REPAIR INSTRUCTION PRECAUTION


  1. BASIC REPAIR HINT


    1. HINTS ON OPERATIONS

      A000NR5E02
      1 Attire

      • Always wear a clean uniform.

      • A hat and safety shoes must be worn.
      2 Vehicle protection Prepare a grille cover, fender cover, seat cover and floor mat before starting work.
      3 Safety procedures

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

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

      • 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.

      • When jacking up the vehicle, be sure to support the specified locations with safety stands.

      • When lifting up the vehicle, use appropriate safety equipment.
      4 Preparation of tools and measuring equipment Before starting work, prepare a tool stand, SST, measuring equipment, oil, and any replacement parts required.
      5 Removal and installation, disassembly and assembly operations

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

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

      • If the procedure is complicated, take notes. For example, note the total number of electrical connections, bolts or hoses removed. Add matchmarks to ensure 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 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 THE 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. A000QH2E10
      Text in Illustration
      *a Seal Lock Adhesive

      PRECOATED PARTS


      1. Precoated parts are bolts and nuts that are coated with 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 appropriately 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. A000SAYE04
      Text in Illustration
      *a INCORRECT
      *b CORRECT

      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
        A000RIJ A000OUE FUSE FUSE
        A000OI4 A000NYG MEDIUM CURRENT FUSE M-FUSE
        A000P1N A000QDV HIGH CURRENT FUSE H-FUSE
        A000N2W A000P8M FUSIBLE LINK FL
        A000RPV A000NLW 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 clips with new ones.

        Shape (Example) Removal/Installation
        A000NH8

        Remove the clips with a clip remover or pliers.

        A000ODW
        A000NAN

        Remove the clips with a clip remover or screwdriver.

        A000OM7
        A000S4Q

        Remove the clips with a wide scraper to prevent panel damage.

        A000QIN
        A000OE0

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

        A000SV0
        A000ON5

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

        A000QBJ
        A000S95

        Remove the clips by prying out the pin and then prying out the shell.

        A000MY0

    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 cap or cover that has damaged claws with a new one.

        Shape (Example) Illustration / Procedures
        A000QO6

        Using a screwdriver, disengage the claws and remove the cap or cover.

        A000SUT
        A000SS9

        Using a screwdriver, disengage the claws and remove the cap or cover.

        A000O0R
        A000S08

        Using a screwdriver, disengage the claws and remove the cap or cover.

        A000RIN

    9. HINGES, GUIDES, CLAMPS, PINS, 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) Removal/Installation
        A000OQ9

        Pull away from the pins to disengage.

        A000SRN
        A000QYP

        Disengage the pins by pulling.

        A000SEI
        A000P2X

        Remove the clamps with pliers.

        A000PB9
        A000NTJ

        Disengage the pins by pulling.

        A000O91

    10. REMOVAL AND INSTALLATION OF VACUUM HOSES


      1. A000REKE04
        Text in Illustration
        *a INCORRECT
        *b CORRECT

        To disconnect a vacuum hose, pull and twist it from the end of the hose. Do not pull it from the middle of the hose as this may damage the hose.

      2. A000NLI

        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, air may leak. Use a step-down adapter if necessary.

    11. A000NOJE03

      TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL


      1. A000NF4E03

        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

          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 used to tighten to a torque specification in this manual, the actual torque will be excessive and parts will be damaged.

  2. PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE

    CAUTION:

    The vehicle has a hybrid system that operates at voltages up to 650 V. The hybrid system uses an HV battery that contains an electrolyte which is a strong alkali solution that includes potassium hydroxide. Be sure to follow the instructions in this manual to handle the system correctly. Failure to do so may result in serious injury or electrocution.


    1. Technicians must undergo special training to be able to service and inspect the high-voltage system.

    2. All high-voltage wire harnesses and connectors are colored orange. The HV battery and other high-voltage components have "High Voltage" caution labels. Do not carelessly touch these wires or components.

    3. When there is a problem with the wire harness or connector of a high-voltage circuit, repairs to the harness or connector should not be attempted. Replace damaged or malfunctioning high voltage cables or connectors.

    4. Before inspecting or servicing the high-voltage system, be sure to follow all safety measures, such as wearing insulated gloves and removing the service plug to prevent electrocution. Carry the removed service plug in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.

      for 2GR-FXE Click here

      for 2AR-FSE Click here

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    5. After removing the service plug grip, wait 10 minutes before touching any of the high-voltage connectors and terminals.

      Tech Tips

      Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

    6. Before using insulated gloves, be sure to check them for cracks, tears and other types of damage by performing the following procedure.

      A000Q53

      1. Place the glove on its side.

      2. Roll the opening up 2 or 3 times.

      3. Fold the opening in half to close it.

      4. Confirm that there are no air leaks.

    7. When servicing the vehicle, do not carry metal objects like mechanical pencils or rulers that can be dropped accidentally and cause a short circuit.

    8. Before touching a bare high-voltage terminal, wear insulated gloves and use a tester to make sure that the terminal voltage is 0 V.

    9. A000T50

      After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulating tape.

    10. Bolts and nuts for high-voltage terminals should be tightened firmly to the specified torque. Both insufficient and excessive torque can cause failure.

    11. Use the "CAUTION: HIGH VOLTAGE DO NOT TOUCH" sign to notify other technicians that the high-voltage system is being inspected and/or repaired.

      A000QDKE01
      *1 When performing work on the HV system, fold this sign and put it on the roof of the vehicle.

    12. After servicing the high-voltage system and before reinstalling the service plug, check again that you have not left a part or tool inside, that the high-voltage terminals are firmly tightened, and that the connectors are correctly connected.

    13. When performing work involving high-voltage wires, use either a tool wrapped with vinyl insulation tape or an insulated tool.

    14. When installing hybrid system components such as the HV battery, make sure that the polarity of all connections is correct.

  3. PRECAUTIONS TO BE OBSERVED WHEN INSPECTING OR SERVICING ENGINE COMPARTMENT


    1. The vehicle automatically turns the engine on and off when the READY light on the meter is illuminated. To avoid injury, make sure that both the indicator on the power switch and the READY light on the meter are off.

  4. ACTIONS TO BE TAKEN WHEN A WARNING LIGHT IS ILLUMINATED

    A000P5HE02
    Text in Illustration
    *A except Sport Package *B for Sport Package
    *1 MIL *2 Master Warning Light
    *3 READY Light *4 Charge Warning Light
    *5 Multi-information Display *6 Charge Warning

    1. If one of the warning lights (2) to (4) illuminates, connect the GTS to the DLC3 to check the DTCs (Diagnostic Trouble Codes). Then, refer to the applicable troubleshooting steps in this manual to inspect and repair the affected area. The foregoing actions are also required if the READY light does not illuminate when attempting to turn the power switch on (READY).

      Indicator Light Vehicle Condition
      (1) READY Light (To Drive) Illuminates when the power switch is turned on (READY), indicating that the vehicle is ready to be driven.
      (2) Master Warning Light

      Depending on the warning, the master warning light comes on or flashes to indicate that a warning is currently being displayed on the multi-information display. Depending on the warning, the buzzer may also sound.

      When any malfunction occurs in the hybrid system or hybrid battery system, the master warning light comes on or flashes along with a buzzer, and a warning, "CHECK HYBRID SYSTEM", is displayed on the multi-information display.
      (3) MIL

      Illuminates when there is a malfunction in the engine control system.

      (Also illuminates when the power switch is turned on (IG) and on (READY).)
      (4) Charge Warning

      Displayed when there is a malfunction in the charging system.

      (Be sure to check the DTC (Diagnostic Trouble Code) if this light illuminates together with the master warning light.)
      (4) Charge Warning Light (for Sport Package)

      Illuminates when there is a malfunction in the charging system.

      (Be sure to check the DTC (Diagnostic Trouble Code) if this light illuminates together with the master warning light.)

  5. ACTIONS TO BE TAKEN WHEN BATTERIES ARE DISCHARGED

    Tech Tips

    The vehicle uses a 12 V auxiliary and a 288 V (for 2GR-FXE) or 230.4V (for 2AR-FSE) HV battery. Therefore, there are 2 recharging methods when the batteries are discharged.


    1. Perform this procedure when the auxiliary battery is fully discharged.

      Tech Tips

      The following problems indicate that the auxiliary battery is discharged:


      • No display appears on the meter when the power switch is turned on (IG).

      • The hybrid system does not start.

      • The headlights are dim.

      • The sound from the horn is weak.

      Note

      Never use a quick charger.

      Tech Tips

      The booster terminal cannot be used to rescue a vehicle with a discharged battery.


      1. Move the shift lever to P to automatically apply the parking brake.

      2. Turn the power switch off and remove the key from the interior detection area.

      3. Remove the No. 1 engine room relay block and No. 1 junction block assembly cover.

      4. A000RUE

        for 2GR-FXE:

        Remove the No. 1 engine cover sub-assembly.

      5. Using booster cables, connect the 12 V battery of the rescue vehicle and the auxiliary battery of the stalled vehicle as shown in the illustration.

        A000S09E01
        Text in Illustration
        *1 Auxiliary Battery Terminal *2 Auxiliary Battery
        Connecting Sequence Connecting Location
        1 Positive auxiliary battery of stalled vehicle
        2 Positive auxiliary battery terminal of rescue vehicle
        3 Negative auxiliary battery terminal of rescue vehicle
        4 Negative auxiliary battery of stalled vehicle

      6. Start the engine of the rescue vehicle and run the engine at a speed slightly higher than usual.

      7. A000NE6

        Turn the power switch on (READY).

        Note

        Immediately disconnect the booster cables in the reverse order of connection after the hybrid system has started. Do not leave the booster cables connected because they are not designed for recharging purposes.

        If the hybrid system fails to start, the master warning light flashes, and the multi-information display is as shown in the illustration, the HV battery may be depleted.

    2. When the HV battery is discharged:


      1. Using the THS charger, charge the HV battery.


        Tech Tips

        Perform this operation when the HV battery is discharged or low, or if Low Traction Battery or Traction battery preservation mode is displayed and DTC P3000-388 or 389 is stored in the power management control ECU.

        A000NE6

  6. ACTIONS TO BE TAKEN FOR VEHICLES DAMAGED BY IMPACT

    CAUTION:

    The vehicle has a hybrid system that operates at voltages of up to 650 V. The hybrid system uses an HV battery that contains an electrolyte which is a strong alkali solution that includes potassium hydroxide. Be sure to follow the instructions in this manual to handle the system correctly. Failure to do so may result in serious injury or electrocution.


    1. Items to be prepared for the accident site


      • Protective clothing (insulated gloves, rubber gloves, goggles and safety shoes)

      • Saturated boric acid solution 20 liters (21.1 US qts, 17.6 Imp.qts) (obtain 800 g (1.76 lb) of boric acid powder, put it into a container, and dissolve it in water)

      • Red litmus paper

      • ABC fire extinguisher (effective against both oil flames and electrical flames)

      • A shop rag or piece of cloth (for wiping off the electrolyte)

      • Insulating tape (for insulating cables)


      • Electrical tester

    2. Actions to be taken at the accident site

      CAUTION:


      • Do not touch any bare cables that may have high-voltage. If a cable must be touched or if accidental contact is possible, wear insulated gloves and insulate the cable using insulating tape.

      • If the vehicle catches on fire, use an ABC fire extinguisher to extinguish the fire. Trying to extinguish a fire using only a small amount of water can be more dangerous than effective. Use a substantial amount of water or wait for firefighters.

      • Visually check the HV battery and the immediate area for any electrolyte leakage. Do not touch any leaked liquid because it could be highly alkaline electrolyte.

      • Work on the vehicle only after the vehicle has been pulled out of the water.


      1. Check the vicinity of the HV battery for any leakage of the electrolyte.

        CAUTION:


        • Do not touch any leaked liquid because it could be highly alkaline electrolyte. Wear rubber gloves and goggles, neutralize the liquid with saturated boric acid solution and then apply red litmus paper to the liquid. Check that the paper does not turn blue. Wipe the neutralized liquid with a shop rag or piece of cloth.

        • If the electrolyte comes in contact with your skin, use a saturated boric acid solution or a large amount of water to wash it off. If the electrolyte comes in contact with an article of clothing, take it off immediately.

        • If the electrolyte comes in contact with your eyes, call out loudly for help. Do not rub your eyes. Wash them immediately with a large amount of water and seek medical care.

      2. If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the following procedure.

        CAUTION:

        Be sure to wear insulated gloves, goggles and safety shoes.

        A000NTYE02
        Text in Illustration
        *A for 2GR-FXE *B for 2AR-FSE
        *1 Inverter with Converter Assembly *2 Auxiliary Battery
        *3 HV Battery *4 No. 4 Floor Wire
        *5 Hybrid Vehicle Transmission Assembly *6 Compressor with Motor Assembly
      3. A000NZ7E01
        Text in Illustration
        *1 IG2 MAIN Fuse
        *2 No. 1 Engine Room Relay Block and Junction Block Assembly

        Turn the power switch off.

        Tech Tips

        If the power switch cannot be turned off, remove the IG2 MAIN fuse from the No. 1 engine room relay block and junction block assembly. Confirm that the READY light is off.

      4. Disconnect the cable from the negative (-) auxiliary battery terminal.

      5. Wear insulated gloves and then remove the service plug grip.

        Note

        After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    3. Moving the damaged vehicle

      If any of the following conditions is met, tow the vehicle away using a tow truck.

      Note

      When towing the vehicle, refer to the "PRECAUTIONS FOR TOWING FRONT WHEEL DRIVE VEHICLES".


      • One or more of the high-voltage components and cables are damaged.

      • Components related to driving, the transmission, or the fuel system are damaged.

      • The master warning light is on.

      • The READY light does not come on when attempting to turn the power switch on (READY).

      CAUTION:

      Before towing the vehicle away using a tow truck, disconnect the cable from the negative (-) auxiliary battery terminal and remove the service plug grip.

      Note

      Perform the procedure below if the master warning light turns on, or there are abnormal noises, unusual smells, or strong vibrations while driving:


      1. Park the vehicle in a safe place.

      2. Apply the parking brake, and then move the shift lever to P.

      3. Turn the power switch off, and disconnect the cable from the negative (-) auxiliary battery terminal.

      4. Remove the service plug grip while wearing insulated gloves.

    4. Actions required after moving the damaged vehicle


      1. Procedure

        If you see any liquid on the road surface, it could be highly alkaline electrolyte leakage.

        Wear rubber gloves and goggles, neutralize the liquid with saturated boric acid solution, and then apply red litmus paper to the liquid. Check that the paper does not turn blue. Wipe up the neutralized liquid with a shop rag or piece of cloth.

    5. Items to be prepared (when repairing a damaged vehicle)


      • Protective clothing (insulated gloves, rubber gloves, goggles and safety shoes)

      • Saturated boric acid solution 20 liters (21.1 US qts, 17.6 Imp.qts) (obtain 800 g (1.76 lb) of boric acid powder, put it into a container, and dissolve it in water)

      • Red litmus paper

      • A shop rag or piece of cloth (for wiping off the electrolyte)

      • Insulating tape (for insulating cables)

      • Electrical tester

    6. Precautions to be observed when servicing a damaged vehicle

      CAUTION:

      Always follow instructions to ensure safety.


      1. Wear insulated or rubber gloves, goggles, and safety shoes.

      2. Check the HV battery and immediate area for any electrolyte leakage.

        CAUTION:


        • Do not touch any leaked liquid because it could be highly alkaline electrolyte. Wear rubber gloves and goggles, neutralize the liquid with saturated boric acid solution and then apply red litmus paper to the liquid. Check that the paper does not turn blue. Wipe the neutralized liquid with a shop rag or piece of cloth.

        • If the electrolyte comes in contact with your skin, use a saturated boric acid solution or a large amount of water to wash it off. If the electrolyte comes in contact with an article of clothing, take it off immediately.

        • If the electrolyte comes in contact with your eyes, call out loudly for help. Do not rub your eyes. Wash them immediately with a large amount of water and seek medical care.

      3. Do not touch any bare cables that could be high voltage cables. If a cable must be touched or if accidental contact is possible, follow the following instructions: 1) wear insulated gloves and goggles, 2) measure the voltage between the cable and body ground using an electrical tester, and 3) insulate the cable using insulating tape.

      4. If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the procedure below.

        CAUTION:

        Do not touch any bare cables that may have high-voltage. If a cable must be touched or if accidental contact is possible, wear insulated gloves and insulate the cable using insulating tape.

      5. A000NZ7E01
        Text in Illustration
        *1 IG2 MAIN Fuse
        *2 No. 1 Engine Room Relay Block and Junction Block Assembly

        Turn the power switch off.

        Tech Tips

        If the power switch cannot be turned off, remove the IG2 MAIN fuse from the No. 1 engine room relay block and junction block assembly. Confirm that the READY light is off.

      6. Disconnect the cable from the negative (-) auxiliary battery terminal.

      7. Wear insulated gloves, and then remove the service plug.

        Note

        After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    7. Precautions to be taken when disposing of an HV battery


      1. When disposing of an HV battery, make sure to return it through an authorized collection agent who is capable of handling it safely. If the HV battery is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.

        CAUTION:


        • Accidents such as electric shock may result if the HV battery is disposed of improperly or abandoned. Therefore, make sure to return all HV batteries through an authorized collection agent.

        • After removing the HV battery, keep it away from water. Exposure to water may cause the HV battery to produce heat, resulting in a fire.

    8. Precautions to be observed when towing


      1. Tow the damaged vehicle with its front and rear wheels lifted off the ground.

        CAUTION:

        Towing the damaged vehicle with its rear wheels on the ground will cause the motor to generate electricity. This electricity could, depending on the nature of the damage, leak and cause a fire.

    9. Towing with the 4 wheels on the ground

      CAUTION:


      • If the vehicle needs to be towed using a rope with all 4 wheels on the ground, low speeds and tow only for a short distance and then have the vehicle towed by a truck.

      • Turn the power switch on (IG), and move the shift lever to N.

      • Make sure not to turn the power switch off while the vehicle is being towed. Moving the shift lever to P may result in damage or an accident.

      • If any abnormality is present in the damaged vehicle during towing, stop towing immediately.

  7. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER

    CAUTION:


    • This vehicle is equipped with a Supplemental Restraint System (SRS), which consists of a horn button assembly, instrument panel passenger airbag, curtain shield airbag, front seat airbag, rear seat airbag, lower No. 1 instrument panel airbag, lower No. 2 instrument panel airbag, front seat outer belt, rear seat 3 point type outer belt, center airbag sensor assembly, front airbag sensor, side airbag sensor, rear airbag sensor and seat position airbag sensor. 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 power switch is turned off and after the cable is disconnected from the negative (-) auxiliary battery terminal (SRS parts are equipped with a backup power source. If work is started within 90 seconds of turning the power switch off and disconnecting the cable from the negative (-) auxiliary 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 (-) auxiliary battery terminal.

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

    • Before performing repairs, remove the airbag sensors 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 the SRS is completed, perform the SRS warning light check Click here.

    • When the cable is disconnected from the negative (-) auxiliary battery terminal, the memory settings of each system are 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 clearing the memory in a system.

    • If the vehicle is equipped with a mobile communication system, refer to the Precaution in the Introduction section.

    • After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    • When disconnecting the cable from the negative (-) auxiliary battery terminal while performing repairs, some systems need to be initialized after the cable is reconnected Click here.

    Tech Tips

    In the airbag system, the center airbag sensor assembly, front airbag sensor LH and RH, side airbag sensor assembly LH and RH, and rear airbag sensor LH and RH are collectively referred to as the airbag sensors.


    1. 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.

    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 (199°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 currents 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. SEAT OUTER BELT ASSEMBLY WITH PRETENSIONER


      1. Never measure the resistance of the seat outer belt. This may cause the pretensioner of the seat outer belt to activate, which could cause a serious injury.

      2. Never install the seat outer belt on another vehicle.

      3. Store the seat outer belt in an area where the ambient temperature is below 80°C (176°F), the humidity is not high and there is no electrical noise.

      4. When using electric welding anywhere on the vehicle, disconnect the center airbag sensor connectors (2 pins). These connectors contain shorting springs. This feature reduces the possibility of the pretensioner deploying due to currents entering the squib wiring.

      5. When disposing of a vehicle or the seat outer belt by itself, the pretensioner should be activated before disposal. Activate the pretensioner in a safe place away from electrical noise.

      6. As the seat outer belt is hot after the pretensioner is activated, allow some time for it to cool down sufficiently before disposal. Never apply water to try to cool down the seat outer belt.

      7. Grease, detergents, oil or water should not be applied to the seat outer belt.

    4. 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 power switch is turned off and the cable is disconnected from the negative (-) auxiliary battery terminal, even if only loosening the set bolts of the airbag sensor assembly.

    5. 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 the connector becomes broken, repair or replace it.

  8. ELECTRONIC CONTROL

    A000P8YE19
    Text in Illustration
    *1 Cable
    *2 Negative (-) Auxiliary Battery Terminal

    Note


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

    • After the power switch is turned off, the multi-media module receiver assembly records various types of memory and settings. As a result, after turning the power switch off, be sure to wait for the time specified in the following table before disconnecting the cable from the negative (-) auxiliary battery terminal.

      Waiting Time before Disconnecting Cable from Negative (-) auxiliary battery Terminal
      Condition Waiting Time
      Vehicle enrolled in telematics system (w/ Telematics Transceiver for G-BOOK) 6 minutes
      Vehicle not enrolled in telematics system (w/ Telematics Transceiver for G-BOOK) 1 minute

    1. DISCONNECTING AND RECONNECTING NEGATIVE AUXILIARY BATTERY CABLE


      1. Before performing work on electronic components, disconnect the cable from the negative (-) auxiliary battery terminal to prevent damage to the electrical system or components.

      2. When disconnecting the cable, turn the power switch and headlight 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 will be cleared when the cable is disconnected from the negative (-) auxiliary battery terminal. Write down any necessary data before disconnecting the cable.

    2. A000NNSE07
      Text in Illustration
      *a INCORRECT

      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 on the wires when disconnecting electronic connectors. Pull on the connector itself.

      3. Do not 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 components 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 between terminals of a wire connector, insert the tester probe carefully to prevent the terminals from bending.

  9. COMMUNICATION FUNCTION RESTRAINT OPERATION (w/ Telematics Transceiver for G-BOOK)


    1. Precautions for vehicle enrolled in telematics system

      Note


      • Set the vehicle to "Communication function restraint" before performing inspections and repairs such as the removal and installation of parts, simulation tests, confirmation driving patterns, etc., which output warning displays and DTCs so that the G-BOOK center will not incorrectly recognize the output warnings and DTCs. Doing so also prevents the delivery of vehicle status alerts emails to customers according to vehicle operations performed and the vehicle status while at the workshop, and the updating of the vehicle status which can be checked via the vehicle status report function.

      • Communication function restraint mode can be entered by using the GTS or operating the multi-display.

    2. Communication function restraint method


      1. Communication function restraint

        Tech Tips


        • When a warning is generated by a vehicle malfunction, the warning notification function sends a warning display signal from the combination meter assembly to the G-BOOK center via the G-BOOK onboard device.

        • Updates to the vehicle status, which can be checked by the delivery of vehicle status alerts emails and the vehicle status report, are based on the vehicle status sent to the G-BOOK center once a fixed amount of time elapses after completing vehicle device operations such as turning the power switch off.

        • Immediately after entering communication function restraint mode using the GTS or when starting the navigation system by turning the power switch from off to on (ACC), the communication function restraint mode can be canceled/ resumed from the displayed communication function suspension screen.

        Communication function restraint setting method (Using the multi-display)


        1. Enter diagnostic mode of navigation system Click here.

        2. Once the above operation(s) are performed, the telematics system enters communication function restraint mode.

        Communication function restraint setting method (Using the GTS)


        1. Turn the power switch off.

        2. Connect the GTS to the DLC3.

        3. Start the hybrid control system.

        4. Turn the GTS on.

        5. Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.

        6. Once the above operation(s) are performed, the telematics system enters communication function restraint mode.

  10. STRICT PROHIBITION OF MANUAL EMERGENCY CALL USING EMERGENCY CALL SERVICE (FOR TELEMATICS SYSTEM)


    1. w/ Telematics Transceiver for G-BOOK:


      1. Do not make an emergency call when not in emergency situations. For inspections, use the manual maintenance check.

        Note


        • If the emergency call service is used to connect to the G-BOOK center when not in an emergency situation, an unnecessary workload will be generated at the G-BOOK center. This may cause a delayed response by the G-BOOK center to other emergency calls.

        • If emergency vehicles are dispatched due to an accidental operation of the emergency call switch, you may be charged or punished according to related laws.

      2. If the emergency call switch is accidentally operated;


        1. If the emergency call switch is accidentally operated, contact the G-BOOK center to tell them that the call was made by mistake.

        2. An emergency call cannot be halted or finished from the vehicle. Only the G-BOOK center can halt or finish the call.

        3. If the G-BOOK center cannot be informed that the call was made by mistake, the center will report to authorities, emergency facilities and dealerships in compliance with its agreements. As a result, emergency vehicles may be dispatched.

    2. w/ Telematics Transceiver except G-BOOK:


      1. Do not make emergency calls in non-emergency situations. When performing an inspection, use the manual maintenance check.

        Note


        • If the emergency call service is used to connect to the PSAP in a non-emergency situation, an unnecessary workload will be generated at the PSAP. This may cause a delayed response by the PSAP to other emergency calls.

        • If emergency vehicles are dispatched due to an accidental operation of the manual (SOS) switch, you may be charged or punished according to local law.

      2. If the manual (SOS) switch is accidentally operated:


        1. Contact the PSAP to tell them that the call was made by mistake.

        2. An emergency call cannot be halted or finished from the vehicle. Only the PSAP can halt or finish an emergency call.

        3. If the PSAP cannot be informed that the emergency call was made by mistake, the center will report an emergency to authorities, emergency facilities and dealerships in compliance with its agreements. As a result, emergency vehicles may be dispatched.

  11. 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 nearby.

      2. Never work in a pit or near a pit as fuel vapors will collect there.

    2. REMOVING AND INSTALLING FUEL SYSTEM PARTS


      1. Prepare a fire extinguisher before starting work.

      2. To prevent static electricity, install a ground wire between the fuel changer and vehicle, and do not spray the surrounding area with water. Be careful when performing work in this area, as the floor 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, work 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.

  12. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS


    1. A000OSM

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

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

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

  13. HANDLING OF HOSE CLAMPS

    A000S8NE13
    Text in Illustration
    *1 Clamp Track
    *2 Spring Type Clamp

    1. Before removing a 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, it may be necessary to spread the tabs slightly after installation by pushing them in the direction of the arrows as shown in the illustration.

  14. FOR VEHICLES EQUIPPED WITH MOBILE COMMUNICATION SYSTEMS

    A000PQ2

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

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

    3. Keep the antenna and feeder separate from other wiring as much as possible. This will prevent signals sent 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 a high-powered mobile communication system.

  15. HEADLIGHT INSPECTION OR MAINTENANCE


    1. A000QS3E03
      Text in Illustration
      *a Illumination for 3 minutes or more prohibited if covered

      When the headlights are illuminated, do not cover the headlights for 3 minutes or more.

      Note

      As the headlight outer lens is made of resin, the resulting heat created when covering the headlight for an extended period of time may deform the headlight.

  16. FOR ELECTRIC PARKING BRAKE SYSTEM


    1. Precautions when working on vehicle.


      1. If the vehicle needs to be tilted after stopping the vehicle on a level surface, press the electric parking brake switch twice, as the braking force may be insufficient.

        Tech Tips


        • The electric parking brake determines how much braking force to apply by automatically detecting the slope of the road.

        • Press the electric parking brake twice to apply the parking brake with the maximum braking force.

  17. FOR VEHICLES EQUIPPED WITH TRACTION CONTROL (TRC) AND VEHICLE STABILITY CONTROL (VSC) SYSTEMS

    When testing with a 2-wheel drum tester such as a speedometer tester, a combination speedometer and brake tester, or a chassis dynamometer, or when jacking up the rear wheels and turning the wheels, perform the following procedure to enter inspection mode and disable the TRC and VSC systems Click here.

    Tech Tips


    • The vehicle may slip unexpectedly out of the dynamometer because of TRC and VSC operation.

    • Pressing the VSC OFF switch (for vehicles with a VSC OFF switch) does not disable TRC and VSC operation completely.

    Note


    • Make sure that the TRC OFF message is displayed on the multi-information display and the VSC OFF indicator light will comes on.

    • Secure the vehicle with chains for safety.

  18. WHEN INSPECTING VEHICLES

    Note

    When the vehicle is run in inspection mode for an operation such as a speedometer test, a DTC may be stored. Therefore, if the warning light comes on, after canceling inspection mode, check for DTCs using the GTS and clear the DTCs.


    1. VEHICLE CONDITIONS


      1. Before activating inspection mode, turn the air conditioning off, start the hybrid system with the shift lever in P, and check that the engine stops within several seconds after starting (engine warm up check).

      2. Activate the appropriate inspection mode and inspect the vehicle Click here.

        Tech Tips

        Different types of inspection modes are available. One is maintenance mode, and the other is certification mode. The following table indicates the mode appropriate for each test item.

        Test Item Mode
        1. Vehicle straight traveling test (side slip inspection) Maintenance mode or normal mode
        2. Braking force test Normal mode
        3. Speedometer test Maintenance mode
        4. Exhaust gas test (idling) Maintenance mode
        5. Headlight test Maintenance mode or normal mode

      3. Cancel inspection mode immediately after completion of inspection.

        Note

        Driving the vehicle without canceling inspection mode may damage the transmission.

  19. WHEN TESTING BRAKES, SPEEDOMETER, ETC.


    1. WHEN USING A SPEEDOMETER TESTER

      Note


      • The inspection should be done using the rear wheels.

      • The maximum vehicle speed must be less than 60 km/h (37 mph) (when using free rollers to support the front wheels, the vehicle speed must be less than 50 km/h (31 mph)).

      • The driving time should be less than 1 minute.

      • Follow all usage and safety procedures in the operator's manual for the speedometer tester.


      1. Place the rear wheels onto the rollers.

      2. Enter Inspection Mode to disable TRC and VSC control Click here.

      3. A000PD4

        Secure the vehicle with suitable chains or straps.

      4. With the engine running, measure the vehicle speed while increasing the speed gradually with the shift lever in D.

      5. After the test is finished, decrease the speed gradually, and then stop the vehicle.

    2. WHEN USING A BRAKE TESTER

      Note


      • A high-speed type brake tester cannot be used.

      • The vehicle speed should be less than 0.5 km/h (0.3 mph).

      • Follow all usage and safety procedures in the operator's manual for the brake tester.


      1. Position the wheels to be tested (front or rear) on the tester.

      2. Enter Inspection Mode to disable TRC and VSC control Click here.

      3. Start the engine to allow normal brake booster operation.

      4. Move the shift lever to N.

      5. Operate the brakes to perform the test.

    3. WHEN USING A CHASSIS DYNAMOMETER


      1. Place the rear wheels onto the rollers.

      2. Enter Inspection Mode to disable TRC and VSC control Click here.

      3. Check that the vehicle is securely fixed in place.

      4. A000PD4

        Secure the vehicle with suitable chains or straps.

        CAUTION:

        Confirm that the vehicle is securely immobilized.

        Note


        • Do not brake or accelerate suddenly.

        • Follow all usage and safety procedures in the operator's manual for the chassis dynamometer.

    4. WHEN USING AN ON-VEHICLE BALANCER


      1. Raise the vehicle until all 4 wheels are off the ground.

      2. Support the vehicle with safety stands at an appropriate height. Make sure that the vehicle does not lean in any direction, and that the tires are completely clear of the floor.

      3. Place the vibration pick-up unit into position for the wheel to be measured*1.

      4. Release the parking brake.

      5. Check that no dragging force exists when turning each wheel by hand.

      6. Put the wheel balancer in position.

      7. The wheel balance measurement should be done by using both the engine and the wheel balancer drive roller to spin the wheels.

        CAUTION:

        Confirm that the vehicle is securely immobilized.

        Note


        • Start the engine and then increase the vehicle speed gradually with the shift lever in D.

        • Do not accelerate or decelerate suddenly.

        • Deceleration should be done by braking gradually.

        • Make sure that no one is standing in front of or behind the spinning wheels.

        • The measurement should be done quickly.

        • Follow all usage and safety procedures in the operator's manual for the wheel balancer.

        Tech Tips

        *1: Different on-vehicle wheel balancers have different requirements for mounting the vibration pick-up unit(s). Refer to the operator's manual for the wheel balancer to confirm requirements for use.

  20. 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).

      A000SKME13
      Text in Illustration
      *1

      Note

      If the vehicle is tilted after parking on a level surface, the braking force may be insufficient as the electric parking brake determines how much braking force to apply by automatically detecting the slope of the road.

      		 *2

      Tech Tips

      Press the electric parking brake switch twice to apply the parking brake with the maximum braking force.

      Note

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

    3. 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 short distances 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 wheels on the ground, the drivetrain or vehicle may be damaged.


      1. Emergency towing procedure


        1. Turn the power switch on (IG).

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

        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.

        • If the hybrid system is off, the power assist for the brakes and steering will not function, making steering and braking more difficult.

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

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

      A000OKE

      1. Do not tow the vehicle from the front wheels on the ground.

        CAUTION:

        If the vehicle is towed with only the front wheels on the ground, the steering may move, causing the vehicle to become unstable.

        Note

        If the vehicle is towed with only the rear wheels on the ground, the drivetrain may overheat and be damaged.

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

        Note

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

  21. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER

    CAUTION:

    If a large amount of unburned gasoline or gasoline vapors flow into the converter, it may cause converter overheating and create a fire hazard. To prevent this, observe the following precautions:


    1. Use only unleaded gasoline.

    2. Avoid performing unnecessary spark tests.


      1. Perform a spark test only when absolutely necessary. Perform this test as rapidly as possible.

      2. While testing, never race the engine unless instructed.

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

    4. 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.

  22. INSPECTION AND ADJUSTMENT OF JOINT ANGLE DURING REMOVAL AND INSTALLATION OF PROPELLER SHAFT


    1. When performing operations which involve the removal and installation of the propeller shaft, always check the joint angle. Make adjustments if necessary Click here.

      A000QUGE01
      Text in Illustration
      *a No. 2 Joint Angle *b No. 3 Joint Angle