CAN SYSTEM (TYPE 9)
LAN-169
[CAN]
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2. CHECK HARNESS FOR OPEN CIRCUIT
1. Disconnect steering angle sensor connector.
2. Check resistance between steering angle sensor harness con-
nector M81 terminals 4 (W) and 5 (R).
OK or NG
OK >> Replace steering angle sensor.
NG >> Repair harness between steering angle sensor and har-
ness connector M75.
Combination Meter Circuit InspectionEKS00NLH
1. CHECK CONNECTOR
1. Turn ignition switch OFF.
2. Disconnect the battery cable from the negative terminal.
3. Check terminals and connector of combination meter for damage, bend and loose connection (meter side
and harness side).
OK or NG
OK >> GO TO 2.
NG >> Repair terminal or connector.
2. CHECK HARNESS FOR OPEN CIRCUIT
1. Disconnect combination meter connector.
2. Check resistance between combination meter harness connec-
tor M44 terminals 22 (W) and 23 (R).
OK or NG
OK >> Replace combination meter.
NG >> Repair harness between combination meter and steer-
ing angle sensor.
CAN Communication Circuit InspectionEKS00NLI
1. CHECK CONNECTOR
1. Turn ignition switch OFF.
2. Disconnect the battery cable from the negative terminal.
3. Check following terminals and connectors for damage, bend and loose connection (control module side,
control unit side, sensor side, meter side, connector side and harness side).
–ECM
–ESP/TCS/ABS control unit
–Steering angle sensor
–Combination meter
–Between ECM and combination meter
OK or NG
OK >> GO TO 2.
NG >> Repair terminal or connector.4 (W) - 5 (R) : Approx. 54 - 66 Ω
SKIA6870E
22 (W) - 23 (R) : Approx. 108 - 132 Ω
SKIA9780E
LAN-170
[CAN]
CAN SYSTEM (TYPE 9)
2. CHECK HARNESS FOR SHORT CIRCUIT
1. Disconnect ECM connector and harness connector M75.
2. Check continuity between ECM harness connector M118 termi-
nals 95 (G/R) and 87 (GY/R).
OK or NG
OK >> GO TO 3.
NG >> Repair harness between ECM and harness connector
M75.
3. CHECK HARNESS FOR SHORT CIRCUIT
Check continuity between ECM harness connector M118 terminals
95 (G/R), 87 (GY/R) and ground.
OK or NG
OK >> GO TO 4.
NG >> Repair harness between ECM and harness connector
M75.
4. CHECK HARNESS FOR SHORT CIRCUIT
1. Disconnect ESP/TCS/ABS control unit connector.
2. Check continuity between ESP/TCS/ABS control unit harness
connector E122 terminals 61 (W) and 63 (R).
OK or NG
OK >> GO TO 5.
NG >> Repair harness between ESP/TCS/ABS control unit and
harness connector E116.
5. CHECK HARNESS FOR SHORT CIRCUIT
Check continuity between ESP/TCS/ABS control unit harness con-
nector E122 terminals 61 (W), 63 (R) and ground.
OK or NG
OK >> GO TO 6.
NG >> Repair harness between ESP/TCS/ABS control unit and
harness connector E116. 95 (G/R) - 87 (GY/R) : Continuity should not exist.
SKIB0120E
95 (G/R) - Ground : Continuity should not exist.
87 (GY/R) - Ground : Continuity should not exist.
SKIB0121E
61 (W) - 63 (R) : Continuity should not exist.
PKIA9632E
61 (W) - Ground : Continuity should not exist.
63 (R) - Ground : Continuity should not exist.
PKIA9633E
CAN SYSTEM (TYPE 9)
LAN-171
[CAN]
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6. CHECK HARNESS FOR SHORT CIRCUIT
1. Disconnect following connectors.
–Steering angle sensor connector
–Combination meter connector
2. Check continuity between combination meter harness connector
M44 terminals 22 (W) and 23 (R).
OK or NG
OK >> GO TO 7.
NG >> Check the following harness. If any harness is dam-
aged, repair the harness.
Harness between combination meter and steering
angle sensor
Harness between combination meter and harness
connector M75
7. CHECK HARNESS FOR SHORT CIRCUIT
Check continuity between combination meter harness connector
M44 terminals 22 (W), 23 (R) and ground.
OK or NG
OK >> GO TO 8.
NG >> Check the following harness. If any harness is dam-
aged, repair the harness.
Harness between combination meter and steering
angle sensor
Harness between combination meter and harness connector M75
8. CHECK ECM AND COMBINATION METER INTERNAL CIRCUIT
Check components inspection. Refer to LAN-171, "
CHECK ECM AND COMBINATION METER INTERNAL
CIRCUIT" .
OK or NG
OK >> Connect all the connectors and diagnose again. Refer to LAN-159, "Work Flow" .
NG >> Replace ECM and/or combination meter.
Component InspectionEKS00NLJ
CHECK ECM AND COMBINATION METER INTERNAL CIRCUIT
Remove ECM and combination meter from vehicle.
Check resistance between ECM terminals 95 and 87.
Check resistance between combination meter terminals 22 and
23.22 (W) - 23 (R) : Continuity should not exist.
SKIA9780E
22 (W) - Ground : Continuity should not exist.
23 (R) - Ground : Continuity should not exist.
SKIA9980E
Unit TerminalResistance (Ω)
(Approx.)
ECM 95 - 87
108 - 132
Combination meter 22 - 23
PKIA0830E
PG-12
POWER SUPPLY ROUTING
Fuse EKS00324
If fuse is blown, be sure to eliminate cause of malfunction before
installing new fuse.
Use fuse of specified rating. Never use fuse of more than speci-
fied rating.
Do not partially install fuse; always insert it into fuse holder prop-
erly.
Remove fuse for “ELECTRICAL PARTS (BAT)” if vehicle is not
used for a long period of time.
Fusible Link EKS00325
A melted fusible link can be detected either by visual inspection or by
feeling with finger tip. If its condition is questionable, use circuit
tester or test lamp.
CAUTION:
If fusible link should melt, it is possible that critical circuit
(power supply or large current carrying circuit) is shorted.
In such a case, carefully check and eliminate cause of mal-
function.
Never wrap outside of fusible link with vinyl tape. Important:
Never let fusible link touch any other wiring harness, vinyl
or rubber parts.
Circuit Breaker EKS00326
The PTC thermistor generates heat in response to current flow. The
temperature (and resistance) of the thermistor element varies with
current flow. Excessive current flow will cause the element's temper-
ature to rise. When the temperature reaches a specified level, the
electrical resistance will rise sharply to control the circuit current.
Reduced current flow will cause the element to cool. Resistance falls
accordingly and normal circuit current flow is allowed to resume.
CEL083
CKWA0098E
SEL109W
MA-1
MAINTENANCE
L MAINTENANCE
CONTENTS
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SECTION MA
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B
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MAINTENANCE
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 3
DESCRIPTION ............................................................ 4
Pre-Delivery Inspection Items .................................. 4
GENERAL MAINTENANCE ....................................... 6
General Maintenance ............................................... 6
PERIODIC MAINTENANCE ....................................... 7
Periodic Maintenance ............................................... 7
ENGINE AND EMISSION CONTROL MAINTE-
NANCE (QR20DE AND QR25DE PETROL
ENGINE) ............................................................... 7
CHASSIS AND BODY MAINTENANCE
(QR20DE AND QR25DE PETROL ENGINE) ....... 8
ENGINE AND EMISSION CONTROL MAINTE-
NANCE (YD22DDTI DIESEL ENGINE) ................ 9
CHASSIS AND BODY MAINTENANCE
(YD22DDTI DIESEL ENGINE) .............................. 9
MAINTENANCE UNDER SEVERE DRIVING
CONDITIONS ...................................................... 10
ENGINE AND EMISSION CONTROL MAINTE-
NANCE (QR20DE AND QR25DE PETROL
ENGINE) ............................................................. 12
CHASSIS AND BODY MAINTENANCE
(QR20DE AND QR25DE PETROL ENGINE) ..... 13
ENGINE AND EMISSION CONTROL MAINTE-
NANCE (YD22DDTI DIESEL ENGINE) .............. 14
CHASSIS AND BODY MAINTENANCE
(YD22DDTI DIESEL ENGINE) ............................ 14
MAINTENANCE UNDER SEVERE DRIVING
CONDITIONS ...................................................... 15
RECOMMENDED FLUIDS AND LUBRICANTS ...... 17
Fluids and Lubricants ............................................. 17
SAE Viscosity Number ........................................... 18
GASOLINE ENGINE ........................................... 18
DIESEL ENGINE ................................................. 18
Engine Coolant Mixture Ratio ................................ 19
ENGINE MAINTENANCE (QR20DE·QR25DE) ........ 20
Checking Drive Belts .............................................. 20
Tension Adjustment ................................................ 20Changing Engine Coolant ....................................... 20
DRAINING ENGINE COOLANT .......................... 20
REFILLING ENGINE COOLANT ......................... 21
FLUSHING COOLING SYSTEM ......................... 22
Checking Cooling System ...................................... 22
CHECKING COOLING SYSTEM HOSES ........... 22
CHECKING RADIATOR ...................................... 22
CHECKING RADIATOR CAP .............................. 22
CHECKING RADIATOR SYSTEM FOR LEAKS ... 23
Checking Fuel Lines ............................................... 24
Changing Air Cleaner Filter .................................... 24
VISCOUS PAPER TYPE ..................................... 24
Changing Engine Oil ............................................... 24
Changing Oil Filter .................................................. 25
REMOVAL ........................................................... 25
INSTALLATION ................................................... 25
INSPECTION AFTER INSTALLATION ................ 26
Checking and Changing Spark Plugs ..................... 26
REMOVAL ........................................................... 26
INSPECTION AFTER REMOVAL (EXCEPT FOR
RUSSIA) .............................................................. 26
INSPECTION AFTER REMOVAL (FOR RUS-
SIA) ..................................................................... 27
INSTALLATION ................................................... 28
Checking EVAP Vapor Lines .................................. 28
ENGINE MAINTENANCE (YD22DDTI) .................... 29
Checking Drive Belts .............................................. 29
Tension Adjustment ................................................ 29
A/C COMPRESSOR BELT .................................. 30
ALTERNATOR AND WATER PUMP BELT .......... 30
Changing Engine Coolant ....................................... 30
DRAINING ENGINE COOLANT .......................... 30
REFILLING ENGINE COOLANT ......................... 31
FLUSHING COOLING SYSTEM ......................... 32
Checking Cooling System ...................................... 32
CHECKING COOLING SYSTEM HOSES ........... 32
CHECKING RADIATOR ...................................... 32
CHECKING RADIATOR CAP .............................. 33
CHECKING RADIATOR SYSTEM FOR LEAKS ... 33
Checking Fuel Lines ............................................... 34
MA-2 Changing Fuel Filter ............................................... 34
REMOVAL ........................................................... 34
INSTALLATION .................................................... 35
INSPECTION AFTER INSTALLATION ................ 35
Changing Air Cleaner Filter .................................... 35
VISCOUS PAPER TYPE ..................................... 35
Changing Engine Oil ............................................... 35
Changing Oil Filter (TYPE A) .................................. 36
REMOVAL ........................................................... 36
INSTALLATION .................................................... 36
INSPECTION AFTER INSTALLATION ................ 36
Changing Oil Filter (TYPE B) .................................. 37
REMOVAL ........................................................... 37
INSTALLATION .................................................... 38
INSPECTION AFTER INSTALLATION ................ 38
Draining Water ........................................................ 38
CHASSIS AND BODY MAINTENANCE ................... 39
Checking Exhaust System ...................................... 39
Checking Clutch Fluid Level and Leaks ................. 39
Checking Clutch System ........................................ 39
Checking M/T Oil .................................................... 39
Changing M/T Oil .................................................... 40
Checking A/T Fluid ................................................. 40
Changing A/T Fluid ................................................. 41
Checking Transfer Oil ............................................. 41
Changing Transfer Oil ............................................. 42
Checking Propeller Shaft ........................................ 42
Checking Differential Gear Oil ................................ 43
Changing Differential Gear Oil ................................ 43
Balancing Wheels ................................................... 43
Rotation .................................................................. 43Checking Brake Fluid Level and Leaks ................... 44
Checking Brake Lines and Cables .......................... 44
Changing Brake Fluid ............................................. 44
Checking Disc Brake ............................................... 44
ROTOR ................................................................ 44
CALIPER .............................................................. 45
PAD ...................................................................... 45
Checking Steering Gear and Linkage ..................... 45
STEERING GEAR ............................................... 45
STEERING LINKAGE .......................................... 45
Checking Power Steering Fluid and Lines .............. 45
Axle and Suspension Parts ..................................... 46
Drive Shaft .............................................................. 46
Lubricating Locks, Hinges and Hood Latches ......... 46
Checking Seat Belts, Buckles, Retractors, Anchors
and Adjusters .......................................................... 47
Checking Body Corrosion ....................................... 48
HEMMED PANELS .............................................. 48
PANEL JOINT ...................................................... 48
PANEL EDGE ...................................................... 48
PARTS CONTACT ............................................... 48
PROTECTORS .................................................... 48
ANTI-CORROSION MATERIALS ........................ 48
DRAIN HOLES ..................................................... 48
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 49
Standard and Limit .................................................. 49
BELT DEFLECTION AND TENSION ................... 49
RADIATOR ........................................................... 49
ENGINE COOLANT CAPACITY .......................... 49
ENGINE OIL CAPACITY (APPROXIMATE) ........ 49
SPARK PLUG ...................................................... 49
PREPARATION
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PREPARATIONPFP:00002
Special Service ToolsELS000B6
Commercial Service ToolsELS000K9
Tool number
Tool nameDescription
KV10115801
Oil filter wrenchRemoving and installing oil filter
(QR20DE and QR25DE engine models)
a: 64.3 mm (2.531 in)
EG17650301
Radiator cap tester adapterAdapting radiator cap tester to radiator cap
and radiator filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
S-NT375
S-NT564
Tool nameDescription
Spark plug wrench Removing and installing spark plug
(QR20DE and QR25DE engine models)
Fuel filter wrench Removing fuel filter
(YD22DDTi engine model)
Radiator cap tester Checking radiator and radiator cap
S-NT047
PBIC0519E
PBIC1982E
MA-4
DESCRIPTION
DESCRIPTIONPFP:00000
Pre-Delivery Inspection ItemsELS000Y5
Shown below are Pre-delivery Inspection Items required for the new vehicle. It is recommended that
necessary items other than those listed here be added, paying due regard to the conditions in each
country.
Perform applicable items on each model. Consult text of this section for specifications.
Install vehicle protection kit
Fit all accessories ordered (if applicable) (e.g. towbar, audio, navigation, air conditioner, styling kit)
UNDER HOOD — engine off
Check coolant level and cooling system for leaks
Charge battery and check terminals for condition
Check drive belts tension (diesel only)
Check fuel filter for water or dust (diesel only) and fuel system for leaks
Check engine oil level and for oil leaks
Check brake and clutch fluid levels and fluid lines for leaks
Check and top up washer reservoirs
Check power steering fluid level and fluid lines for leaks (if applicable)
Check air conditioning system for gas leaks (if applicable)
ON INSIDE AND OUTSIDE
Install transit fuse if removed for vehicle storage
Check instruments, gauges, lamps, horn and accessories for operation
Check wipers and washers for operation and adjustment
Check interior and door mirrors and sun visors for operation
Set radio code and set clock
Check parking brake adjustment
Check clutch pedal adjustment
Check steering lock operation
Check seat adjusters and seat belts for operation
Check all windows for operation and alignment
Check mouldings, trim and fittings for fit and alignment
Check weatherstrips for fit and adhesion
Check hood, trunk lid, door panels and fuel lid for fit and alignment
Check latches, keys, remote key, door locks and remote trunk lid and fuel lid release for operation
Check wheel nut torques
Check tyre pressure (incl. spare tyre)
Check tool kit and jack for operation
Check automatic transmission/transaxle starter inhibitor (if applicable)
Check sunroof for operation and alignment (if applicable)
UNDER BODY
Check manual transmission/transaxle, differential and transfer box for oil level and oil leaks
Tighten bolts and nuts steering linkage and gear box, axle/suspension parts, propeller and exhaust system
Check brake and clutch lines, and oil/fluid reservoirs for leaks
Remove front suspension spacer blocks (if applicable)
Check body mounting torque (if applicable)