Part 2

INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION - Continued


(a) 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, driver side knee airbag assembly, front seat side airbag assembly, curtain shield airbag assembly and front seat outer belt assembly should be inspected before further use of the vehicle.
Disposal for steering pad)
Disposal for front passenger airbag assembly)
Disposal for front seat side airbag assembly)
Front Seat Side Airbag Assembly for driver side knee airbag assembly)
Disposal for curtain shield airbag assembly)
Disposal 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
3 Driver side 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 assembly or airbag assembly to hot air or flames.
(9) Use a voltmeter / ohmmeter with high impedance (minimum=10 kOhms) 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.






(b) 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 Testing and Inspection.

(c) STEERING PAD
(1) Always place a removed or new steering pad surface upward as shown in the illustration. Placing the steering pad of the pad surface facing down could cause a serious accident if the airbag inflates. 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 inflate, 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 (200°F), the humidity is not high and there is no electrical noise.
(5) When using electric welding anywhere on the vehicle, disconnect the center airbag sensor 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 Disposal. Activate the airbag in a safe place away from electrical noise.
(d) 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.





(2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, 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 (200°F), the humidity is not high and there is no electrical noise.
(5) When using electric welding anywhere on the vehicle, disconnect the center airbag sensor 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 Disposal. Activate in a safe place, away from electrical noise.
(e) DRIVER SIDE KNEE AIRBAG ASSEMBLY AND FRONT PASSENGER SIDE KNEE AIRBAG ASSEMBLY
(1) Always place a removed or new knee airbag assembly with the airbag inflation direction facing upward. Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag inflates.





(2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, 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 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 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 inflated using SST before disposal Disposal. Activate in a safe place, away from electrical noise.
(f) FRONT SEAT SIDE AIRBAG ASSEMBLY
(1) Always place a removed or new front seat side airbag assembly with the airbag inflation direction facing up.
(2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury.





(3) Grease or detergents of any kind should not be applied to the front seat side 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 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 Front Seat Side Airbag Assembly. Activate in a safe place away from electrical noise.
(g) 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 is not reusable.
NOTE: Never disassemble the curtain shield airbag assembly.
(2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, 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 (200°F), the humidity is not high and there is no electrical noise.
(5) When using electric welding anywhere on the vehicle, disconnect the center airbag sensor 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 Disposal. Activate in a safe place away from electrical noise.
(h) FRONT SEAT OUTER BELT ASSEMBLY (SEAT BELT PRETENSIONER)
(1) Never measure the resistance of the front seat outer belt. This may cause the pretensioner of the front seat outer belt to activate, which could cause serious injury.





(2) Never disassemble the front seat outer belt.
(3) Never install the front seat outer belt on another vehicle.
(4) Store the front 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 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 unit by itself, the front seat outer belt should be activated before disposal Disposal. Activate in a safe place away from electrical noise.
(7) As the front 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.
(i) CENTER AIRBAG SENSOR ASSEMBLY
(1) Never reuse an 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 placed on the floor. If the connectors are connected or disconnected while the center 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 center airbag sensor assembly.
(j) WIRE HARNESS AND CONNECTOR
(1) 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.
9. ELECTRONIC CONTROL





(a) 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.






(b) 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.

10. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
(a) 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.
(b) 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.






11. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS
(a) If any metal particles enter inlet system parts, this may damage the engine.
(b) When removing and installing inlet system parts, cover the openings of the removed parts and engine openings. Use gummed tape or other suitable materials.
(c) When installing inlet system parts, check that no metal particles have entered the engine or the installed parts.





12. HANDLING OF HOSE CLAMPS
(a) Before removing the hose, check the clamp position so that it can be reinstalled in the same position.
(b) Replace any deformed or dented clamps with new ones.
(c) When reusing a hose, attach the clamp on the clamp track portion of the hose.
(d) 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.





13. FOR VEHICLES EQUIPPED WITH MOBILE COMMUNICATION SYSTEMS
(a) Install the antenna far away from the ECU and sensors of the vehicle electronic systems as possible.
(b) 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.
(c) 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.
(d) Check that the antenna and feeder are correctly adjusted.
(e) Do not install any high-powered mobile communication system.

14. WHEN SERVICING FULL-TIME 4WD VEHICLES






(a) Braking Force Test (Vehicle Speed : Below 0.5 km/h or 0.3 mph)
When performing low-speed type brake tester measurements, observe the following instructions:
(1) Position the wheels to be tested (front or rear) on the tester.
(2) Shift the transaxle shift lever to the "N" position.
(3) READY ON and perform the breaking force test.





(b) Speedometer Test

(c) Activating 2WD inspection mode (Not using Techstream)
Perform the following steps from (1) through (4) in 60 seconds.
(1) Turn the ignition switch to the ON position.
(2) Fully depress the accelerator pedal twice times with the transmission P position.
(3) Fully depress the accelerator pedal twice times with the transmission N position.
(4) Fully depress the accelerator pedal twice times with the transmission P position.
(5) Check that the HV system warning light flashed on the multi-information display.
(6) Start the engine by turning the ignition switch while depressing the brake pedal.
(d) Activating 2WD inspection mode (Using Techstream)
(1) Connect Techstream to the DLC3.
(2) Turn the ignition switch to the ON position.
(3) Turn Techstream on.
(4) Select following menu items: Powertrain / Hybrid Control / Active Test / Inspection Mode -2WD Inspection.
(5) Check that the HV system warning light flashers on the multi-information display and the master warning light is illuminated in the combination meter.
(6) Start the engine by turning the ignition switch while depressing the brake pedal.
(e) Activating 4WD inspection mode (Not using Techstream)
Perform the following steps from (1) through (4) in 60 seconds.
(1) Turn the ignition switch to the ON position.
(2) Fully depress the accelerator pedal four with the transmission P position.
(3) Fully depress the accelerator pedal four with the transmission N position.
(4) Fully depress the accelerator pedal four with the transmission P position.
(5) Check that the HV system warning light flashed on the multi-information display.
(6) Start the engine by turning the ignition switch while depressing the brake pedal.
(f) Activating 4WD inspection mode (Using Techstream)
(1) Connect Techstream to the DLC3.
(2) Turn the ignition switch to the ON position.
(3) Turn Techstream on.
(4) Select following menu items: Powertrain / Hybrid Control / Active Test / Inspection Mode -4WD Inspection.
(5) Check that the HV system warning light flashers on the multi-information display and the master warning light is illuminated in the combination meter.
(6) Start the engine by turning the ignition switch while depressing the brake pedal.
NOTE: If you do not observe the following conditions for the test, there will be the cases where the 4WD functions will deteriorate; the parts in the drive-train system will have a malfunction; the vehicle will jump out. Therefore, do not conduct a test unless observing the following conditions.
HINT: When conducting a test under a large load at high speeds, observe the following conditions:





NOTICE:
- Do not suddenly accelerate and do not suddenly apply brake.
- Confirm that the vehicle is securely immobilized.
- Never operate the brakes to drive the wheels or stop them suddenly.

(g) On-Vehicle Wheel Balancing
When doing on-vehicle wheel balancing on a full-time 4WD vehicle, to prevent the wheels from each other, always observe the following precautions:





(1) All 4 wheels should be jacked up, clearing the ground completely.
(2) The parking brake lever should be fully released.
(3) None of the brakes should be allowed to drag.
(4) The wheels should be driven on the wheel balancer with the inspection mode.
HINT: When doing this, be careful of the other wheels, which will rotate at the same time.

(h) Activating 4WD inspection mode (Not using Techstream)
Perform the following steps from (1) through (4) in 60 seconds.
(1) Turn the ignition switch to the ON position.
(2) Fully depress the accelerator pedal four with the transmission P position.
(3) Fully depress the accelerator pedal four with the transmission N position.
(4) Fully depress the accelerator pedal four with the transmission P position.
(5) Check that the HV system warning light flashed on the multi-information display.
(6) Start the engine by turning the ignition switch while depressing the brake pedal.
(i) Activating 4WD inspection mode (Using Techstream)
(1) Connect Techstream to the DLC3.
(2) Turn the ignition switch to the ON position.
(3) Turn Techstream on.
(4) Select following menu items: Powertrain / Hybrid Control / Active Test / Inspection Mode -4WD Inspection.
(5) Check that the HV system warning light flashers on the multi-information display and the master warning light is illuminated in the combination meter.
(6) Start the engine by turning the ignition switch while depressing the brake pedal.
(7) Avoid sudden acceleration, deceleration and braking.
(8) Carry out wheel balancing with the transaxle in the D position.
15. FOR VEHICLES EQUIPPED WITH VEHICLE STABILITY CONTROL (VSC) SYSTEM






(a) NOTICES WHEN USING DRUM TESTER

(b) Activating 2WD inspection mode (Not using Techstream)
Perform the following steps from (1) through (4) in 60 seconds.
(1) Turn the ignition switch to the ON position.
(2) Fully depress the accelerator pedal twice times with the transmission P position.
(3) Fully depress the accelerator pedal twice times with the transmission N position.
(4) Fully depress the accelerator pedal twice times with the transmission P position.
(5) Check that the HV system warning light flashed on the multi-information display.
(6) Start the engine by turning the ignition switch while depressing the brake pedal.
(c) Activating 2WD inspection mode (Using Techstream)
(1) Connect Techstream to the DLC3.
(2) Turn the ignition switch to the ON position.
(3) Turn Techstream on.
(4) Select following menu items: Powertrain / Hybrid Control / Active Test / Inspection Mode -2WD Inspection.
(5) Check that the HV system warning light flashers on the multi-information display and the master warning light is illuminated in the combination meter.
(6) Start the engine by turning the ignition switch while depressing the brake pedal.
(d) Activating 4WD inspection mode (Not using Techstream)
Perform the following steps from (1) through (4) in 60 seconds.
(1) Turn the ignition switch to the ON position.
(2) Fully depress the accelerator pedal four with the transmission P position.
(3) Fully depress the accelerator pedal four with the transmission N position.
(4) Fully depress the accelerator pedal four with the transmission P position.
(5) Check that the HV system warning light flashed on the multi-information display.
(6) Start the engine by turning the ignition switch while depressing the brake pedal.
(e) Activating 4WD inspection mode (Using Techstream)
(1) Connect Techstream to the DLC3.
(2) Turn the ignition switch to the ON position.
(3) Turn Techstream on.
(4) Select following menu items: Powertrain / Hybrid Control / Active Test / Inspection Mode -4WD Inspection.
(5) Check that the HV system warning light flashers on the multi-information display and the master warning light is illuminated in the combination meter.
(6) Start the engine by turning the ignition switch while depressing the brake pedal.
(7) Before beginning testing, disable the VSC. To disable the VSC, turn the ignition switch off and connect SST to terminals TS and CG of the DLC3.
SST: 09843-18040
NOTICE:
- Confirm that the VSC warning light blinks.
- VSC system will be reset when the engine is restarted.
- For safety, secure the vehicle with restraint chains while using a wheel dynamometer.

(f) NOTICES OF RELATED OPERATIONS TO VSC
(1) Do not carry out unnecessary installation and removal as it might affect the adjustment of VSC related parts.
(2) Be sure to follow the instructions for work preparation and final confirmation of proper operation of the VSC system.
16. WHEN TOWING FULL-TIME 4WD VEHICLES
(a) Use one of the methods shown below to tow the vehicle.
(b) If the vehicle has trouble with the chassis or drive train, use method 1 (flat bed truck).





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

(c) 4WD only:
The towing methods shown below are dangerous and can damage the vehicle, so do not use them.





17. 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:

(a) Use only unleaded gasoline.
(b) Avoid idling the engine for more than 20 minutes.
(c) 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.
(d) Avoid a prolonged engine compression measurement. Engine compression measurements must be performed as rapidly as possible.
(e) 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.