Servicing and Handling
| WARNING | Many of service procedures require disconnection of "AIR BAG" fuse and all air bag (inflator) module(s) from initiator circuit to avoid an accidental deployment. Driver, Passenger and Side Air Bag (Inflator) Modules For handling and storage of a live air bag (inflator) module, select a place where the ambient temperature below 65°C (150°F), without high humidity and away from electric noise. When carrying a live air bag (inflator) module, make sure the bag opening is pointed away from you. In case of an accidental deployment, the bag will then deploy with minimal chance of injury. Never carry the air bag (inflator) module by the wires or connector on the underside of the module. When placing a live air bag (inflator) module on a bench or other surface, always face the bag up, away from the surface. As the live passenger air bag (inflator) module must be placed with its bag facing up, place it on the workbench with a slit (1) or use the workbench vise (2) to hold it securely at its lower mounting bracket (3). It is also prohibited to place anything on top of the trim cover and stack air bag (inflator) modules. This is necessary so that a free space is provided to allow the air bag to expand in the unlikely event of accidental deployment. Otherwise, personal injury may result. Never dispose of live (undeployed) air bag (inflator) modules (driver, passenger and side of driver and passenger). If disposal is necessary, be sure to deploy them according to deployment procedures described in AIR BAG SYSTEM -- AERIO before disposal. The air bag (inflator) module immediately after deployment is very hot. Wait for at least half an hour to cool it off before proceeding the work. After an air bag (inflator) module has been deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates) and byproducts of the chemical reaction. As with many service procedures, gloves and safety glasses should be worn. |
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| WARNING | SDM For handling and storage of a SDM, select a place where the ambient temperature below 65°C (150°F),without high humidity and away from electric noise. During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM). Never strike or jar the SDM. Never power up the air bag system when the SDM is not rigidly attached to the vehicle. All SDM and mounting bracket fasteners must be carefully torqued and the arrow must be pointing toward the front of the vehicle to ensure proper operation of the air bag system. The SDM could be activated when powered while not rigidly attached to the vehicle which could cause deployment and result in personal injury. |
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| CAUTION | Even when the accident was light enough not to cause air bags to activate, be sure to inspect system parts and other related parts according to instructions under Inspection and Repair Required after Accident:Advanced Air Bag or Inspection and Repair Required after an Accident:Except Advanced Air Bag. When servicing parts other than air bag system, if shocks may be applied to air bag system component parts, remove those parts beforehand. When handling the air bag (inflator) modules (driver, passenger and side of driver and passenger), seat belt pretensioners (driver and passenger), forward sensors, side sensors or SDM, be careful not to drop it or apply an impact to it. If an excessive impact was applied, never attempt disassembly or repair but replace it with a new one. When grease, cleaning agent, oil, water, etc. has got onto air bag (inflator) modules (driver, passenger and side of driver and passenger) or seat belt pretensioners (drive and passenger), wipe off immediately with a dry cloth. Air bag wire harness is included in floor wire harness and main wire harness. Air bag wire harness branched off from floor wire harness can be identified easily as it is covered with a yellow protection tube and it has yellow connectors. Be very careful when handling it. When an open in air bag wire harness, damaged wire harness, connector or terminal is found, replace wire harness, connectors and terminals as an assembly. Do not apply power to the air bag system unless all components are connected or a diagnostic flow requests it, as this will set a DTC. Never use air bag system component parts from another vehicle. When using electric welding, be sure to disconnect all air bag (inflator) module connectors and pretensioner connectors from air bag wire harness respectively. Never expose air bag system component parts directly to hot air (drying or baking the vehicle after painting) or flames. WARNING / CAUTION labels are attached on each part of air bag system components. Be sure to follow the instructions. After vehicle is completely repaired, see AIR BAG SYSTEM -- AERIO to activate system. |
The WARNING and CAUTION describe some general precautions that you should observe when servicing a vehicle. These general precautions apply to many of the service procedures described in this manual, and they will not necessarily be repeated with each procedure to which they apply.
| WARNING | Whenever raising a vehicle for service, be sure to follow the instructions under Vehicle Lifting Points. When it is necessary to do service work with the engine running, make sure that the parking brake is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for automatic transmission vehicles), Keep hands, hair, clothing, tools, etc. away from the fan and belts when the engine is running. When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors. Do not perform service work in areas where combustible materials can come in contact with a hot exhaust system. When working with toxic or flammable materials (such as gasoline and refrigerant), make sure that the area you work in is well-ventilated. To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold, tail pipe, muffler, etc. New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or used oil. Keep new and used oil and used engine oil filters away from children and pets. Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory animals. Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil, wear a long-sleeve shirt and moisture-proof gloves (such as dish washing gloves) when changing engine oil. If engine oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or rags if wet with oil, recycle or properly dispose of used oil and filters. Make sure the bonnet is fully closed and latched before driving. If it is not, it can fly up unexpectedly during driving, obstructing your view and resulting in an accident. |
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| CAUTION | For vehicles equipped with a catalytic converter, use only unleaded gasoline and be careful not to let a large amount of unburned gasoline enter the converter or it can be damaged. Conduct a spark jump test only when necessary, make it as short as possible, and do not open the throttle. Conduct engine compression checks within the shortest possible time. Avoid situations which can result in engine misfire (e.g. starting the engine when the fuel tank is nearly empty.) |
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Scheme 21: Precautions for Electrical Circuit Service
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Precaution for Installing Mobile Communication Equipment
| CAUTION | When installing mobile communication equipment such as CB (Citizens-Band)-radio or cellular-telephone, be sure to observe the following precautions. Failure to follow cautions may adversely affect electronic control system. Keep the antenna as far away as possible from the vehicle's electronic control unit. Keep the antenna feeder more than 20 cm (7.9 in) away from electronic control unit and its wire harnesses. Do not run the antenna feeder parallel with other wire harnesses. Confirm that the antenna and feeder are correctly adjusted. |
Precaution for Vehicle Tie-Down Hooks
| CAUTION | Never use hooks (1) to tie down vehicle when vehicle is transported by land carrier, or body may be deformed. Be sure to use hooks (2) (hooks and frame holes) then. When vehicle is shipped by sea, use hooks ((1) and/or (2)) to tie-down vehicle. |
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Precaution in Servicing Full-Time 4WD Vehicle
| CAUTION | This full-time 4WD vehicle can not be converted to 2WD manually. Observe the following caution in servicing. Otherwise, front wheels drive rear wheels or vise-versa and vehicle accidents, drivetrain damage and personal injury may result. |
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- Never perform any of the following types of service work. [A]:Testing with 2-wheel chassis dynamometer, speedometer tester or brake tester. [B]:Driving front wheels, which are jacked up. [C]:Towing under the condition where either front or rear wheels can not rotate.
- When testing with 2-wheel chassis dynamometer, speedometer tester or brake tester, be sure to make the vehicle as front wheel drive by removing rear propeller shaft.
- When using On-vehicle type wheel balancing equipment (1), be sure to jack up all four wheels, off the ground completely and support vehicle with safety stands (2). Be careful of the other wheels, which will rotate at the same time.
- This vehicle should be towed under one of the following conditions: With all wheels on a flatbed truck. With front or rear wheels lifted and a dolly under the other wheels.
Air Bag Warning
| WARNING | For vehicles equipped with Supplemental Restraint (Air Bag) System: When performing service on and around the air bag system components or wiring, see AIR BAG SYSTEM -- AERIO . Please observe all WARNINGS and Precautions on Service and Diagnosis of Air Bag System:Advanced Air Bag or Precautions on Service and Diagnosis of Air Bag System:Except Advanced Air Bag before performing service on or around the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative. Either of these two conditions may result in severe injury. Technical service work must be started at least 90 seconds after the ignition switch is turned to the "LOCK" position and the negative cable is disconnected from the battery. Otherwise, the system may be activated by reserve energy in the Sensing and Diagnostic Module (SDM). |
Fastener Caution
| CAUTION | When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread-locking compound, will be called out. The correct torque value must be used when installing fasteners that require it. If the procedures are not followed, parts or system damage could result. |
Suspension Caution
| CAUTION | All suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of this part. Never attempt to heat, quench or straighten any suspension part. Replace it with a new part or damage to the part may result. |
Wheels and Tires Caution
| CAUTION | All wheel fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of all parts. There is to be no welding as it may result in extensive damage and weakening of the metal. |
Brake Caution
| CAUTION | All brake fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of same part number or with an equivalent part if replacement becomes necessary. Do not use a replacement part or lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of all parts. There is to be no welding as it may result in extensive damage and weakening of the metal. |
Open Circuit Check
Possible causes for the open circuit are as follows. As the cause is in the connector or terminal in many cases, they need to be checked particularly carefully.
- Loose connection of connector
- Poor contact of terminal (due to dirt, corrosion or rust on it, poor contact tension, entry of foreign object etc.)
- Wire harness being open
When checking system circuits including an electronic control unit such as ECM, TCM, ABS control module, etc., it is important to perform careful check, starting with items which are easier to check.
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- Disconnect negative (-) cable from battery
- Check each connector at both ends of the circuit being checked for loose connection. Also check lock condition of connector if equipped with connector lock.
- Using a test male terminal, check both terminals of the circuit being checked for contact tension of its female terminal by inserting and removing just for once (1). Check each terminal visually for poor contact (possibly caused by dirt, corrosion, rust entry of foreign object, etc.). At the same time, check to make sure that each terminal is locked in the connector fully.
- Using continuity check or voltage check the following procedure, check the wire harness for open circuit (2) and poor connection with its terminals. Locate abnormality, if any.
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Scheme 38: Continuity Check
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- Measure resistance between connector terminals at both ends of the circuit being checked (between A-1 and C-1 in the figure). If no continuity is indicated (infinity or over limit), that means that the circuit is open between terminals A-1 and C-1.
- Disconnect the connector included in the circuit (connector-B in the figure) and measure resistance between terminals A-1 and B- 1. If no continuity is indicated, that means that the circuit is open between terminals A-1 and B-1. If continuity is indicated, there is an open circuit between terminals B-1 and C-1 or an abnormality in connector-B.
Voltage Check
If voltage is supplied to the circuit being checked, voltage check can be used as circuit check.
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- With all connectors connected and voltage applied to the circuit being checked, measure voltage between each terminal and body ground. If measurements were taken as shown in the figure and results were as listed in the following, it means that the circuit is open between terminals B-1 and A-1. Voltage between C-1 and body ground: Approx. 5 V B-1 and body ground: Approx. 5 V A-1 and body ground: 0 V Also, if measured values were as listed in the following, it means that there is a resistance (abnormality) of such level that corresponds to the voltage drop in the circuit between terminals A-1 and B-1. Voltage between C-1 and body ground: Approx. 5 V B-1 and body ground: Approx. 5 V A-1 and body ground: Approx. 3 V
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Scheme 41: Short Circuit Check (wire harness to ground)
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- Disconnect negative (-) cable at battery.
- Disconnect connectors at both ends of the circuit to be checked. NOTE: If the circuit to be checked is connected to other parts (1), disconnect all connectors of those parts. Otherwise, diagnosis will be misled.
- Measure resistance between terminal at one end of circuit (A-1 terminal in the figure) and body ground. If continuity is indicated, it means that there is a short to ground between terminals A-1 and C-1 of the circuit.
- Disconnect the connector included in circuit (connector B) and measure resistance between A-1 and body ground. If continuity is indicated, it means that the circuit is shorted to the ground between terminals A-1 and B-1.
