1-03 To 8-03: Precaution

1. HINTS ON OPERATIONS
   Fig 1: Basic Repair Hints Table

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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 (See page VEHICLE LIFT AND SUPPORT LOCATIONS ).
3. PRE-COATED PARTS
   1. Pre-coated parts are bolts, nuts, etc. that are coated with a seal lock adhesive at the factory.
      Fig 2: Locating Pre-Coated Parts

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   2. If a pre-coated part is retightened, loosened or caused to move in any way, it must be re-coated with the specified adhesive.
   3. When reusing pre-coated parts, clean off the old adhesive and dry the part with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads.
      NOTE: Check the torque with the lower limit value of the torque tolerance.
   4. Depending on the seal lock agent to apply, there may be a case where it is necessary to leave it for a specified time until it hardens.
4. GASKETS
   1. When necessary, use a sealer on gaskets to prevent leaks.
5. BOLTS, NUTS AND SCREWS
   1. Carefully observe all the specifications for tightening torques. Always use a torque wrench.
6. FUSES
   1. When replacing fuses, be sure that a new fuse has the correct amperage rating. DO NOT exceed the rating, or use one with a lower rating.
      Fig 3: Inspecting Fuse Amperage Rating

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      Fig 4: Identifying Fuse Specification Table

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7. CLIPS
   1. The removal and installation methods of typical clips used in body parts are shown in the table below.
   NOTE: If the clip is damaged during operation, always replace it with a new clip.
   Fig 5: Removal/Installation Of Clips (1 Of 2)

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   Fig 6: Removal/Installation Of Clips (2 Of 2)

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8. REMOVAL AND INSTALLATION OF VACUUM HOSES
   1. To disconnect vacuum hoses, pull them by holding the end, not the middle of the hose.
      Fig 7: Disconnecting Vacuum Hoses

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   2. When disconnecting vacuum hoses, use tags to identify where they should be reconnected.
      Fig 8: Identifying Vacuum Hoses Tags

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   3. After completing the job, make a double check whether the vacuum hoses are properly connected. A 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. Use a step-down adapter for adjustment. Once the hose has been stretched, it may leak air.
9. TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL
   1. When SST or an extension tool is combined with the torque wrench to extend its entire length, if you tighten until the reading of the torque wrench reaches the specified torque value, the actual torque becomes excessive.
      Fig 9: Measuring Extended Torque Wrench Length

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   2. In this data, only the specified torque is described. In case of using SST or extension tool, calculate the reading of the torque wrench by the following formula.
   3. Formula T'=T x L2/(L1 + L2)
      Fig 10: Identifying Extended Torque Wrench Length

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   EXTENDED TORQUE WRENCH DESCRIPTION
   
   

   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)
   L2	Length of torque wrench (cm)

Failure to carry out the service operations in the correct sequence could cause the supplemental restraint system to unexpectedly deploy while servicing. It may lead to a serious accident.

Furthermore, if a mistake is made when servicing the supplemental restraint system, it is possible that the SRS will fail to operate when required. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully. Then follow the correct procedures described in this data.

1. GENERAL NOTICE
   1. Malfunction symptoms of the supplemental restraint system are difficult to be confirmed, so the diagnostic trouble codes become the most important source of information when troubleshooting. When troubleshooting the supplemental restraint system, always check the diagnostic trouble codes before disconnecting the battery on AIR BAG WARNING LIGHT CHECK ).
   2. Work must be started after 90 seconds from the time that the ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the battery.

      (The supplemental restraint system is equipped with a back-up power source. So, if work is started within 90 seconds after disconnecting the negative (-) terminal cable from the battery, the SRS may deploy).

      When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio systems is cancelled. So, before starting work, make a record of the contents recorded in each memory system. Then, when work is finished, reset the clock and audio systems as before.

   3. Even in case of a minor collision where the SRS does not deploy, the horn button assembly, instrument panel passenger airbag assembly, front seat airbag assembly, curtain shield airbag assembly and seat belt pretensioner should be inspected on AIR BAG RESTRAINT SYSTEMSHORN BUTTON ASSYAIR BAG RESTRAINT SYSTEMSFRONT SEATFRONT SEAT BELT ).
   4. Never use the SRS related parts from another vehicle. When replacing the parts, replace them with new parts.
   5. Before repairs, remove the airbag sensor if it may be shocked during repairs.
   6. Never disassemble and repair the airbag sensor assembly, horn button assembly, instrument panel passenger airbag assembly, front seat airbag assembly, curtain shield airbag assembly or seat belt pretensioner.
   7. If the airbag sensor assembly, the side airbag sensor assembly, the horn button assembly, the instrument panel passenger airbag assembly, the front seat airbag assembly or the curtain shield airbag assembly have been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones.
   8. Do not directly expose the airbag sensor assembly, the side airbag sensor assembly, the horn button assembly, the instrument panel passenger airbag assembly, the front seat airbag assembly, the curtain shield airbag assembly or the seat belt pretensioner to hot air or flames.
   9. Use a volt/ohmmeter with high impedance (10 kΩ/W minimum) for troubleshooting an electrical circuit.
   10. Information labels are attached to the SRS components. Follow the instructions on the notices.
   11. After work on the supplemental restraint system is completed, check the SRS warning light. Refer to AIR BAG WARNING LIGHT CHECK ).
2. SPIRAL CABLE (in Combination Switch)
   1. The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, otherwise cable disconnection and other troubles may occur. Refer to SPIRAL CABLE (POWER SEAT) of this data concerning the correct installation of the steering wheel.
      Fig 11: Locating Steering Spiral Cable

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3. HORN BUTTON ASSEMBLY (with Airbag)
   1. When removing the horn button assembly or handling a new horn button, it should be placed with the pad top surface facing upward. Placing it with the pad surface facing downward may lead to a serious accident if the airbag accidentally inflates. Also, do not place the horn button on the top of one another.
   2. Never measure the resistance of the airbag squib (This may cause the airbag to inflate, which is very dangerous).
   3. Grease should not be applied to the horn button assembly, and the pad should not be cleaned with detergents of any kinds.
   4. Store the horn button assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise.
   5. When using electric welding, first disconnect the airbag connector (2 yellow pins) under the steering column near the combination switch connector before starting work.
   6. When disposing of the vehicle or the horn button assembly alone, the airbag should be deployed using an SST before disposal. Refer to HORN BUTTON ASSY .

      Perform the operation in a safe place away from electrical noise.

      Fig 12: Identifying Correct Method Of Disposing Horn Button Assembly

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      Fig 13: Wrong Airbag Resistance Measuring Method

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4. INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY
   1. Always place a removed or new instrument panel passenger 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 deploys.
   2. Never measure the resistance of the airbag squib (This may cause the airbag to inflate, which is very dangerous).
   3. Grease should not be applied to the instrument panel passenger airbag assembly, and the airbag door should not be cleaned with detergents of any kind.
   4. Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise.
   5. When using electric welding, first disconnect the airbag connector (2 yellow pins) installed on the assembly before starting work.
   6. When disposing of a vehicle or the airbag assembly alone, the airbag should be deployed using SST before disposal. Refer to INSTRUMENT PANEL .

      Activate in a safe place away from electrical noise.

      Fig 14: Identifying Correct Method Of Disposing Instrument Panel Airbag Assy

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   Fig 15: Identifying Incorrect Method Of Testing Airbag Resistance

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5. FRONT SEAT AIRBAG ASSEMBLY
   1. Always place a removed or new front seat 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 deploys.
   2. Never measure the resistance of the airbag squib (This may cause the airbag to inflate, which is very dangerous).
   3. Grease should not be applied to the front seat airbag assembly, and the airbag door should not be cleaned with detergents of any kind.
   4. Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise.
   5. When using electric welding, first disconnect the airbag connector (2 yellow pins) installed on the assembly before starting work.
   6. When disposing of a vehicle or the side airbag assembly alone, the airbag should be deployed using SST before disposal. Refer to FRONT SEAT .

      Activate in a safe place away from electrical noise.

      Fig 16: Identifying Correct Method Of Disposing Front Seat Airbag Assy

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      Fig 17: Identifying Incorrect Method Of Testing Seat Airbag

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6. CURTAIN SHIELD AIRBAG ASSEMBLY
   1. Always place the removed or new curtain shield airbag assembly in a clear plastic bag, and keep it in a safe place.
      NOTE: Protection bag is not re-useable.
      CAUTION: Never disassemble the curtain shield airbag assembly.
   2. Never measure the resistance of the airbag squib (This may cause the airbag to inflate, which is very dangerous).
   3. Grease should not be attached to the curtain shield airbag assembly, and the surface should not be cleared with detergents of any kind.
   4. Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise.
   5. When using electric welding, disconnect the airbag connector (2 yellow pins) into the instrument panel before starting work.
   6. When disposing of a vehicle or the curtain shield airbag assembly unit, the airbag should be deployed using SST before disposal. Refer to CURTAIN SHIELD AIR BAG ASSY LH ). Activate in a safe place away from electrical noise.
      Fig 18: Identifying Correct Method Of Disposing Curtain Shield Airbag Assy

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      Fig 19: Identifying Incorrect Method Of Testing Curtain Shield Airbag

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7. SEAT BELT PRETENSIONER
   1. Never measure the resistance of the seat belt pretensioner (This may cause the seat belt pretensioner to activate, which is very dangerous).
   2. Never disassemble the seat belt pretensioner.
   3. Never install the seat belt pretensioner to another vehicle.
   4. Store the seat belt pretensioner where the ambient temperature remains below 80°C (176°F) without high humidity and away from electrical noise.
   5. When using electric welding, first disconnect the connector (2 yellow pins) before starting work.
   6. When disposing of a vehicle or the seat belt pretensioner alone, the seat belt pretensioner should be activated before disposal. Refer to FRONT SEAT BELT . Perform the operation in a safe place away from electrical noise.
   7. The seat belt pretensioner is hot after activated, so cool it down sufficiently before disposal. Never apply water to cool down the seat belt pretensioner.
   8. Oil or water should not be put on the front seat outer belt, and the front seat outer belt should not be cleaned with detergents of any kind.
   Fig 20: Identifying Wrong Method Of Testing Resistance Of Seat Belt Pretensioner

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8. AIRBAG SENSOR ASSEMBLY
   1. Never reuse an airbag sensor assembly involved in a collision where the SRS has deployed.
   2. The connectors to the airbag sensor assembly should be connected or disconnected with the sensor mounted on the floor. If the connectors are connected or disconnected while the airbag sensor assembly is not mounted to the floor, it could cause the supplemental restraint system to deploy potentially resulting in injury.
   3. Work must be started after 90 seconds from the time that the ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the battery, even if only loosening the set bolts of the airbag sensor assembly.
9. WIRE HARNESS AND CONNECTOR
   1. The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes broken due to an accident, etc., repair or replace it.

1. REMOVAL AND INSTALLATION OF BATTERY TERMINAL
   1. Before performing electrical work, disconnect the battery negative (-) terminal cable beforehand so as to prevent burnt-out damage by short.
      Fig 21: Locating Negative Terminal

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   2. When disconnecting and installing the terminal cable, turn the ignition switch and lighting switch OFF, and loosen the terminal nut completely. Perform these operations without twisting or prying the terminal.
   3. When the battery terminal is removed, all the memories of the clock, radio, DTCs, etc. will be erased. So before removing it, check them and make a note.
   4. When the battery terminal is disconnected, the sliding roof position memory is erased.

      Make sure to reset the sliding roof to the zero point. Refer to SLIDING ROOF SYSTEM .

2. 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).
      Fig 22: Use Care While Handling Electronic Components

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   2. To disconnect electronic connectors, pull the connector itself, not the wires.
   3. Be careful not to drop electronic components, such as sensors or relays. If they are dropped on a hard floor, they should be replaced and not be reused.
   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 checking the continuity at the wire connector, insert the tester probe carefully to prevent terminals from bending.

1. PLACE FOR REMOVING AND INSTALLING OF FUEL SYSTEM PARTS
   1. Work in a place with good air ventilation and without anything that could cause combustion such as a welder, grinder, drill, electric motor or stove in the surroundings.
   2. Never work in a place such as a pit or nearby a pit, as there is a possibility that vaporized fuel will collect in those places.
2. REMOVING AND INSTALLING OF FUEL SYSTEM PARTS
   1. Prepare a fire extinguisher before starting operation.
   2. To prevent static electricity, install a ground on the fuel changer, vehicle and fuel tank, and do not spray much water so as to prevent slipping.
   3. Never use any electric equipment like an electric motor or a working light, as they may create sparks or a high temperature.
   4. Never use an iron hammer, as it may cause sparks.
   5. Dispose separately of shop rags containing fuel deposits.

1. If any metal tip is mixed in the inlet pass, that may give a bad effect to the engine and turbocharger.
   Fig 23: Locating Inlet System Covering Parts

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2. When removing and installing the inlet system parts, close the opening of the removed inlet system parts and the engine with a clean shop rag or gummed tape.
3. When installing the inlet system parts, check that no metal particles have entered.

1. Before removing the hose, check the clamp position to ensure that it can be restored securely.
   Fig 24: Locating Clamp Position

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2. Replace a deformed or dented clamp with a new one.
3. When reusing the hose, install the clamp on the hose where it has a clamp track.
4. For a spring type clamp, make an adjustment after installation by pushing in the direction of the arrow mark.

1. Install the antenna as far away from the ECU and sensors of the vehicle electronic systems as possible.
   Fig 25: Identifying Mobile Communication System Antenna Position

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2. Install an antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle electronic systems. For details of the ECU and sensors locations, refer to the section on the applicable component.
3. Prevent the antenna feeder from getting entangled with the other wiring, and keep the antenna feeder separate from other wiring as much as possible.
4. Check that the antenna and feeder are correctly adjusted.
5. Do not install any high-powered mobile communication system.

1. NOTICES WHEN USING 2-WHEEL DRUM TESTER
   1. When using a 2-wheel drum tester such as a speedometer tester, a combination tester of speedometer and brake, chassis dynamometer or else, always turn the TRAC system off via the TRAC OFF switch before measurement.
   NOTE: TRAC system OFF condition can be confirmed by the indication, "TRAC OFF" of the warning light in the combination meter.

1. NOTICES WHEN USING DRUM TESTER
   1. When using a drum tester, be sure to start the engine with the ignition switch OFF, and connect SST to the terminals TS and CG of the DLC3 before the measurement in order to cancel the VSC operation.
      Fig 26: Identifying DLC3 Connector Terminals

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   SST 09843-18040

   NOTE:

   • Confirm that the VSC warning light blinks.
   • The VSC system is reset when the engine is restarted.
   • Fasten the vehicle with lock chains.
2. NOTICES OF RELATED OPERATIONS TO VSC
   1. Do not carry out unnecessary installation and removal, because it may interfere with the setting of the parts related to the VSC.
   2. Be sure to carry out the preparations for operations and the confirmation of operation completion, in accordance with the instructions of the text, when the operations related to the VSC are performed.

1. Use only unleaded gasoline.
2. Avoid prolonged idling.

   Avoid idling the engine for more than 20 minutes.

3. Avoid a spark jump test.
   1. Perform a spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
   2. While testing, never race the engine.
4. Avoid a prolonged engine compression measurement.

   Engine compression measurements must be performed as rapidly as possible.

5. Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter.