REPAIR INSTRUCTION PRECAUTION


  1. BASIC REPAIR HINT


    1. HINTS ON OPERATIONS

      A01CIL1E01
      1 Attire

      • Always wear a clean uniform.


      • Hat and safety shoes must be worn.
      2 Vehicle protection Prepare a grille cover, fender cover, seat cover and floor mat before starting the operation.
      3 Safe operation

      • Use wheel chocks to secure the vehicle.

      • When working with the engine running, make sure to provide ventilation for exhaust fumes in the workshop.

      • When removing or installing heavy parts, such as the engine, transmission, differential, etc., before starting work make sure there are no problems with the equipment that will be used.

      • When working with 2 or more persons, be sure to check safety for one another.

      • If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others.
      4 Preparation of tools and measuring gauge Before starting any operation, prepare a tool stand, SST, necessary gauges, oil and any parts for replacement.
      5 Removal, installation, disassembly and assembly operations

      • Diagnose with a thorough understanding of proper procedures and of the reported problem.


      • Before removing the parts, check the general condition of the assembly and for deformation and damage.


      • When the assembly is complicated, take notes. For example, note the total number of electrical connections, bolts, or hoses removed. Add matchmarks to insure reassembly of components in the original positions. Temporarily mark hoses and their fittings if needed.


      • Clean and wash the removed parts if necessary and assemble them after a thorough check.
      6 Removed parts

      • Place the removed parts in a separate box to avoid mixing them up with the new parts or contaminating the new parts.


      • For non-reusable parts such as gaskets, O-rings and self-locking nuts, replace them with new ones as instructed in this manual.


      • Retain the removed parts for customer inspection, if requested.
      7* Checks to perform after work is finished

      • Make sure that removed and installed parts (oil filler cap, level dipstick, floor mat, etc.) are properly installed/tightened.


      • Make sure that none of the cloths or tools that were used have been left in the engine compartment or within the vehicle.


      • Check that there are no oil leaks.

      CAUTION:

      *: Be sure to perform these checks properly. Not performing these checks properly after finishing work can lead to serious accident or injury.

    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. A01CI6CE03

      PRECOATED PARTS


      1. Precoated parts are bolts and nuts that are coated with a seal lock adhesive at the factory.

      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 torque. Always use a torque wrench.

      2. Make sure that no foreign matter (burrs, paint, etc.) gets trapped under the heads of the bolts and nuts when tightening them.

    6. A01CGNJE01

      FUSES


      1. When inspecting a fuse, check that the wire of the fuse is not broken.

      2. If the wire of a fuse is broken, confirm that there are no shorts in its circuit.

      3. When a fuse is replaced, a fuse with the same amperage rating must be used.

        Illustration Symbol Part Name Abbreviation
        A01CI5D A01CJDE FUSE FUSE
        A01CIH0 A01CHLH MEDIUM CURRENT FUSE M-FUSE
        A01CI9B A01CJ7U HIGH CURRENT FUSE H-FUSE
        A01CIWB A01CIL2 FUSIBLE LINK FL
        A01CJ6R A01CISC 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.

        Tech Tips

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

        Shape (Example) Illustration Procedures
        A01CIOC A01CI5O

        1. Remove clips with clip remover or pliers.
        A01CH07 A01CIFD

        1. Remove the clips with clip remover or screwdriver.
        A01CJGY A01CHFF

        1. Remove clips with wide scraper to prevent panel damage.
        A01CJ2U A01CJ1O

        1. Remove clips by pushing center pin through and prying out the shell.
        A01CJ64 A01CJ6U

        1. Remove clips by unscrewing the center pin and prying out the shell.
        A01CIZ1 A01CHQD

        1. Remove 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.

        Tech Tips

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

        Shape (Example) Illustration Procedures
        A01CHHN A01CJ7F

        1. Using a screwdriver, detach the claws and remove the cap or covers.
        A01CH2C A01CIRC

        1. Using a screwdriver, detach the claws and remove the cap or covers.
        A01CJ66 A01CH56

        1. Using a screwdriver, detach the claws and remove the cap or covers.

    9. HINGE, GUIDE, CLAMP, PIN, ETC.


      1. The removal and installation methods of typical hinges, guides, clamps and pins used for vehicle body parts are shown in the table below.

        Tech Tips

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

        Shape (Example) Illustration Procedures
        A01CGUF A01CH0L Disengage the pins by pulling.
        A01CILM A01CJGT Disengage the pins by pulling.
        A01CHK0 A01CINW Remove the clamps with pliers.
        A01CH7T A01CJ4T Disengage the pins by pulling.

    10. REMOVAL AND INSTALLATION OF VACUUM HOSES


      1. A01CHIME01

        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.

      2. A01CGQXE01

        When disconnecting vacuum hoses, use tags to identify where they should be reconnected.

      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. A01CINIE02

      TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL


      1. A01CINTE01

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

        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.

      2. TILT UP CAB

        CAUTION:


        • Make sure that the vehicle is on a level surface before tilting the cab up.

        • Make sure that all the doors are closed before tilting the cab up.

        • Make sure that nobody is inside or near the cab when tilting it up.

        • Be sure to have 2 people tilt the cab up when a heavy object such as a roof rack or cargo carrier is installed to the cab.

        • Be sure to remove anything set on top of the cab before tilting it up.

        • Make sure that the cab is securely locked in place after it is tilted up.

        • Make sure that there are no tools, cloths, etc. left in the engine room before tilting the cab back down.

        • Make sure that the cab is securely locked in place after it is tilted up.

        Note

        Make sure that there is enough space un front of and above the cab before tilting it up.

      3. FOR VEHICLES WITH SUPPLEMENTAL RESTRAINT SYSTEM

        This vehicle equipped with a Supplemental Restraint System (SRS). The SRS of this vehicle consists of the following:

        CAUTION:


        • Failure to carry out service procedures in the correct sequence could cause SRS parts to unexpectedly deploy and possibly lead to serious injuries. Furthermore, if a mistake is made when servicing SRS parts, they may fail to operate when required. Before performing servicing (including installation/removal, inspection and replacement of parts), be sure to read the following precautions.

        • Before starting work, wait at least 90 seconds after the ignition switch is turned off and after the cable is disconnected from the negative (-) battery terminal. (SRS parts are equipped with a backup power source. If work is started within 90 seconds of turning the ignition switch off and disconnecting the cable from the negative (-) battery terminal, SRS parts may deploy).

        • Do not expose SRS parts directly to hot air or flames.

        Note


        • Malfunction symptoms of SRS parts are difficult to confirm. DTCs are the most important source of information when troubleshooting. During troubleshooting, always confirm DTCs before disconnecting the cable from the negative (-) battery terminal.

        • For minor collisions where SRS parts do not deploy, always inspect the SRS parts.

        • Before performing repairs, remove airbag sensors as necessary if any kind of impact is likely to occur to an airbag sensor during repairs.

        • Never use SRS parts from another vehicle. When replacing SRS parts, replace them with new ones.

        • Never disassemble or attempt to repair SRS parts.

        • If an SRS part has been dropped, or if there are any cracks, dents or other defects in the case, bracket or connector, replace the SRS part with a new one.

        • Use an ohmmeter/voltmeter with high impedance (10 kΩ/V minimum) for troubleshooting the electrical circuits.

        • Information labels are attached to the periphery of SRS parts. Follow the cautions and instructions on the labels.

        • After work on SRS parts is completed, perform the SRS warning light check.

        • When the cable is disconnected from the negative (-) battery terminal, the memory settings of each system will be cleared. Because of this, be sure to write down the settings of each system before starting work. When work is finished, reset the settings of each system as before. Never use a backup power supply from outside the vehicle to avoid erasing the memory in a system.

        • An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with bare hands to discharge static electricity before performing this procedure.


        1. SPIRAL CABLE


          1. The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, otherwise cable disconnection and other problems may occur. Refer to the information about correct installation of the steering wheel.

        2. AIRBAG ASSEMBLY


          1. Airbag assembly with pad: Always place a removed or new airbag assembly with the pad surface facing upward. Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag inflates. Also, do not place anything on top of the airbag assembly.

          2. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause a serious injury.

          3. Grease or detergents of any kind should not be applied to the 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 center airbag sensor connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.

          6. When disposing of the vehicle or the airbag assembly by itself, the airbag should be deployed using SST before disposal. Activate the airbag in a safe place away from electrical noise.

        3. AIRBAG SENSOR ASSEMBLY


          1. Never reuse an airbag sensor assembly that has been involved in a collision where the SRS has deployed.

          2. The connectors to the airbag sensor assembly should be connected or disconnected with the sensor placed on the floor. If the connectors are connected or disconnected while the airbag sensor assembly is not placed on the floor, the SRS may activate.

          3. Work must be started at least 90 seconds after the ignition switch is turned off and the cable is disconnected from the negative (-) battery terminal, even if only loosening the set bolts of the airbag sensor assembly.

        4. WIRE HARNESS AND CONNECTOR


          1. The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are yellow. If the SRS wire harness becomes disconnected or a connector becomes broken, repair or replace it.

      4. ELECTRONIC CONTROL

        A01CHO3E02

        1. REMOVAL AND INSTALLATION OF BATTERY TERMINAL

          Note

          Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.


          1. Before performing electronic work, disconnect the cable from the negative (-) battery terminal to prevent component and wire damage caused by accidental short circuits.

          2. When disconnecting the cable, turn the engine switch and headlight dimmer switch OFF and loosen the cable nut completely. Perform these operations without twisting or prying the cable. Then disconnect the cable.

          3. Clock settings, radio settings, audio system memory, DTCs and other data are erased when the cable is disconnected from the negative (-) battery terminal. Write down any necessary data before disconnecting the cable.

        2. A01CGM6E01

          HANDLING OF ELECTRONIC PARTS


          1. Do not open the cover or case of the ECU unless absolutely necessary. If the IC terminals are touched, the IC may be rendered inoperative by static electricity.

          2. Do not pull the wires when disconnecting electronic connectors. Pull the connector itself.

          3. Be careful not to drop electronic components, such as sensors or relays. If they are dropped on a hard surface, they should be replaced.

          4. When cleaning the engine with steam, protect the electronic components, air filter and emission-related components from water.

          5. Never use an impact wrench to remove or install temperature switches or temperature sensors.

          6. When measuring the resistance of a wire connector, insert the tester probe carefully to prevent terminals from bending.

      5. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS


        1. PLACE FOR REMOVING AND INSTALLING FUEL SYSTEM PARTS


          1. Work in a location with good air ventilation that does not have welders, grinders, drills, electric motors, stoves, or any other ignition sources.

          2. Never work in a pit or near a pit as vaporized fuel will collect in those places.

        2. REMOVING AND INSTALLING FUEL SYSTEM PARTS


          1. Prepare a fire extinguisher before starting the operation.

          2. To prevent static electricity, install a ground wire to the fuel changer, vehicle and fuel tank, and do not spray the surrounding area with water. Be careful when performing work in this area, as the work surface will become slippery. Do not clean up gasoline spills with water, as this may cause the gasoline to spread, and possibly create a fire hazard.

          3. Avoid using electric motors, working lights and other electric equipment that can cause sparks or high temperatures.

          4. Avoid using iron hammers as they may create sparks.

          5. Dispose of fuel-contaminated cloth separately using a fire resistant container.

      6. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS

        A01CJ32E01

        1. If any metal particles enter inlet system parts, this may damage the engine.

        2. When removing and installing inlet system parts, cover the openings of the removed parts and engine openings. Use gummed tape or other suitable materials.

        3. When installing inlet system parts, check that no metal particles have entered the engine or the installed parts.

      7. HANDLING OF HOSE CLAMPS

        A01CHI3E01

        1. Before removing the hose, check the clamp position so that it can be reinstalled in the same position.

        2. Replace any deformed or dented clamps with new ones.

        3. When reusing a hose, attach the clamp on the clamp track portion of the hose.

        4. For a spring type clamp, you may want to spread the tabs slightly after installation by pushing in the direction of the arrows as shown in the illustration.

      8. FOR VEHICLES EQUIPPED WITH MOBILE COMMUNICATION SYSTEMS

        A01CGKY

        1. Install the antenna far away from the ECU and sensors of the vehicle electronic systems as possible.

        2. Install an antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle electronic systems. For details about ECU and sensors locations, refer to the section on the applicable components.

        3. Keep the antenna and feeder separate from other wirings as much as possible. This will prevent signals from the communication equipment from affecting vehicle equipment and vice-versa.

        4. Check that the antenna and feeder are correctly adjusted.

        5. Do not install any high-powered mobile communication system.

        6. Avoid a prolonged engine compression measurement. Engine compression measurements must be performed as rapidly as possible.

        7. Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter.

      9. PRECAUTIONS FOR TOWING REAR WHEEL DRIVE VEHICLES


        1. Use one of the following methods to tow the vehicle.

        2. If the vehicle has trouble with the chassis or drivetrain, use method 1 (flatbed truck).

          A01CHC1E03

          Note

          Do not use any towing method other than those shown above.

        3. A01CIN8

          If a tow truck is not available, in an emergency the vehicle may be temporarily towed using a cable or chain secured to the emergency towing eyelet(s). This should only be attempted on hard surfaced roads for distances of less than 80 km, and at speeds below 30 km/h (19 mph).

          A driver must be in the vehicle to steer and operate the brakes. The vehicle's wheels, drivetrain, axles, steering and brakes must be in good condition.

          Note

          If the towing speed or distance exceeds the above limits, or the vehicle is towed in a backward direction with the front wheels on the ground, the transmission may be damaged.


          1. Emergency towing procedure


            1. Turn the ignition switch to ON.

            2. Depress the brake pedal and move the transmission shift lever to neutral.

            3. Release the parking brake.

            4. Release the brake pedal slowly.

            Note


            • Use extreme caution when towing the vehicle. Avoid sudden starts or erratic driving maneuvers which place excessive stress on the emergency towing eyelet and the cables or chains.

            • Do not turn off the ignition switch. Turning off the ignition switch may result in engagement of the steering lock, resulting in a hazardous situation or accident.

        4. The following towing methods shown below are dangerous and can damage the vehicle, so do not use them.

          A01CHI2

          1. Do not tow the vehicle facing rearward with the front wheels on the ground.

          2. Do not use a sling-type towing method either from the front or rear.

            Note

            If these towing methods are used either from the front or rear, the following may occur.


            • The drivetrain may overheat and be damaged.

            • If a sling-type tow truck is used, damage may occur to the vehicle body.