REPAIR INSTRUCTION PRECAUTION


  1. BASIC REPAIR HINT


    1. HINTS ON OPERATIONS

      B005YCVE13
      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 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. B005YPXE34
      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. B005XKUE23
      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
        B005YNI B005Y4O FUSE FUSE
        B005Y4N B005ZJJ MEDIUM CURRENT FUSE M-FUSE
        B005ZGE B005Y9Y HIGH CURRENT FUSE H-FUSE
        B005ZSJ B005XQ1 FUSIBLE LINK FL
        B005YPH B005XYG 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
        B005Y0O

        Remove the clips with a clip remover or pliers.

        B005XJW
        B005XF3

        Remove the clips with a clip remover or screwdriver.

        B005ZTW
        B005Y0J

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

        B005ZFQ
        B005Y7M

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

        B005XCJ
        B005ZTU

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

        B005ZIN
        B005ZA1

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

        B005Y6Y
    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 Procedure
        B005Y7B B005YFJ Using a screwdriver, disengage the claws and remove the cap or cover.
        B005YAU B005YMY Using a screwdriver, disengage the claws and remove the cap or cover.
        B005Z6G B005YML Using a screwdriver, disengage the claws and remove the cap or cover.
    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
        B005ZGZ B005YVJE01
        *1 Pull away from the pins to disengage.
        B005XO2 B005XJIE01
        *1 Disengage the pins by pulling.
        B005Z0Y B005Z0IE01
        *1 Remove the clamps with pliers.
        B005XZ1 B005XM9E01
        *1 Remove the clamps with pliers.
    10. REMOVAL AND INSTALLATION OF VACUUM HOSES


      1. B005YAPE21
        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. B005ZVN

        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. B005Y7LE06

      TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL


      1. B005YUME04

        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.

      B005YRV

      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.

      B005YLB

      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. B005YAK

      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.

      B005Y79
    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 a 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 instrument panel is illuminated. To avoid injury, make sure that both the indicator on the power switch and the READY light on the combination meter are off.

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

    B005YXEE07
    Text in Illustration
    *1 READY Light *2 Hybrid Battery Indicator Light
    *3 Auxiliary Battery Charging Warning Light *4 MIL
    *5 Hybrid System Overheat Warning Light *6 HV System Warning Light

    1. If one of the warning lights (3) to (6) 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 Illuminates when the power switch is turned on (READY), indicating that the vehicle is ready to be driven.
      (2) Hybrid Battery Indicator Light Illuminates when replacement or inspection of the lithium ion HV battery is necessary.
      (3) Auxiliary Battery Charging Warning Light

      Illuminates when there is a malfunction of a charging system component such as the DC/DC converter.

      (If the HV system warning light also illuminates, check for DTCs.)

      (4) 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).)

      (5) Hybrid System Overheat Warning Light Illuminates when the HV system or HV battery overheats with the READY light illuminated.
      (6) HV System Warning Light Illuminates and the warning buzzer sounds when there is a malfunction in the HV system or HV battery.
  5. ACTIONS TO BE TAKEN WHEN BATTERIES ARE DISCHARGED

    Tech Tips

    The vehicle uses a 12 V auxiliary and a 201.6 V 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 instrument panel 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.

      • Park (P) cannot be disengaged.

      • The auxiliary battery charging warning light is blinking or illuminated.

      Note

      Never use a quick charger.


      1. Engage the parking brake.

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

      3. Remove the engine room relay block and junction block cover.

      4. B005YAS

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

        Tech Tips

        Use the booster terminal in the engine compartment.

        Connecting Sequence Connecting Location
        1 Positive booster terminal of stalled vehicle
        2 Positive auxiliary battery terminal of rescue vehicle
        3 Negative auxiliary battery terminal of rescue vehicle
        4 Position shown in the illustration on stalled vehicle
      5. Start the engine of the rescue vehicle and run the engine at a speed slightly higher than usual.

      6. B005YQ4E04
        Text in Illustration
        *1 P Position Request Indicator Light (Blinking)
        *2 HV Battery SOC Indicator light (Blinking)

        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 and HV battery SOC indicator light or P position request indicator light in the combination meter is blinking, the HV battery may be discharged.

    2. When the HV battery is discharged:


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

        Tech Tips

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

  6. ACTIONS TO BE TAKEN FOR VEHICLES DAMAGED BY IMPACT

    CAUTION:

    This vehicle has a hybrid system that operates at voltages of up to 650 V. An organic electrolyte containing carbonic acid esters as its main component is used as the electrolyte for the HV battery. 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, organic solvent mask, safety shoes and solvent resistant apron (for organic solvent))

      • Soap

      • 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 organic electrolyte that contains carbonic acid esters.

      • The electrolyte is flammable. Keep all ignition sources such as open flame and hot objects away from the electrolyte.

      • Electrolyte leaks may cause acute poisoning if a high concentration of the vapor from the organic solvent is inhaled. In case of inhalation, move the affected person to a place with ample fresh air and let them lie quietly. Seek medical care.

      • If the vehicle is immersed in water, do not touch any high-voltage components or cables including service plug grips. This is to prevent a shock hazard. Work on the vehicle only after the vehicle has been pulled out of the water.

      • In case of skin contact with the electrolyte, wash the area thoroughly with soap and plenty of water, and seek medical care. Immediately remove any contaminated clothing. Prolonged contact with the electrolyte may cause skin irritation.

      • If the electrolyte comes in contact with your eyes, call out loudly for help. Do not rub your eyes. Immediately flush them with a large amount of water for at least 15 minutes and seek medical care.

      • If electrolyte is swallowed, seek medical care immediately. Do not induce vomiting, unless instructed by the doctor.


      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 the organic electrolyte that contains carbonic acid esters. If contact is unavoidable, wipe the fluid off using a cloth while wearing rubber gloves, goggles and an organic solvent mask. Do not leave electrolyte-contaminated cloths unattended. Place contaminated cloths in an appropriate airtight container and dispose of them according to local regulations.

      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.

        B005XM3E02
        Text in Illustration
        *1 Inverter with Converter Assembly *2 Engine Room Relay Block and Junction Block Assembly
        *3 Auxiliary Battery *4 Frame Wire (Low Voltage)
        *5 HV battery *6 Frame Wire (High Voltage)
        *7 Hybrid Vehicle Transaxle Assembly *8 Inverter Water Pump Assembly
        *9 Compressor with Motor Assembly - -
      3. B005XS2E01
        Text in Illustration
        *1 IG2 Fuse
        *2 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 fuse from the 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 Vehicles.


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

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

      • The HV system 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 HV system 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 grip while wearing insulated gloves.

    4. Actions required after moving the damaged vehicle


      1. Procedure

        If there is liquid on the floor, it could be organic electrolyte containing carbonic acid esters. Wipe the liquid away while wearing rubber gloves, goggles and an organic solvent mask. Do not leave electrolyte-contaminated cloths unattended. Place contaminated cloths in an appropriate airtight container and dispose of them according to local regulations.

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


      • Protective clothing (insulated gloves, rubber gloves, goggles, organic solvent mask, safety shoes and solvent resistant apron (for organic solvent))

      • Soap

      • 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

    6. Precautions to be observed when servicing a damaged vehicle

      CAUTION:

      Always follow instructions to ensure safety.

      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.

      • Visually check the HV battery and the immediate area for any electrolyte leakage. Do not touch any leaked liquid because it could be organic electrolyte that contains carbonic acid esters.

      • The electrolyte is flammable. Keep all ignition sources such as open flame and hot objects away from the electrolyte.

      • Electrolyte leaks may cause acute poisoning if a high concentration of the vapor from the organic solvent is inhaled. In case of inhalation, move the affected person to a place with ample fresh air and let them lie quietly. Seek medical care.

      • In case of skin contact with the electrolyte, wash the area thoroughly with soap and plenty of water, and seek medical care. Immediately remove any contaminated clothing. Prolonged contact with the electrolyte may cause skin irritation.

      • If the electrolyte comes in contact with your eyes, call out loudly for help. Do not rub your eyes. Immediately flush them with a large amount of water for at least 15 minutes and seek medical care.

      • If electrolyte is swallowed, seek medical care immediately. Do not induce vomiting, unless instructed by the doctor.


      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 the organic electrolyte that contains carbonic acid esters. If contact is unavoidable, wipe the fluid off using a cloth while wearing rubber gloves, goggles and an organic solvent mask. Do not leave electrolyte-contaminated cloths unattended. Place contaminated cloths in an appropriate airtight container and dispose of them according to local regulations.

      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. B005XS2E01
        Text in Illustration
        *1 IG2 Fuse
        *2 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 fuse from the engine room relay block and junction block assembly. Confirm that the READY light is off.

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

      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:


        • Before returning the HV battery, make sure to perform recovery inspection Click here

        • 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.

        • To reduce the risk of fire, the HV battery must not be stored in an area where it will be exposed to fire or high temperatures.

    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 front 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, do not exceed 30 km/h (18 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, as park (P) may be selected which may result 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.

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

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

    CAUTION:


    • Before performing pre-disposal deployment of any SRS component, review and closely follow all applicable environmental and hazardous material regulations. Pre-disposal deployment may be considered hazardous material treatment.

    • 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 the 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 for DTCs before disconnecting the auxiliary battery.

      2. Work must be started at least 90 seconds after the power switch is turned off and after 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 after 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 other) 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 assembly, curtain shield airbag assembly and seat outer belt assembly 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 repair, 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 airbag sensor assemblies or airbag assemblies.


        1. Steering pad

        2. Front passenger airbag assembly

        3. Knee airbag assembly

        4. Front seat side airbag assembly

        5. Curtain shield airbag assembly

        6. Front 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 surface facing upward. Placing the steering pad with the pad 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 the steering pad by itself, the airbag should be deployed using SST before disposal Click here. Deploy 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 deployment direction 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 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 the airbag assembly unit by itself, the airbag should be deployed using SST before disposal Click here. Deploy the airbag in a safe place away from electrical noise.

    5. KNEE AIRBAG ASSEMBLY


      1. Always place a removed or new knee airbag assembly with the airbag deployment direction facing upward as shown in the illustration. Placing the airbag assembly with the airbag deployment direction 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 a vehicle or knee airbag assembly unit by itself, the airbag should be deployed using SST before disposal Click here. Deploy the airbag in a safe place away from electrical noise.

    6. FRONT SEAT SIDE AIRBAG ASSEMBLY


      1. Always place a removed or new seat side airbag assembly with the airbag deployment direction 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 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 a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal Click here. Deploy the airbag in a safe place away from electrical noise.

    7. 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 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 a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal Click here. Deploy the airbag in a safe place away from electrical noise.

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


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

      2. Never disassemble the front seat outer belt assembly.

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

      4. Store the front 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 a vehicle or the front seat outer belt assembly unit by itself, the front seat outer belt assembly should be activated before disposal Click here. Activate the front seat outer belt assembly in a safe place away from electrical noise.

      7. As the front 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 front seat outer belt assembly.

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

    9. CENTER AIRBAG SENSOR ASSEMBLY


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

      2. The connectors to the center airbag sensor assembly should be connected or disconnected with the sensor installed to the vehicle. If the connectors are connected or disconnected while the center airbag sensor assembly is not installed, 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 bolts of the center airbag sensor assembly.

    10. 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.

  8. ELECTRONIC CONTROL

    B005ZB2E45
    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 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 60 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal.

    • When the auxiliary battery is replaced or the cable is disconnected from its negative (-) battery terminal, the ISC learning value will be initialized and symptoms as a noise from the hybrid vehicle transaxle assembly may occur until ISC learning is performed. Therefore, perform ISC learning when the auxiliary battery is replaced or the cable is disconnected from the negative (-) terminal of the auxiliary battery Click here.


    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. B005XSOE22
      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 compartment 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. COOLING FAN SYSTEM

    Note


    • When the power switch is turned off and the engine temperature is high, the engine water pump assembly and cooling fans may operate for a maximum of 3 minutes depending on the auxiliary battery voltage.

    • After turning the power switch off, keep hands and objects away from the fans when they are operating.

    Tech Tips


    • If all of the following are met for a certain period of time during a few minutes immediately before the power switch is turned off, the cooling fans will continue to operate for a maximum of 3 minutes after the engine is stopped. This is performed to ensure restartability.


      • The GTS indicates a very high coolant temperature.

      • The GTS indicates a high outside air temperature.

  10. 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.

  11. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS


    1. B005XIP

      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.

  12. HANDLING OF HOSE CLAMPS

    B005YROE38
    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.

  13. FOR VEHICLES EQUIPPED WITH MOBILE COMMUNICATION SYSTEMS

    B005YBX

    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.

  14. HEADLIGHT INSPECTION OR MAINTENANCE


    1. B005XKEE35
      Text in Illustration
      *1 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.

  15. 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.

  16. ELECTRONIC SHIFT LEVER SYSTEM


    1. BASIC OPERATION


      1. This vehicle is equipped with an electronic shift lever system. This system electrically communicates the driver's intended shift state to the ECUs responsible for system control. The system also uses an electrically operated transaxle parking lock mechanism.

        Tech Tips

        The parking lock mechanism of the transaxle cannot be operated if the auxiliary battery is discharged or has been disconnected. There is no mechanical connection between the P position switch (transmission shift main switch), shift lever and the transaxle.

      2. This system allows the driver to select the reverse (R), neutral (N), drive (D) and brake (B)* shift states using the shift lever, or select park (P) by pushing the P position switch (transmission shift main switch). Shift states are ECU controlled based on the actions of the driver and various conditions. Shift states can be verified using the shift position indicator in the combination meter or by using the GTS.


        • *: For enhanced engine braking.

  17. WHEN INSPECTING VEHICLES

    Note

    When the vehicle is run in inspection mode for an operation such as a speedometer test, a DTC may be set. 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 park (P) selected, 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 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 shift state for each test is as follows:

        Test Item Mode
        1. Vehicle straight travelling 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 transaxle.

    2. WHEN USING A BRAKE TESTER

      CAUTION:

      Be sure to perform the test in maintenance mode.

      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 hybrid 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. Make a measurement.

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

    4. WHEN USING A CHASSIS DYNAMOMETER


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

        Note

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

    5. 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.

        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.

      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 engine and the wheel balancer drive roller to spin the wheels.

        Note


        • Be sure to perform the test in maintenance mode.

        • Start the engine 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.

  18. WHEN TOWING 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).

      B005XUSE70

      Note

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

    3. If a tow truck is not available, in an emergency 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 front wheels on the ground, the transaxle may be damaged.


      1. Emergency towing procedure


        1. Turn the power switch on (IG).

        2. Depress the brake pedal, move the shift lever to N and confirm that neutral (N) has been selected.

        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 parking lock, resulting in a hazardous situation or accident.

        Tech Tips


        • Neutral (N) cannot be selected if the auxiliary battery is discharged or if it has been disconnected.

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

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

      B005ZKK

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

        Note


        • If the vehicle is towed facing rearward with the front wheels on the ground, the drivetrain may overheat and be damaged.

        • In addition, if the vehicle is equipped with the VSC system, the system may apply the brakes to the rotating wheels.

      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.

  19. 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 a spark test as rapidly as possible with the injector connectors disconnected.

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

    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.