REPAIR INSTRUCTION PRECAUTION


  1. BASIC REPAIR HINT


    1. HINTS ON OPERATIONS

      A01BG5BE01
      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 Safety 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 operation, prepare a tool stand, SST, gauge, oil and parts for replacement.
      5 Removal and 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. A01BCYHE03

      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. A01BH48E01

      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
        A01BI2N A01BC5O FUSE FUSE
        A01BCZ2 A01BEH1 MEDIUM CURRENT FUSE M-FUSE
        A01BFUN A01BFYJ HIGH CURRENT FUSE H-FUSE
        A01BCNM A01BF5N FUSIBLE LINK FL
        A01BB5K A01BED6 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 work, always replace the damaged clip with a new one.

        Shape (Example) Removal/Installation
        A01BDGW A01BBTR

        Remove clips with clip remover or pliers.

        A01BAMK A01BFCR

        Remove fasteners with clip remover or screwdriver.

        A01BGLJ A01BBN8

        Remove clips with wide scraper to prevent panel damage.

        A01BC9E A01BCVL

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

        A01BAI1 A01BALB

        Remove clips by unscrewing center pin and prying out shell.

        A01BDA1 A01BFSK

        Remove clips by prying out pin and then prying out 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 cap or cover that has damaged claws with a new one.

        Shape (Example) Illustration Procedures
        A01BH8K A01BADA
        1. Using a screwdriver, detach the claws and remove the cap or cover.

        A01BDZC A01BBFI
        1. Using a screwdriver, detach the claws and remove the cap or cover.

        A01BF1E A01BEN2
        1. Using a screwdriver, detach the claws and remove the cap or cover.

    9. HINGE, GUIDE, CLAMP AND PIN ETC.


      1. The removal and installation methods of typical hinge, guide, clamp and pin used for vehicle body parts are shown in the table below.

        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
        A01BGWH A01BA74E01
        A01BE4S A01BCB0E01
        A01BG3P A01BHM6E01
        A01BD01 A01BD7PE01
    10. REMOVAL AND INSTALLATION OF VACUUM HOSES


      1. A01BH89E01

        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. A01BEIJE01

        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. A01BDZPE02

      TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL


      1. A01BHUWE01

        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. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER

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

        CAUTION:

        Failure to carry out the service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing and lead to serious injury. Furthermore, if a mistake is made when servicing SRS, it is possible that the SRS may fail to operate properly. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following section carefully.


        1. GENERAL NOTICE


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

          2. Work must be started at least 90 seconds after the ignition switch is turned off and after the cable is disconnected from the negative (-) battery terminal.

            The SRS is equipped with a back-up power source. If work is started within 90 seconds after turning the ignition switch off and disconnecting the cable from the negative (-) battery terminal, the SRS may deploy.

            When the cable is disconnected from the negative (-) battery terminal, clock and audio system memory is erased. Before starting work, make a note of the settings of each memory system. When work is finished, reset the clock and audio system as before.

            CAUTION:

            Never use a back-up power source (battery or other) to avoid erasing system memory. The back-up power source may inadvertently power the SRS and cause it to deploy.

          3. In minor collisions where the SRS does not deploy, the steering pad, front passenger airbag assembly and front seat outer belt assembly should be inspected before further use of the vehicle.

            Click here for steering pad

            Click here for front passenger airbag assembly

            Click here for front seat outer belt assembly

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

          5. Before 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 all airbag sensor assemblies and all airbag assemblies.


            1. Steering pad

            2. Front passenger airbag 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 assembly or airbag assembly 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. A01BD2GE01

          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 Click here.

        3. STEERING PAD


          1. Always place a removed or new steering pad surface upward as shown in the illustration. Placing the horn button with the pad surface facing down could cause a serious accident if the airbag inflates. Also, do not place anything on top of the horn button.

            A01BF7QE01
          2. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury.

            A01BAJ1E03
          3. Grease or detergents of any kind should not be applied to the horn button.

          4. Store the horn button assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.

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

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

        4. FRONT PASSENGER AIRBAG ASSEMBLY


          1. Always place a removed or new front passenger airbag assembly with the pad surface facing upward as shown in the illustration. Placing the airbag assembly with the airbag inflation direction facing down could cause a serious accident if the airbag inflates.

            A01BEH4E01
          2. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury.

            A01BB7OE04
          3. Grease or detergents of any kind should not be applied to the front passenger airbag assembly.

          4. Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.

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

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

        5. FRONT SEAT OUTER BELT ASSEMBLY (SEAT BELT PRETENSIONER)


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

            A01BC49E02
          2. Never disassemble the seat outer belt.

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

          4. 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.

          5. When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (2 pins). 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 a vehicle or the seat outer belt unit by itself, the seat outer belt should be activated before disposal Click here. Activate in a safe place away from electrical noise.

          7. As the seat outer belt 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.

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

        6. 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.

        7. 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 a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes broken, repair or replace it.

      3. ELECTRONIC CONTROL

        A01BHXDE02

        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 ignition 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. A01BEA1E02

          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. 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 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 terminals from bending.

      4. 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, 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 equipments 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.

      5. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS

        A01BDR8E01

        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.

      6. HANDLING OF HOSE CLAMPS

        A01BHYJE01

        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.

      7. FOR VEHICLES EQUIPPED WITH MOBILE COMMUNICATION SYSTEMS

        A01BFGH

        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 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 any high-powered mobile communication system.

      8. 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).

          A01BAQOE02

          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 distances of less than 80 km, and at speeds below 30km/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 ignition switch to ON.

            2. for Manual Transmission:

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

            3. for Automatic Transmission:

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

            4. Release the parking brake.

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

          A01BGUZ

          1. Do not tow the vehicle with only 2 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.

      9. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER

        CAUTION:

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


        1. Use only unleaded gasoline.

        2. Avoid idling the engine for more than 20 minutes.

        3. Avoid performing unnecessary spark jump tests.


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

          2. While testing, never race the engine.

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

        5. 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.