REPAIR INSTRUCTION PRECAUTION

BASIC REPAIR HINT

PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE

ACTIONS TO BE TAKEN WHEN A WARNING LIGHT IS ILLUMINATED

*A	for LHD	-	-
*1	READY Indicatot	*2	Master Warning Light
*3	Hydrogen Leak Warning Light	*4	Multi-information Display

*A	for RHD	-	-
*1	READY Indicatot	*2	Master Warning Light
*3	Hydrogen Leak Warning Light	*4	Multi-information Display

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 indicator does not illuminate when attempting to turn the power switch on (READY).

   Indicator Light	Vehicle Condition
   (1) READY Indicatot (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.
   (3) Charge Warning	Illuminates when there is a malfunction in the charging system. (Be sure to check the DTCs (Diagnostic Trouble Codes) if this light illuminates together with the master warning light.)
   (4) Hydrogen Warning Light	Illuminates if the hydrogen concentration is at or above the threshold value. (Approximately 2%)

ACTIONS TO BE TAKEN WHEN BATTERIES ARE DISCHARGED

ACTIONS TO BE TAKEN FOR VEHICLES DAMAGED BY IMPACT (Hydrogen System)

CAUTION:

• 

  Hydrogen gas is a colorless, odorless and flammable gas.

• Because the flammable concentration range is wide (4 - 74.5%) and the energy required for ignition is extremely low, even static electricity can easily cause hydrogen gas to ignite. While working on the vehicle, if the sound of hydrogen gas leaking (a loud hissing sound) can be heard, measure the hydrogen gas concentration with a hydrogen concentration detector. If the hydrogen gas concentration near the vehicle is more than 4%, there is a danger that the hydrogen could ignite, so move away from the vehicle immediately.

• 

  Even after the vehicle is stopped, there is still hydrogen gas remaining in hydrogen equipment such as the hydrogen tanks and in the hydrogen piping. To avoid fires or explosions, do not cut or destroy hydrogen equipment or hydrogen piping.

• Because of the danger of hydrogen igniting, when a hydrogen leak is present, do not use electrical devices or rescue devices that could generate static electricity.

*1	FC Stack Assembly	*2	No. 1 Hydrogen Tank Assembly
*3	No. 2 Hydrogen Tank Assembly	*4	Hydrogen Supply Regulator Assembly
*5	Hydrogen Tube Joint (Inlet Side)	*6	Hydrogen Tube Joint (Outlet Side)

1. In case of a vehicle fire

   
   

   1. A fuel cell vehicle (FCV) contains compressed hydrogen gas.

   2. When spraying water on the fire, prepare for the hydrogen to ignite, and keep your distance from the vehicle while spraying water.

   3. In particular, spray a large amount of water on the hydrogen tanks under the floor at the rear of the vehicle to keep them cool.

   4. If the hydrogen has ignited, completely extinguishing the fire could cause unburned hydrogen gas to collect, which could result in a secondary explosion. To prevent this, spray water to keep the fire from spreading to the surroundings, and wait for the fire to burn itself out (when all the fuel has been expended).

   5. To prevent the hydrogen tanks from exploding due to abnormal temperature / pressure increase, pressure relief device designed into the hydrogen tanks will open when the temperature exceeds 110°C, causing the hydrogen gas inside the tanks to be discharged toward the rear of the vehicle.

   6. Although pure hydrogen gas burns with a nearly colorless flame that is very difficult to see, in the case of a vehicle fire, the flames will be mixed with other flames from nearby combustible materials, making them easier to see.

   7. A peculiar characteristic of hydrogen flame is that while the temperature of the flame itself is extremely high, because the flame emits very little radiant heat, it is difficult to feel the heat of the fire when approaching it.

2. Make sure that the sound of hydrogen gas leaking (a loud hissing sound) cannot be heard.

   
   

   1. When approaching the vehicle, approach from the front side of the vehicle.

   2. When a leaking sound can be heard, there is a danger of igniting the hydrogen, so move away from the vehicle immediately.

   3. Check that the leaking sound has stopped before moving on to the following procedure.

3. Using a hydrogen concentration detector, measure the hydrogen concentration around the vehicle to make sure that it does not exceed 4%.

   
   

   1. If the concentration exceeds 4%, there is a danger of igniting the hydrogen, so move away from the vehicle immediately.

   2. If a fan or blower is available, blow air to reduce the hydrogen concentration. When approaching the vehicle, approach from the upwind side.

   3. Periodically measure the hydrogen concentration, and make sure that the hydrogen concentration does not exceed 4% before moving on to the following procedure.

ACTIONS TO BE TAKEN FOR VEHICLES DAMAGED BY IMPACT (High-voltage System)

1. Items to be prepared for the accident site

   
   

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

   • 20 liters (21.1 US qts, 17.6 Imp. qts) saturated boric acid solution (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 up the neutralized 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 EV battery and the immediate area for any electrolyte leakage. Do not touch any leaked liquid because it could be a highly alkaline electrolyte.

   • If the vehicle is submerged in water, work on the vehicle only after the vehicle has been pulled out of the water.

   
   

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

      CAUTION:

      
      

      • Do not touch any leaked liquid because it could be a highly alkaline electrolyte. Wear rubber gloves and goggles, neutralize the liquid with a 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.

      • 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.

      

      *1	FCV TRANSAXLE WITH MOTOR ASSEMBLY	*2	FC AIR COMPRESSOR WITH MOTOR ASSEMBLY
      *3	INVERTER WITH CONVERTER ASSEMBLY	*4	FRAME WIRE
      *5	EV BATTERY	-	-

      

      *1	FC STACK ASSEMBLY	*2	FC CONVERTER ASSEMBLY
      *3	MOTOR COMPARTMENT RELAY BLOCK	*4	COMPRESSOR WITH MOTOR ASSEMBLY
      *5	NO. 3 MOTOR WIRE	*6	MG-IGCT FUSE
      *7	FC CONVERTER POWER OUTLET CABLE	*8	HYDROGEN PUMP INVERTER CABLE

   3. 

      *1	IG2-MAIN Fuse

      Turn the power switch off.

      Tech Tips

      If the power switch cannot be turned off, remove the IG2-MAIN fuse from the motor compartment relay block. Confirm that the READY light is off.

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

   5. While wearing insulated gloves, remove the service plug grips.

      for FC:

      Click here

      for EV:

      Click here

      Note

      After removing the service plug grips, 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 are met, tow the vehicle away using a tow truck.

   
   

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

   • One or more of the hydrogen system components and pipes are damaged.

   • Components related to driving, the transaxle, 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 grips.

   for FC:

   Click here

   for EV:

   Click here

   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 push the P position switch.

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

   4. Remove the service plug grips 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.

      Wear rubber gloves and goggles, neutralize the liquid with a 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)

   • 20 liters (21.1 US qts, 17.6 Imp. qts) saturated boric acid solution (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 EV battery and immediate area for any electrolyte leakage.

      CAUTION:

      
      

      • Do not touch any leaked liquid because it could be a 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 up 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. 

      *1	IG2-MAIN Fuse

      Turn the power switch off.

      Tech Tips

      If the power switch cannot be turned off, remove the IG2-MAIN fuse from the motor compartment relay block. Confirm that the READY light is off.

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

   7. While wearing insulated gloves, remove the service plug grips.

      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 EV battery

   
   

   1. When disposing of an EV battery, make sure to return it through an authorized collection agent who is capable of handling it safely. If the EV 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 EV battery is disposed of improperly or abandoned. Therefore, make sure to return all EV batteries through an authorized collection agent.

      • After removing the EV battery, keep it away from water. Exposure to water may cause the EV 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 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 cable or chain with all 4 wheels on the ground, do not exceed 5 km/h (3 mph) and tow only for a short distance and then have the vehicle towed by a truck.

   • Turn the power switch on (IG), move the shift lever to N and confirm that neutral (N) has been selected.

   • Make sure not to turn the power switch off while the vehicle is being towed. Park (P) may be selected, resulting in damage or an accident.

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

   Tech Tips

   
   

   • Neutral (N) cannot be selected if the auxiliary battery is disconnected.

   • There is a possibility that neutral (N) cannot be selected when parts related to the transmission control ECU have a malfunction.

FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER

This vehicle is equipped with a Supplemental Restraint System (SRS).

1. GENERAL NOTICE

   
   

   1. As malfunctions of the SRS are difficult to confirm, Diagnostic Trouble Codes (DTCs) become the most important source of information when troubleshooting. When troubleshooting the SRS, always check for DTCs before disconnecting the auxiliary battery.

   2. 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.

      The SRS is equipped with a back-up 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, the SRS may deploy.

      When the cable is disconnected from the negative (-) auxiliary battery terminal, the clock and audio system memory will be cleared. 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 back-up power source (auxiliary battery or others) to avoid clearing the system memory. The back-up power source may inadvertently power the SRS and cause it to deploy.

   3. If the vehicle has been involved in a minor collision where the SRS does not deploy, the steering pad, front passenger airbag assembly, knee airbag assembly, seat side airbag assemblies, SRS seat cushion airbag assembly, curtain shield airbag assemblies and seat outer belt assemblies should be inspected before further use of the vehicle.

   4. Never use SRS parts from another vehicle. When replacing parts, use new ones.

   5. Before performing repairs, remove the airbag sensor assemblies if impacts are likely to be applied to the sensor during repairs.

   6. Never disassemble and attempt to repair any of the airbag sensor assemblies or airbag assemblies.

      
      

      1. Steering pad

      2. Front passenger airbag assembly

      3. Knee airbag assembly

      4. Seat side airbag assembly

      5. SRS seat cushion airbag assembly

      6. Curtain shield airbag assembly

      7. Seat outer belt assembly

   7. Replace the airbag sensor assemblies and the airbag assemblies if: 1) damage has occurred from being dropped, or 2) cracks, dents or other defects in the case, bracket or connector are present.

   8. Do not directly expose the airbag sensor assemblies or airbag assemblies to hot air or flames.

   9. Use a voltmeter/ohmmeter with high impedance (minimum = 10 kΩ) for troubleshooting electrical circuits.

   10. Information labels are attached to the SRS components. Follow the instructions on the labels.

   11. 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. Otherwise, cable damage and other problems may occur. Refer to the information about correct installation of the steering wheel.

      Click here

3. STEERING PAD

   
   

   1. Always place a removed or new steering pad with the deployment surface facing upward. Placing the steering pad with the deployment surface facing downward could cause a serious accident if the airbag deploys. Also, do not place anything on top of the steering pad.

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

   3. Grease or detergents of any kind should not be applied to the steering pad.

   4. Store the steering pad 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. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly 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 steering pad by itself, the airbag should be deployed using SST before disposal. Deploy the airbag in a safe place away from electrical noise.

      Click here

4. FRONT PASSENGER AIRBAG ASSEMBLY

   
   

   1. Always place a removed or new front passenger airbag assembly with the deployment surface facing upward. Placing the airbag assembly with the airbag deployment surface facing downward could cause a serious accident if the airbag deploys.

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

   3. Grease or detergents of any kind should not be applied to the front passenger airbag assembly.

   4. Store the front passenger 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. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly 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 front passenger airbag assembly by itself, the airbag should be deployed using SST before disposal. Deploy the airbag in a safe place away from electrical noise.

      Click here

5. KNEE AIRBAG ASSEMBLY

   
   

   1. Always place a removed or new knee airbag assembly with the airbag deployment surface facing upward. Placing the airbag assembly with the airbag deployment surface facing downward could cause a serious accident if the airbag deploys.

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

   3. Grease or detergents of any kind should not be applied to the knee airbag assembly.

   4. Store the knee 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. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly 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 a knee airbag assembly by itself, the airbag should be deployed using SST before disposal. Deploy the airbag in a safe place away from electrical noise.

      Click here

6. SEAT SIDE AIRBAG ASSEMBLY

   
   

   1. Always place a removed or new seat side airbag assembly with the airbag deployment surface facing upward.

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

   3. Grease or detergents of any kind should not be applied to the seat side airbag assembly.

   4. Store the seat side 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. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly 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 a seat side airbag assembly by itself, the airbag should be deployed using SST before disposal. Deploy the airbag in a safe place away from electrical noise.

      Click here

7. SRS SEAT CUSHION AIRBAG ASSEMBLY

   
   

   1. Always place a removed or new SRS seat cushion airbag assembly with the airbag deployment surface facing upward.

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

   3. Grease or detergents of any kind should not be applied to the SRS seat cushion airbag assembly.

   4. Store the SRS seat cushion 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. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly 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 an SRS seat cushion airbag assembly by itself, the airbag should be deployed using SST before disposal. Deploy the airbag in a safe place away from electrical noise.

      Click here

8. 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.

      CAUTION:

      The plastic bag should be disposed of after use.

      Note

      Never disassemble the curtain shield airbag assembly.

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

   3. Grease or detergents of any kind should not be applied to the curtain shield airbag assembly.

   4. Store the curtain shield 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. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly 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 a curtain shield airbag assembly by itself, the airbag should be deployed using SST before disposal. Deploy the airbag in a safe place away from electrical noise.

      Click here

9. SEAT OUTER BELT ASSEMBLY (SEAT BELT PRETENSIONER)

   
   

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

   2. Never disassemble the seat outer belt assembly.

   3. Never install the seat outer belt assembly on another vehicle.

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

   5. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly 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 a seat outer belt assembly by itself, the seat outer belt assembly should be activated before disposal. Activate the seat outer belt assembly in a safe place away from electrical noise.

      Click here

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

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

10. AIRBAG ECU ASSEMBLY

    
    

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

    2. The connectors to the airbag ECU assembly should be connected or disconnected with the sensor installed to the vehicle. If the connectors are connected or disconnected while the airbag ECU assembly is not installed, the SRS may be activated.

    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 bolts of the airbag ECU assembly.

11. WIRE HARNESS AND CONNECTOR

    
    

    1. All the connectors in the system are a standard yellow color. If an SRS wire harness has an open circuit or a connector is broken, replace it.

ELECTRONIC CONTROL

*1	Cable
*2	Negative (-) Auxiliary Battery Terminal

Note

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

• Before starting the hybrid system, make sure that the ground point is installed to the body with the bolts.

• After the power switch is turned off, the navigation receiver assembly records various types of memory and settings. As a result, after turning the power switch off, make sure to wait at least 90 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal.

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. 

   *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 motor room 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.

REMOVING/INSTALLING COMPRESSED HYDROGEN SYSTEM COMPONENTS

REMOVING/INSTALLING FC COOLING SYSTEM COMPONENTS

INSTALLING/REMOVING EV COOLING SYSTEM COMPONENTS

1. If foreign contaminants such as metal fragments enter the cooling system, they will adversely affect the inverter and other components.

2. When installing or removing cooling system components, cover the openings of the removed cooling system components as well as the openings of the parts they connect to with protective tape to prevent entry of foreign matter.

3. When installing cooling system components, make sure there is no contamination by foreign matter.

REMOVAL AND INSTALLATION OF INTAKE PARTS

HANDLING OF HOSE CLAMPS

*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.

FOR VEHICLES EQUIPPED WITH MOBILE COMMUNICATION SYSTEMS

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 ECUs 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.

HEADLIGHT INSPECTION OR MAINTENANCE

1. 

   *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.

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

1. NOTICES FOR WHEN TESTING WITH DRUM TESTER

   
   

   1. When testing with a 2-wheel drum tester such as a speedometer tester, a combination speedometer and brake tester, or a chassis dynamometer, perform the following procedure to enter inspection mode and disable the TRC and VSC systems.

      Click here

      Note

      
      

      • If the vehicle is tested in normal mode on the tester, TRC and VSC operation may cause the vehicle to jump off of the tester.

      • Secure the vehicle with chains for safety.

      • Make sure to cancel inspection mode after completing a check using a 2-wheel drum tester.

      • After performing a check, never drive the vehicle without canceling inspection mode.

      Tech Tips

      
      

      • During inspection mode, the TRC and VSC systems are disabled and slip indicator light is illuminated.

      • Inspection mode is canceled when the power switch is turned off. As a result, if it is necessary to perform an inspection after the power switch has been turned off, perform the procedure again to re-enter inspection mode.

2. NOTICES FOR VSC RELATED PROCEDURES

   
   

   1. For VSC related parts, adjustments are required after removal and installation. Therefore, perform removal and installation only when necessary.

   2. When performing VSC related procedures, be sure to strictly follow the preparation and completion procedures.

   3. When performing removal and installation or replacement of VSC related parts, first disconnect the cable from the negative (-) auxiliary battery terminal.

WHEN INSPECTING VEHICLES

1. VEHICLE CONDITIONS

   
   

   1. Activate the appropriate inspection mode and inspect the vehicle.

      Click here

      Tech Tips

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

      The controls in maintenance mode and certification mode are the same.

      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

   2. Cancel inspection mode immediately after completing the inspection.

      Note

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

2. WHEN USING A BRAKE TESTER

   Note

   
   

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

   • 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. Place the wheels to be tested (front or rear) onto the rollers.

   2. Start the FC system to allow normal brake booster operation.

   3. Move the shift lever to N and confirm that neutral (N) has been selected.

   4. Operate the brakes to perform the test.

3. WHEN USING A SPEEDOMETER TESTER

   CAUTION:

   Be sure to perform the test in maintenance mode.

   Note

   Do not perform rapid starting or quick acceleration on a speedometer tester. If rapid starting or quick acceleration is performed on a speedometer tester, damage may occur to the transaxle.

   
   

   1. Depress the accelerator pedal slowly and gradually accelerate the vehicle, then take a measurement.

   2. After the measurement, use the brakes to gradually decelerate the vehicle.

4. WHEN USING A CHASSIS DYNAMOMETER

   CAUTION:

   Be sure to perform the test in maintenance mode.

   Note

   Sudden acceleration or deceleration of the vehicle on a chassis dynamometer under minimal load may damage the transaxle.

   
   

   1. Always set an appropriate load before starting the test.

5. WHEN USING AN ON-VEHICLE BALANCER

   Note

   
   

   • Be sure to perform the test in maintenance mode.

   • Start the FC system and then increase the vehicle speed gradually with drive (D) selected.

   • Do not accelerate or decelerate suddenly.

   • Deceleration should be done by braking gradually.

   • Make sure that no one is standing in-line with the spinning wheels.

   • Measurement should be done quickly.

   • Confirm that the vehicle is securely immobilized.

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

      Tech Tips

      *: 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.

   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. Wheel balance measurement should be done by using both the motor and the wheel balancer drive roller to spin the wheels.

PRECAUTIONS FOR TOWING FRONT WHEEI DRIVE VEHICLES