ATC-160
REFRIGERANT LINES
Checking for Refrigerant LeaksEJS000VJ
Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant
leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow
extra inspection time in these areas when using either an electronic refrigerant leak detector or fluorescent
dye leak detector.
If dye is observed, confirm the leak with an electronic refrigerant leak detector. It is possible a prior leak was
repaired and not properly cleaned.
When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all
system components and connections.
When searching for refrigerant leaks using an electronic leak detector, move the probe along the suspected
leak area at 1 to 2 inches per second and no further than 1/4 inch from the component.
CAUTION:
Moving the electronic leak detector probe slower and closer to the suspected leak area will improve
the chances of finding a leak.
Checking System for Leaks Using the Fluorescent Leak DetectorEJS000VK
1. Check A/C system for leaks using the UV lamp and safety goggles (J-42220) in a low sunlight area (area
without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a bright
green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain opening indi-
cates an evaporator core assembly (tubes, core or expansion valve) leak.
2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or
cloth, with the UV lamp for dye residue.
3. After the leak is repaired, remove any residual dye using dye cleaner (J-43872) to prevent future misdiag-
nosis.
4. Perform a system performance check and verify the leak repair with an approved electronic refrigerant
leak detector.
NOTE:
Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield
washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be
checked are clean.
Clean with a dry cloth or blow off with shop air.
Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings
and may damage the detector.
Dye InjectionEJS000VL
(This procedure is only necessary when recharging the system or when the compressor has seized and was
replaced.)
1. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.45 bar, 3.52 kg/cm
2 , 50
psi).
2. Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool (J-41459).
3. Connect the injector tool to the A/C LOW-PRESSURE side service fitting.
4. Start engine and switch A/C ON.
5. When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye
through the low-pressure service valve using dye injector tool J-41459 (refer to the manufacture's operat-
ing instructions).
6. With the engine still running, disconnect the injector tool from the service fitting.
CAUTION:
Be careful the A/C system or replacing a component, pour the dye directly into the open system con-
nection and proceed with the service procedures.
7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the
leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to
penetrate a leak and become visible.
TROUBLE DIAGNOSIS
MTC-7
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MTC
Operational CheckEJS001FE
The purpose of the operational check is to confirm that the system operates properly.
CHECKING BLOWER
1. Turn fan switch to 1st-speed. Blower should operate on low
speed.
2. Then turn fan switch to 2nd-speed, and continue checking
blower speed until all speeds are checked.
3. Leave blower on Max. speed.
If NG, go to trouble diagnosis procedure for MTC-15, "
Blower Motor
Circuit" .
If OK, continue with the check.
CHECKING DISCHARGE AIR
1. Turn mode control dial to each position.
2. Confirm that discharge air comes out according to the air distri-
bution table. Refer to MTC-5, "
Discharge Air Flow" .
If NG, go to trouble diagnosis procedure for MTC-9, "
Mode Door" .
If OK, continue the check.
CHECKING RECIRCULATION
1. Press REC switch. Recirculation indicator should eliminate.
2. Press REC switch again. Recirculation indicator should not illu-
minate.
3. Listen for intake door position change (you should hear blower
sound change slightly).
If NG, go to trouble diagnosis procedure for MTC-11, "
Intake Door
Motor Circuit" .
If OK, continue the check.Conditions :Engine running at usual operating temperature
RJIA0587E
RJIA0588E
RJIA0492E
RJIA0589E
LT-14
HEADLAMP
Aiming Adjustment for HeadlampEKS003CG
When performing headlamp aiming adjustment, use an aiming machine, aiming wall screen or headlamp
tester. Aimers should be in good repair, calibrated and operated in accordance with respective operation man-
uals.
If any aimer is not available, aiming adjustment can be done as follows:
For details, refer to the regulations in your own country.
Keep all tires inflated to correct pressures.
Place vehicle and tester on one and same flat surface.
See that there is no-load in vehicle (coolant, engine oil filled up to correct level and full fuel tank) other
than the driver (or equivalent weight placed in driver's position).
CAUTION:
Be sure aiming switch is set to “0” when performing aiming adjustment.
LOW BEAM
1. Turn headlamp low beam on.
High beam indicator does not
work.1. Bulb
2. Grounds M27 and M70
3. Open in high beam circuit1. Check bulb in combination meter.
2. Check grounds M27 and M70.
3. Check the wire between lighting switch terminal 9 and
combination meter terminal 20 for an open circuit.
Driving lamp does not operate,
but high beam LH operates.1. 15A fuse
2. Open in driving lamp switch
3. Driving lamp switch circuit
4. Driving lamp relay-2
5. Open in driving lamp relay-2 circuit
6. Grounds E24 and E50
7. Driving lamp relay-1
8. Open in driving lamp relay-1 circuit
9. Open driving lamp circuit
10.Ground R8
11 . B u l b1. Check 15A fuse (No. 38, located in fuse and fusible
link box). Verify battery positive voltage is present at
terminal 3 of driving lamp relay-1.
2. Check the wire between lighting switch terminal 9 and
driving lamp switch terminal 7 for an open circuit.
3. Check driving lamp switch.
4. Check driving lamp relay-2.
5. Check the wire between driving switch terminal 4 and
driving lamp relay-2 terminal 1 for an open circuit.
Check the wire between driving switch terminal 6 and
driving lamp relay-2 terminal 3 for an open circuit.
Check the wire between lighting switch terminal 9 and
driving lamp relay-2 terminal 5 for an open circuit.
Check the wire between driving lamp relay-1 terminal
2 and driving lamp relay-2 terminal 7 for an open cir-
cuit.
6. Check grounds E24 and E50.
7. Check driving lamp relay-1.
8. Check the wire between lighting switch terminal 9 and
driving lamp relay-1 terminal 1 for an open circuit.
9. Check the wire between driving lamp relay-1 terminal
5 and driving lamp terminal 2 for an open circuit.
10.Check ground R8.
11.Check bulbs. Symptom Possible cause Repair order
PKIA5554E
HEADLAMP
LT-15
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LT
2. Use adjusting screws to perform aiming adjustment.
First tighten the adjusting screw all the way and then make adjustment by loosening the screw.
If the vehicle front body has been repaired and/or the headlamp assembly has been replaced, check
aiming. Use the aiming chart shown in the figure.
Adjust headlamps so that main axis of light is parallel to cen-
ter line of body and is aligned with point P shown in illustra-
tion.
Figure to the right shows headlamp aiming pattern for driving
on right side of road; for driving on left side of road, aiming
pattern is reversed.
Dotted lines to point P in illustration show center of head-
lamp.
Basic illuminating area for adjustment should be within the
range shown at right. Adjust headlamps accordingly.
CAUTION:
Be sure aiming switch is set to “0” when preforming aiming
adjustment.
Aiming Adjustment for Driving LampEKS00AP6
Turn the aiming adjusting screw to adjust.
For positions of the adjustment screws and direction to turn,
refer to the figures.
When adjusting for right or left side, adjust upper and lower
adjustment screws at the same time.
PREPARATION BEFORE ADJUSTING
For details, refer to the regulations in your own country.
Before performing aiming adjustment, check the following.
1. Keep all tires inflated to correct pressures.
2. Place vehicle on level ground.
3. Set that there is no-load in vehicle other than the driver (or equivalent weight placed in driver's position),
coolant, engine oil filled up to correct level, full fuel tank and spare tire, jack, and tools."H" : Horizontal center line of headlamps
"W
L " : Distance between each headlamp center
"L" : 25,000mm (984.25 in)
"C" : 315mm (12.40 in) – 315mm(12.40in)+60mm
(2.36 in)
PKIA3537E
PKIA3394E
IDX-3
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IDX
ALPHABETICAL INDEX
Blower unit ....................... ATC-125, MTC-22, MTC-24
BOOST - Wiring diagram ............... EC-1040, EC-1347
Boring/horning cylinder block(QR20DEQR25DE) .......
EM-103
Brake booster .................................................... BR-23
Brake fluid change ............................................... BR-8
Brake fluid level ................................................. MA-41
Brake fluid level and line check ........................... BR-8
Brake hydraulic line ........................................... BR-10
Brake inspection ................................................ MA-43
Brake lines and cables inspection ..................... MA-41
Brake master cylinder ........................................ BR-14
Brake pedal ......................................................... BR-6
Brake switch ..... EC-380, EC-733, EC-1177, EC-1475
BRK/SW - Wiring diagram EC-381, EC-735, EC-1178,
EC-1476
Bulb specifications .............................................. LT-92
Bumper, front ....................................................... EI-14
Bumper, rear ........................................................ EI-17
C
Camshaft inspection(QR20DEQR25DE) .......... EM-55
Camshaft inspection(YD22DDTi) .................... EM-171
Camshaft position sensor (CMPS) EC-1056, EC-1062,
EC-1363
, EC-1369
Camshaft position sensor (PHASE) .. EC-254, EC-646
Camshaft(QR20DEQR25DE) ........................... EM-53
Camshaft(YD22DDTi) ...................................... EM-170
CAN - Wiring diagram ......... EC-133, EC-580, EC-945,
EC-1269
, LAN-10, LAN-26, LAN-51, LAN-69, LAN-87
CAN (Controller Area Network) ........... BRC-8, LAN-9,
LAN-25
, LAN-50, LAN-68, LAN-86
CAN communication EC-38, EC-132, EC-500, EC-579,
EC-888
, EC-944, EC-1268, AT-32, AT-97, AT-329,
TF-43
, BRC-8, LAN-9, LAN-25, LAN-50, LAN-68,
LAN-86
Canister-See EVAP canister ............. EC-476, EC-868
CHARGE - Wiring diagram .................... SC-13, SC-14
Charging system ................................................ SC-12
Chassis and body maintenance ........................ MA-37
CHIME - Wiring diagram ................ DI-52, DI-55, DI-56
CIGAR - Wiring diagram .................................. WW-27
Cigarette lighter ............................................... WW-27
Circuit breaker ................................................... PG-12
CKPS - Wiring diagram .. EC-947, EC-1046, EC-1052,
EC-1271
, EC-1353, EC-1359
Clearance lamp ........................................ LT-4, LT-60
Clock ................................................................... DI-61
CLOCK - Wiring diagram .................................... DI-61
Closed loop control .............................. EC-35, EC-497
Clutch cover ....................................................... CL-14
Clutch disc ......................................................... CL-14
Clutch master cylinder ......................................... CL-8
Clutch operating cylinder ................................... CL-10
Clutch pedal ......................................................... CL-5
Clutch release bearing ....................................... CL-12
Clutch release mechanism ................................ CL-12
Clutch withdrawal lever ...................................... CL-12
CMPS - Wiring diagram . EC-947, EC-1058, EC-1064,
EC-1271
, EC-1365, EC-1371
Coil spring (rear) ............................................... RSU-8
Collision diagnosis .......................................... SRS-48
Combination meter ............................................... DI-4
Combination switch ............................................. LT-40
Component Location (auto A/C) ......... ATC-35, MTC-4
Compression pressure(QR20DEQR25DE) ..... EM-67
Compression pressure(YD22DDTi) ................ EM-196
Compressor clutch removal and installation .. ATC-146
Compressor special service tool ...................... ATC-14
Condenser ..................................................... ATC-155
Connecting rod bearing clearance(QR20DEQR25DE)
EM-101
Connecting rod bearing clearance(YD22DDTi) EM-232
Connecting rod bushing clearance(YD22DDTi) EM-226
Connecting rod(QR20DEQR25DE) ............... EM-101
Connecting rod(YD22DDTi) .............. EM-223, EM-228
CONSULT for engine ......................... EC-102, EC-551
CONSULT-II for engine ................... EC-926, EC-1251
Control lever (M/T) ............................................. MT-14
Control unit ..................................... ATC-120, MTC-21
Control units (terminal arrangement) ................. PG-72
Controller Area Network (CAN) ........... BRC-8, LAN-9,
LAN-25
, LAN-50, LAN-68, LAN-86
Converter housing installation ......................... AT-523
COOL/F - Wiring diagram EC-352, EC-704, EC-1014,
EC-1322
Coolant replacement(QR20DEQR25DE) ........ MA-20
Coolant replacement(YD22DDTi) ..................... MA-28
Cooling circuit (engine)(QR20DEQR25DE) ....... CO-7
Cooling circuit (engine)(YD22DDTi) ................. CO-29
Cooling fan ............................................ CO-18, CO-36
Cooling fan relay EC-363, EC-715, EC-1024, EC-1331
Coupling sleeve (M/T) ........................... MT-20, MT-25
Cowl top .............................................................. EI-20
Cowl top cover .................................................... EI-20
Crankcase ventilation system .......... EC-888, EC-1219
Crankcase ventilation system - See Positive crankcase
ventilation ........................................... EC-478
, EC-870
Crankshaft position sensor (POS) ..... EC-247, EC-638
Crankshaft position sensor (TDC) EC-1044, EC-1050,
EC-1351
, EC-1357
Crankshaft(QR20DEQR25DE) ........................ EM-83
Cylinder block boring(QR20DEQR25DE) ...... EM-104
Cylinder block boring(YD22DDTi) ................... EM-230
Cylinder block(QR20DEQR25DE) ................... EM-82
Cylinder block(YD22DDTi) .............................. EM-212
Cylinder head bolt tightening(QR20DEQR25DE) ........
EM-69
Cylinder head bolt tightening(YD22DDTi) ....... EM-198
Cylinder head gasket selection(YD22DDTi) ... EM-199
Cylinder head(QR20DEQR25DE) ................... EM-67
Cylinder head(YD22DDTi) .............................. EM-196
D
Data link connector ............................ EC-469
, EC-861
Data link connector for Consult ......... EC-104, EC-553,