LT-46
< SERVICE INFORMATION >
FRONT FOG LAMP
1. Check continuity between front fog lamp harness connector and
ground.
OK or NG
OK >> Replace IPDM E/R. Refer to PG-26, "Removal and
Installation of IPDM E/R" .
NG >> Repair harness or connector.
Aiming AdjustmentINFOID:0000000001704409
The front fog lamp is a semi-sealed beam type which uses a replaceable halogen bulb. Before performing
aiming adjustment, make sure of the following.
• Keep all tires inflated to correct pressure.
• Place vehicle on level surface.
• 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 and full fuel tank, spare tire, jack and tools are properly stowed.
Adjust aiming in the vertical direction by turning the adjusting screw (A).
1. Set the distance (C) between the screen and the center of front
fog lamp lens (E) as shown.
2. Turn front fog lamps (1) to ON.
3. Adjust front fog lamps using adjusting screw so that the top edge
of the high intensity zone (A) is as shown.
NOTE:
When performing adjustment, if necessary, cover the headlamps
and opposite front fog lamp.
Front fog lamp connector Terminal
Ground Continuity
RH E28
2Yes
LH E27
PKIA6277E
PKIC1070E
Aiming distance from center of fog lamp to screen (C) 25,000 mm (984.3 in)
Foglamp beam width (D) 870 mm (34.3 in)
Horizontal distance from ground to bottom edge of high
intensity zone (B)220 mm (8.7 in)
Horizontal distance from bottom edge to top edge of
high intensity zone (A)21.75 mm (0.9 in)
LKIA0931E
LU-6
< SERVICE INFORMATION >
ENGINE OIL
ENGINE OIL
InspectionINFOID:0000000001702518
ENGINE OIL LEVEL
NOTE:
Before starting engine, park vehicle on a level surface and check the engine oil level. If engine is already
started, stop it and allow 10 minutes before checking.
1. Pull out oil level gauge and wipe it clean.
2. Insert oil level gauge and make sure the engine oil level is within
the range (A) as shown.
3. If it is out of range, adjust it.
ENGINE OIL APPEARANCE
• Check engine oil for white turbidity or heavy contamination.
• If engine oil becomes turbid and white, it is highly probable that it is contaminated with engine coolant.
Repair or replace damaged parts.
ENGINE OIL LEAKAGE
Check for engine oil leakage around the following areas:
• Oil pan (upper and lower)
• Oil pan drain plug
• Oil pressure switch
• Oil filter
• Intake valve timing control solenoid valve
• Front cover
• Mating surface between cylinder block and cylinder head
• Mating surface between cylinder head and rocker cover
• Crankshaft oil seals (front and rear)
• Oil filter (for intake valve timing control)
OIL PRESSURE CHECK
WARNING:
• Be careful not to burn yourself, as engine oil may be hot.
• For engine oil pressure check the transaxle should be in “ Park position” (A/T models) and (CVT
models) or “Neutral position” (M/T models), and apply the parking brake securely.
1. Disconnect harness connector at oil pressure switch (1), and
remove oil pressure switch using a suitable tool.
• Oil pan (lower) (2)
•⇐ Front
WBIA0776E
PBIC3310E
ENGINE OIL
LU-7
< SERVICE INFORMATION >
C
D
E
F
G
H
I
J
K
L
MA
LU
N
P O
2. Install oil pressure gauge and hose.
3. Check engine oil level. Refer to LU-6, "
Inspection".
4. Start engine and warm it up to normal operating temperature.
5. Check oil pressure with engine running under no-load.
NOTE:
When engine oil temperature is low, engine oil pressure becomes high.
Engine oil pressure [Engine oil temperature at 80°C (176°F)]
If difference is extreme, check oil passage and oil pump for oil leaks.
6. After the inspections, install oil pressure switch as follows:
a. Remove old liquid gasket adhering to oil pressure switch and engine.
b. Apply liquid gasket and tighten oil pressure switch to specification.
Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-42
.
c. Check engine oil level. Refer to LU-6, "
Inspection".
d. After warming up engine, make sure there are no engine leaks of oil with running engine.
Changing Engine OilINFOID:0000000001702519
WARNING:
• Be careful not to burn yourself, as engine oil may be hot.
• Prolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct skin
contact with used engine oil. If skin contact is made, wash thoroughly with soap or hand cleaner as
soon as possible.
1. Warm up engine, park vehicle on a level surface and check for engine oil leakage from engine compo-
nents. Refer to LU-6, "
Inspection".
2. Stop engine and wait for 10 minutes.Tool number : ST25051001 (J-25695-1)
: ST25052000 (J-25695-2)
WBIA0571E
Engine speed
rpm Approximate discharge pressure
kPa (bar, kg/cm2, psi)
Idle speed More than 60 (0.60, 0.61, 9)
2,000 More than 200 (2.0, 2.0, 29)
Oil pressure switch : 14.7 N·m (1.5 kg-m, 11 ft-lb)
MTC-2
DUCTS AND GRILLES ......................................69
Removal and Installation ........................................69
REFRIGERANT LINES ......................................74
HFC-134a (R-134a) Service Procedure .................74
Component .............................................................76
Removal and Installation of Compressor ................78
Removal and Installation of Low-Pressure Flexi-
ble Hose .................................................................
79
Removal and Installation of High-pressure Flexi-
ble Hose .................................................................
80
Removal and Installation of High-pressure Pipe ....81
Removal and Installation of Refrigerant Pressure
Sensor ....................................................................
81
Removal and Installation of Condenser ..................82
Removal and Installation of Liquid Tank .................82
Removal and Installation of Evaporator ..................83
Removal and Installation of Expansion Valve .........84
Checking of Refrigerant Leaks ................................84
Checking System for Leaks Using the Fluorescent
Leak Detector ..........................................................
85
Dye Injection ...........................................................85
Electronic Refrigerant Leak Detector ......................85
SERVICE DATA AND SPECIFICATIONS
(SDS) .................................................................
88
Compressor ............................................................88
Oil ............................................................................88
Refrigerant ..............................................................88
Engine Idling Speed ................................................88
Belt Tension ............................................................88
MTC-4
< SERVICE INFORMATION >
PRECAUTIONS
- Do not allow A/C oil to come in contact with styrofoam parts. Damage may result.
General Refrigerant PrecautionINFOID:0000000001704277
WARNING:
• Avoid breathing A/C refrigerant and oil vapor or mist. Exposure may irritate eyes, nose and throat.
Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. If acci-
dental system discharge occurs, ventilate work area before resuming service. Additional health and
safety information may be obtained from refrigerant and oil manufacturers.
• Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the
refrigerant every time an air conditioning system is discharged.
• Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or air
conditioning system.
• Do not store or heat refrigerant containers above 52°C (126° F).
• Do not heat a refrigerant container with an open flame; if container warming is required, place the
bottom of the container in a warm pail of water.
• Do not intentionally drop, puncture, or incinerate refrigerant containers.
• Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.
• Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent suf-
focation.
• Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air condition-
ing systems with compressed air during repair. Some mixtures of air and HFC-134a (R-134a) have
been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or
property damage. Additional health and safety information may be obtained from refrigerant manu-
facturers.
Oil PrecautionINFOID:0000000001704278
• Use only specified oil for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. If oil
other than that specified is used, compressor malfunction is likely to occur.
• The specified HFC-134a (R-134a) oil rapidly absorbs moisture from the atmosphere. The following handling
precautions must be observed:
- When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize
the entry of moisture from the atmosphere.
- When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before con-
necting the components. Connect all refrigerant loop components as quickly as possible to minimize the
entry of moisture into system.
- Only use the specified oil from a sealed container. Immediately reseal containers of oil. Without proper seal-
ing, oil will become moisture saturated and should not be used.
• Avoid breathing A/C refrigerant and oil vapor or mist. Exposure may irritate eyes, nose and throat.
Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. If accidental
system discharge occurs, ventilate work area before resuming service. Additional health and safety informa-
tion may be obtained from refrigerant and oil manufacturers.
• Do not allow A/C oil to come in contact with styrofoam parts. Damage may result.
Precaution for Refrigerant ConnectionINFOID:0000000001704279
A new type refrigerant connection has been introduced to all refrigerant lines except the following location.
• Expansion valve to evaporator
• Refrigerant pressure sensor to condenser
MTC-6
< SERVICE INFORMATION >
PRECAUTIONS
TYPE 2
WARNING:
Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system is
less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it.
CAUTION:
The new and former refrigerant connections use different O-ring configurations. Do not confuse O-
rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or
around, the connection.
O-Ring Part Numbers and Specifications
CAUTION:
When replacing or cleaning refrigerant cycle components, observe the following.
• When the compressor is removed, store it in the same position as it is when mounted on the vehicle.
Doing so will cause oil to enter the low-pressure chamber.
• When connecting tubes, always use a torque wrench and a back-up wrench.
• After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture.
• When installing an air conditioner in the vehicle, connect the pipes as the final stage of the opera-
tion. Do not remove the seal caps of pipes and other components until just before required for con-
nection.
SJIA1327E
Connection type Piping connection point Part number QTY O-ring size
NewCondenser to high-pressure flexible hose 92472 N8210 1 12
Condenser to high-pressure pipe 92471 N8210 1 8
Low-pressure flexible hose to expansion valve 92473 N8210 1 16
High-pressure pipe to expansion valve 92471 N8210 1 8
Compressor to low-pressure flexible hose 92474 N8210 1 19
Compressor to high-pressure flexible hose 92472 N8210 1 12
Liquid tank to condenser pipeInlet
92471 N82101
8
Outlet 1
FormerRefrigerant pressure sensor to condenser J2476 89956 1 10
Expansion valve to evaporatorInlet 92471 N8200 2 12
Outlet 92473 N8200 2 16
MTC-8
< SERVICE INFORMATION >
PRECAUTIONS
The oil contained inside the vacuum pump is not compatible with the
specified oil for HFC-134a (R-134a) A/C systems. The vent side of
the vacuum pump is exposed to atmospheric pressure. So the vac-
uum pump oil may migrate out of the pump into the service hose.
This is possible when the pump is switched off after evacuation (vac-
uuming) and hose is connected to it.
To prevent this migration, use a manual valve placed near the hose-
to-pump connection, as follows.
• Usually vacuum pumps have a manual isolator valve as part of the
pump. Close this valve to isolate the service hose from the pump.
• For pumps without an isolator, use a hose equipped with a manual
shut-off valve near the pump end. Close the valve to isolate the
hose from the pump.
• If the hose has an automatic shut-off valve, disconnect the hose
from the pump. As long as the hose is connected, the valve is open
and lubricating oil may migrate.
Some one-way valves open when vacuum is applied and close
under a no vacuum condition. Such valves may restrict the pump’s
ability to pull a deep vacuum and are not recommended.
MANIFOLD GAUGE SET
Be certain that the gauge face indicates HFC-134a or R-134a. Be
sure the gauge set has 1/2″-16 ACME threaded connections for ser-
vice hoses. Confirm the set has been used only with refrigerant
HFC-134a (R-134a) and specified oils.
SERVICE HOSES
Be certain that the service hoses display the markings described
(colored hose with black stripe). All hoses must include positive shut-
off devices (either manual or automatic) near the end of the hoses
opposite the manifold gauge.
SERVICE COUPLERS
RHA270DA
SHA533D
RHA272D
MTC-50
< SERVICE INFORMATION >
TROUBLE DIAGNOSIS
High-pressure Side is Too High and Low-pressure Side is Too Low
High-pressure Side is Too Low and Low-pressure Side is Too High
Both High- and Low-pressure Sides are Too Low
Gauge indication Refrigerant cycle Probable cause Corrective action
Both high- and low-pressure
sides are too high.Pressure is reduced soon af-
ter water is splashed on con-
denser.Excessive refrigerant charge in refrig-
eration cycle.Reduce refrigerant until
specified pressure is ob-
tained.
Air suction by cooling fan is in-
sufficient.Insufficient condenser cooling perfor-
mance.
↓
1. Condenser fins are clogged.
2. Improper fan rotation of cooling
fan.• Clean condenser.
• Check and repair cooling
fan if necessary.
• Low-pressure pipe is not
cold.
• When compressor is
stopped high-pressure val-
ue quickly drops by approx-
imately 196 kPa (1.96 bar, 2
kg/cm
2 , 28 psi). It then de-
creases gradually thereaf-
ter.Poor heat exchange in condenser
(After compressor operation stops,
high-pressure decreases too slowly.).
↓
Air in refrigeration cycle.Evacuate repeatedly and
recharge system.
Engine tends to overheat. Engine cooling systems malfunction.Check and repair each en-
gine cooling system.
• An area of the low-pressure
pipe is colder than areas
near the evaporator outlet.
• Plates are sometimes cov-
ered with frost.• Excessive liquid refrigerant on low-
pressure side.
• Excessive refrigerant discharge
flow.
• Expansion valve is open a little
compared with the specification.
↓
Improper expansion valve adjust-
ment.Replace expansion valve.
AC359A
Gauge indication Refrigerant cycle Probable cause Corrective action
High-pressure side is too high
and low-pressure side is too low.
Upper side of condenser and
high-pressure side are hot,
however, liquid tank is not so
hot.High-pressure tube or parts located
between compressor and condenser
are clogged or crushed.• Check and repair or re-
place malfunctioning
parts.
• Check oil for contami-
nation.
AC360A
Gauge indication Refrigerant cycle Probable cause Corrective action
High-pressure side is too low
and low-pressure side is too
high.High- and low-pressure sides
become equal soon after com-
pressor operation stops.Compressor pressure operation
is improper.
↓
Damaged inside compressor
packings.Replace compressor.
No temperature difference be-
tween high- and low-pressure
sides.Compressor pressure operation
is improper.
↓
Damaged inside compressor
packings.Replace compressor.
AC356A