight and heatwire "ON".

3.

Measure voltage between terminal (+) and (-) of battery maintaining ENG. RPM at 2,500RPM(idle) over 2 minutes.

Specification : less than 16 [V]

4.

Is the measured voltage within specifications?

▶ Go to "Power Circuit Inspection" procedure.

▶ Check that the tension of drive velt, ENG RPM, fuse, terminal of battery, all terminals of alternator are in good condition and Check for damaged harness and poor connection between alternator and battery.

▶ Repair as necessary and then go to "Verification of Vehicle Repair" procedure.

Power Circuit Inspection
■ Open or Short Check
1.

Ignition "OFF"

2.

Disconnect EPS CM connector.

3.

Ignition "ON" & Engine "OFF".

4.

Measure voltage between ON/START INPUT terminal of 4WD ECU harness connector and chassis ground.

Specification : less than 16 [V]

5.

Is the measured resistance within specification ?

▶ Go to "Ground Circuit Inspection" procedure.

▶ Check for open or blown fuse referring to "Circuit Diagram".

▶ Repair open or short in power circuit between battery and 4WD ECU harness connector and then go to "Verification of vehicle Repair" procedure.

■ Ground Circuit Inspection
6.

IG Key "OFF".

7.

Disconnect 4WD ECU connector.

8.

Measure resistance between ground terminal of 4WD ECU harness connector and chassis ground.

Specification : Approx. 1.0 Ω

9.

Is the measured resistance within specification ?

▶ Substitute with a known-good 4WD ECU and check for proper operation. If the problem is corrected,replace 4WD ECU and then go to "Verification of Vehicle Repair" procedure.

▶ Check for open or contact resistance in ground harness.

▶ Repair as necessary and then go to "Verification of Vehicle Repair" procedure.

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