0A-4 GENERAL INFORMATION
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 and Passenger 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 (trim cover) facing up, place it on the work-
bench with a slit or use the workbench vise to hold it
securely at its lower mounting bracket. This is neces-
sary 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 and passenger). If disposal is neces-
sary, be sure to deploy them according to deployment
procedures described in SECTION 10B before dis-
posal.
The air bag (inflator) module immediately after deploy-
ment 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 resi-
due. This powder consists primarily of cornstarch
(used to lubricate the bag as it inflates) and by-prod-
ucts of the chemical reaction. As with many service
procedures, gloves and safety glasses should be
worn.
[A] : ALWAYS CARRY AIR BAG (INFLATOR) MODULE WITH TRIM COVER (AIR BAG
OPENING) AWAY FROM BODY.
[B] : ALWAYS PLACE AIR BAG (INFLATOR) MODULE ON WORKBENCH WITH TRIM
COVER (AIR BAG OPENING) UP, AWAY FROM LOOSE OBJECTS.
1. Slit on workbench
2. Workbench vise
3. Lower mounting bracket
GENERAL INFORMATION 0A-11
PRECAUTIONS FOR ELECTRICAL CIRCUIT
SERVICE
When replacing a fuse, make sure to use a fuse of the
specified capacity. Use of a fuse with a larger capacity
will cause a damage to the electrical parts and a fire.
When disconnecting and connecting coupler, make sure
to turn ignition switch OFF, or electronic parts may get
damaged.
When disconnecting connectors, never pull the wiring
harness. Unlock the connector lock first and then pull
them apart by holding connectors themselves.
When connecting connectors, also hold connectors and
put them together until they lock securely (a click is
heard).
GENERAL INFORMATION 0A-21
WHEN USING FLOOR JACK
In raising front or rear vehicle end off the floor by jacking, be sure
to put the jack against the front jacking bracket (1), the center por-
tion of rear axle (2) (2WD vehicle) or rear axle housing (3) (4WD
vehicle).
To perform service with either front or rear vehicle end jacked up,
be sure to place safety stands (1) under vehicle body so that vehi-
cle body is securely supported. And then check to ensure that
vehicle body does not slide on safety stands (1) and the vehicle is
held stable for safety’s sake. WARNING:
If the vehicle to be jacked up only at the front or rear end,
be sure to block the wheels on ground in order to ensure
safety.
After the vehicle is jacked up, be sure to support it on
stands. It is extremely dangerous to do any work on the
vehicle raised on jack alone.
CAUTION:
Never apply jack against suspension parts (i.e., stabi-
lizer, etc) or vehicle floor, or it may get deformed.
[A] : Front
[B] : Rear
2. Embossed mark
MAINTENANCE AND LUBRICATION 0B-7
1) Drain engine oil by removing drain plug.
2) After draining oil, wipe drain plug clean. Reinstall drain plug,
and tighten it securely as specified below.
Tightening torque
Engine oil drain plug (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
3) Loosen oil filter by using oil filter wrench (special tool).
Special tool
(A) : 09915-47330
4) Screw new filter on oil filter stand by hand until the filter O-
ring contacts the mounting surface.
5) Tighten the filter (1) 3/4 turn from the point of contact with
the mounting surface using an oil filter wrench (2).
Tightening torque
Oil filter (b) : 14 N·m (1.4 kg-m, 10.5 lb-ft) (for reference)
NOTE:
Before fitting new oil filter, be sure to oil its O-ring. Use
engine oil for this purpose.
CAUTION:
To tighten oil filter properly, it is important to accurately
identify the position at which filter O-ring first contacts
the mounting surface.
MAINTENANCE AND LUBRICATION 0B-9
1) Remove radiator cap when engine is cool.
2) Loosen radiator drain plug (1) to drain coolant.
3) Remove reservoir and drain.
4) Tighten plug securely. Also reinstall reservoir.
5) Fill radiator with specified amount of coolant, and run engine
for 2 or 3 minutes at idle. This drives out any air which may
still be trapped within cooling system. STOP ENGINE.
Add coolant as necessary until coolant level reaches the
filler throat of radiator. Reinstall radiator cap.
6) Add coolant to reservoir so that its level aligns with Full
mark. Then, reinstall cap aligning arrow marks on reservoir
and cap. CAUTION:
When changing engine coolant, use mixture of 50% water
and 50% ANTIFREEZE/ANTICORROSION COOLANT for
the market where ambient temperature falls lower than –
16°C (3°F) in winter, and mixture of 70% water and 30%
ANTIFREEZE/ANTICORROSION COOLANT for the market
where ambient temperature doesn’t fall lower than –16°C
(3°F).
Even in a market where no freezing temperature is antici-
pated, mixture of 70% water and 30% ANTIFREEZE/ANTI-
CORROSION COOLANT should be used for the purpose
of corrosion protection and lubrication.
1. Reservoir
2. Reservoir cap
3. FULL level marks
4. Arrow marks
MAINTENANCE AND LUBRICATION 0B-11
4) Install air cleaner filter fitting protrusion (1) of filter into
groove (2) of case and clamp upper case securely.
REPLACEMENT
Replace air cleaner filter with new one according to steps 1), 2)
and 4) of inspection procedure.
FUEL LINES AND CONNECTIONS
INSPECTION
Visually inspect fuel lines and connections for evidence of fuel
leakage, hose cracking and damage. Make sure all clamps are
secure.
Repair leaky joints, if any.
Replace hoses that are suspected of being cracked.
FUEL FILTER
REPLACEMENT
Fuel filter (1) is installed in fuel pump assembly (2) in fuel tank.
Replace fuel filter with new one, referring to “FUEL PUMP
ASSEMBLY” in Section 6C for proper procedure.
WARNING:
This work must be performed in a well ventilated area
and away from any open flames (such as gas hot water
heaters).
MAINTENANCE AND LUBRICATION 0B-19
ALL LATCHES, HINGES AND LOCKS
INSPECTION
DOORS
Check that each door of front, rear and back doors opens and
closes smoothly and locks securely when closed.
If any malfunction is found, lubricate hinge and latch or repair
door lock system.
ENGINE HOOD
Check that secondary latch operates properly (check that sec-
ondary latch keeps hood from opening all the way even when
pulling hood release handle inside vehicle.) Also check that hood
opens and closes smoothly and properly and hood locks securely
when closed.
If any malfunction is found, lubricate hinge and latch, or repair
hood lock system.
FINAL INSPECTION
SEATS
Check that seat slides smoothly and locks securely at any position. Also check that reclining mechanism of front
seat back allows it to be locked at any angle.
SEAT BELT
Inspect belt system including webbing, buckles, latch plates, retractors and anchors for damage or wear.
Check that seat belt is securely locked. If “REPLACE BELT” label on front seat belt is visible, replace belt.
BATTERY ELECTROLYTE LEVEL CHECK
Check that the electrolyte level of all battery cells is between the upper and lower level lines on the case. If bat-
tery is equipped with built-in indicator, check battery condition by the indicator.
ACCELERATOR PEDAL OPERATION
Check that pedal operates smoothly without getting caught or interfered by any other part.
WARNING:
When carrying out road tests, select a safe place where no man or no running vehicle is seen so as to
prevent any accident.
1B-24 AIR CONDITIONING (OPTIONAL)
CHARGING
CHARGING PROCEDURE
The initial charging of the A/C system is performed from the high
pressure side with the engine stopped.
And next, this method must be followed by charging from the low
pressure side with the engine running.
1) Check to make sure that hoses are routed properly after
evacuating the system.
2) Connect Low charging hose (1) and High charging hose (2)
of the manifold gauge set (3) in position. Thus open refriger-
ant container valve (4) to purge the charging line.
3) Open the high pressure side valve (5) and charge refrigerant
to system.
4) After a while, open the low pressure side valve (6) and close
the high pressure side valve (5).
5) Start engine and keep engine speed at 1500 r/min. Then,
operate air conditioning.
6) Charge A/C system with refrigerant in vapor state. At this
time, refrigerant container (4) should be held upright. CAUTION:
Always charge through low pressure side of A/C system at after the initial charging is performed
from the high pressure side with the engine stopped.
Never charge to high pressure side of A/C system with engine running.
Do not charge while compressor is hot.
When installing tap valve to refrigerant container to make a hole there through, carefully follow
directions given by manufacturer.
A pressure gauge should always be used before and during charging.
The refrigerant container should be emptied of refrigerant when discarding it.
The refrigerant container should not be heated up to 40°C (104°F) or over.
Refrigerant container should not be reversed in direction during charging. Reversing in direction
causes liquid refrigerant to enter compressor, causing troubles, such as compression of liquid
refrigerant and the like.
NOTE:
The air conditioning system contains HFC-134a (R-134a).
Described here is a method to charge the air conditioning system with refrigerant from the refrigerant
service container.
When charging refrigerant recovered by using the refrigerant and recycling equipment (when recy-
cling refrigerant), follow the procedure described in the equipment manufacturer’s instruction man-
ual.
WARNING:
Make sure that high pressure side valve is closed
securely.