1.Prior to the inspection, be sure to turn OFF the ignition switch.
2.Never touch the terminals of the battery which is mounted on the vehicle immediately after the vehicle has been operated.
3.Since the battery electrolyte harms or damages the skin and clothes, pay utmost attention to handling of the battery.
4.The following shows how to apply first aid in the event that unexpected incidents happen in connection with the battery electrolyte.
JCH00002-00000
(1)When you swallow the electrolyte:
Immediately rinse your mouth with clean water. Drink raw eggs, milk or a large quantity of water. Lie down and remain quiet. At the same time, call an ambulance or a doctor to receive medical treatments at a medical agency.
(2)When the electrolyte gets into your eyes:
Flush the electrolyte gets away from your eyes with a large quantity of clean running water for at least 15 minutes. At the same time, call an ambulance or a doctor to receive medical treatments at a medical agency.
(3)When the electrolyte splashes on your skin or clothes:
Flush the electrolyte away with a large quantity of clean running water, until there in no more electrolyte there. Then, neutralize the spot with soap water. After this treatment, call a doctor or consult with a doctor for advice.
(4)When the electrolyte is spilled over the floor:
Flush the electrolyte away with a large quantity of clean running water, until there in no more electrolyte there. Then, neutralize the spot with hydrated lime.
(5)When the electrolyte gets to a vehicle body:
Flush the electrolyte away from the affected section with a large quantity of clean running water, until there is no more electrolyte there.
JCH00003-00000
CHARGING SYSTEM CIRCUIT
RATED OUTPUT: 70 A
JCH00004-00001
RATED OUTPUT: 80 A
IN-VEHICLE INSPECTION
BATTERY
1.If the battery case exhibits cracks, replace the battery with a satisfactory one.
2.If contamination, foreign matters or corrosion is found at the battery terminals, clean the battery.
3.Check that the battery terminals are connected with the cable securely without any looseness.
4.Ensure that the standard cover is mounted at the positive pole of the battery.
5.Ensure that a thin film of lithium grease has been applied to the negative pole of the battery.
6.Check to see if the electrolyte level of each cell of the battery has reached the specified level indicated on the battery case. If the level is below the specified level, replenish distilled water to the specified level.
7.To check the charging condition of the battery, measure the specific gravity of each cell of the battery with a hydrometer. In the case of a maintenance-free battery, take a reading of the indicator provided at the battery. If the battery is inadequately charged, charge the battery in accordance with the instructions of the charger manufacturer.
Specified Value:
When fully-charged:1.25 - 1.28 (at 20°C)
ALTERNATOR
Check of drive belt
1.Visually check the drive belt for wear or cracks.
2.If there is any evidence which shows that the contact surface with the pulley has lost elasticity or slipping occurred in the surface, replace the drive belt or check the drive belt for tension.
3.Check and adjustment of tension of drive belt (In the case of M101, M201 series) (1)Check of tension of drive belt
Apply a force of 98 N to the position between the water pump pulley and the power steering pulley, as shown in the right figure. Measure the deflection amount.
Specified Values
NOTE:
• The tension can be measured by using a belt tension gauge.
• When installing a new belt, set the values to the median values of the specified values for new belts.
• When installing the belt that has been used on a running engine for more than five minutes, it should be adjusted to the median values of the specified values for used belts.
(2)Adjustment of tension of drive belt
q Loosen the nut B. Then, loosen the bolt A. Under this condition, no belt tension is applied to the tensioner.
w Tighten the nut B by hand to such an extent that the tensioner may be retained without any excessive looseness.
e Tighten the bolt A so that the belt tension may reach the specified value. Proceed to tighten the nut B fully to tighten the tensioner securely.
Tightening Torque:35.2 - 52.8 N·m
NOTE:
• As for the bolt A, be very careful not to over-tighten it beyond of a tension of 8 N·m.
r Loosen the bolt A to a tightening torque of 3.9 to 4.1 N·m. (For this operation, loosen the bolt A about 1/2 turn.)
t Check the tension of the drive belt.
(In the case of J102 series)
(1)Check of tension of drive belt
Apply a force of 98 N to the position between the water pump pulley and the tensioner, as shown in the right figure. Measure the deflection amount.
Specified Values
NOTE:
• The tension can be measured by using a belt tension gauge.
• When installing a new belt, set the values to the median values of the specified values for new belts.
• When installing the belt that has been used on a running engine for more than five minutes, it should be adjusted to the median values of the specified values for used belts.
(2)Adjustment of tension of drive belt
q Loosen the nut B.
w Adjust the tension by turning the bolt A and moving the idler pulley.
e Tighten the nut B
Tightening Torque:35.2 - 52.8 N·m
r Check the tension of the drive belt.
(In the case of S221 series)
(1)Check of tension of drive belt
Apply a force of 98 N to the position between the water pump pulley and the power steering pump pulley, as shown in the right figure. Measure the deflection amount.
Specified Values
DeflectionW/PS L/PS
Tension
NOTE:
New belt 11 - 13 mm 9.5 - 11.5 mm 490 - 690 N
Used belt 15 - 17 mm
13.5 - 15.5 mm
340 - 440 N
• The tension can be measured by using a belt tension gauge.
• When installing a new belt, set the values to the median values of the specified values for new belts.
• When installing the belt that has been used on a running engine for more than five minutes, it should be adjusted to the median values of the specified values for used belts.
(2)Adjustment of tension of drive belt
q Loosen the bolt A and the lower side bolt of the alternator.
w Tighten the nut B, using the SST given below. This will adjust the tension by moving the alternator.
SST:09286-87701-000
e Tighten the bolt A and the lower side bolt of the alternator.
Tightening Torque:
Upper side bolt:15.2 - 22.8 N·m (Bolt A)
Lower side bolt:35.2 - 52.8 N·m
r Check the tension of the drive belt
Alternator
Crank pulley
Check of battery charge warning circuit
Set the ignition switch to the ON position. Visually check to see if the charge warning lamp goes on.
Then, start the engine. At this time, visually check to see if the charge warning lamp goes out.
NOTE:
• The battery charge warning light is provided in the combination meter.
Check of alternator
Ensure that the connector section of the wiring of the alternator is securely connected.
Check to see if abnormal noise is emitted from the alternator while the engine is operating.
Check of charging circuit under unloaded state
Connect the terminal B of the alternator with the negative (–) terminal of the battery by means of a voltmeter. Turn OFF all switches of the headlamps and other devices which will become electric loads.
Start the engine and warm it up.
Raise the engine revolution speed to 2500 rpm. At this time, measure the voltage.
Specified Value:14.2 - 14.8 V
NOTE:
• If the measured value exceeds the specified value, replace the IC regulator.
If the measured voltage is less than the specified value, ground the terminal F of the alternator to the alternator proper, as shown in the right figure. Raise the engine revolution speed to 2500 rpm. At this time, measure the voltage.
NOTE:
• If the measured value exceeds the specified value, replace the IC regulator.
• If the measured value is less than the specified value, disassemble the alternator.
Check of charging circuit under loaded state
1.Disconnect the cable from the terminal B of the alternator and the battery.
2.Connect the terminal B of the alternator with the positive terminal (+) of the battery by means of an ammeter.
3.Turn ON the headlamp switch with the high beam position selected.
4.Turn ON the switch of the heater blower with the Hi position selected.
5.Start the engine and warm it up.
6.Raise the engine revolution speed to 2500 rpm. At this time, measure the current.
Specified Value:More than 30 A
NOTE:
• If the measured value less than the specified value, replace the alternator. However, there may be cases where the reading of the ammeter will not reach 30 A when the battery is fully charged.
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ALTERNATOR COMPONENTS
- 22.8 35.2 - 52.8 94.0 - 127.0
:Tightening torque
Unit:N·m
q Generator cap
w Alternator assembly
e Pulley lock nut
r Alternator pulley
t Spacer collar
y Drive end frame assembly
u Stud bolt
i Front bearing
o Retainer plate
! Alternator rotor assembly
! Rear bearing
! Bearing cover
! Wave washer
! Rectifier end frame
! Nut
! Insulator terminal
! Rectifier holder
! Generator regulator assembly (IC regulator)
! Brush
@ Brush spring
@ Brush holder
@ Rear end cover
DISASSEMBLY
1.Remove the alternator pulley lock nut by means of an impact wrench, while holding the shaft by using a hexagonal box wrench.
NOTE:
• Be sure to use an impact wrench having a hexagonal hole.
2.Remove the alternator pulley and spacer collar.
3.Remove the attaching nut of the insulator terminal.
4.Pull out the insulator terminal.
5.Remove the three rear end cover attaching nuts.
6.Remove the rear end cover.
7.Remove the brush holder by removing the two attaching screws.
8.Remove the IC regulator by removing the three attaching screws.
9.Remove the rectifier holder by removing the four attaching screws and one attaching bolt.
10.Remove the rectifier end frame by removing the four attaching nuts.
Bolt wit washer
11.Remove the wave washer from the alternator rotor assembly.
12.Remove the alternator rotor assembly from the drive end frame assembly.
NOTE:
• If any difficulty is encountered in removing the alternator rotor assembly, lightly tap the rotor shaft with a plastic hammer or the like.
INSPECTION
Rotor
1.Inspection of rotor for open circuit
Using an ohmmeter, check to see if the specified resistance exists between the rotor slip rings.
Standard Resistance:2.9 ±0.2 Ω
If the resistance does not conform to the specification, replace the rotor.
2.Inspection of rotor for ground
Ensure that no continuity exists between the rotor slip rings and the rotor core. If continuity exists, replace the rotor.
3.Inspection of slip rings
(1)Check to see if the slip ring surface exhibits roughness, abnormal wear and/or burning. Replace the rotor, if necessary.
NOTE:
• When correcting the smear and roughness of the slip ring, polish the slip ring, using fine sand paper (#300500). In this case, the slip ring can be used, until the outer diameter of the slip ring is reduced 0.4 mm from that of a new one.
JCH00031-00026
JCH00032-00027
JCH00033-00028
JCH00034-00029
JCH00035-00030
(2)Measure the outer diameter of the slip ring, using vernier calipers.
Standard Diameter:14.4 mm
Minimum Diameter:14.0 mm
If the slip ring diameter is less than the minimum diameter, replace the rotor assembly.
Stator
1.Inspection of stator for open circuit
Using an ohmmeter, check to see if any open circuit of the stator coil is present between the leads. If no continuity exists, replace the end frame assembly.
Specified Resistance:About 0.2 Ω
NOTE:
• If no continuity exists, there is no possibility that the stator coil itself exhibits open wire. Therefore, check the connecting section of the lead wire.
2.Inspection of stator for short circuit
Using an ohmmeter, check to see if any short circuit of the stator coil is present between the coil lead and the drive end frame.
If continuity exists, replace the drive end frame assembly.
Specified Resistance:More than 1 kΩ
Brush and brush holder
1.Measurement of exposed brush length
Measure the exposed brush length, using a scale.
Standard Exposed Length:10.5 mm
Minimum Exposed Length:8.4 mm
If the exposed length is less than the minimum requirement, replace the brushes.
2.Replacement of brushes
(1)Remove the brush and spring from the brush holder by melting the solder by means of a soldering iron.
CH–11
(2)Install the brush cord in the brush holder with the spring fitted in place.
JCH00041-00036
(3)Solder the brush cord in the brush holder in such a way that the exposed length of the brush meets the specification.
Standard Exposed Length:10.5 mm
JCH00042-00037
(4)Ensure that the brush moves freely in the brush holder.
JCH00043-00038
(5)Cut off any excess wire and apply insulation paint.
Rectifier
NOTE:
• Be sure to confirm the specification of the ohmmeter to be used for inspection before putting it into use.
• The current flow direction differs according to the design of an ohmmeter.
<Reference>
• The measured resistance should be about the same as those of other rectifiers, for the measurement results differ according to the input voltage of each tester.
• If the measured resistance of the rectifier differs more than 20 percent, replace the rectifier holder.
JCH00044-00039
1.Inspection of rectifier at positive side
(1)While using an ohmmeter, connect one tester probe to the positive terminal. Also, connect the other probe to each of the rectifier terminals.
(2)Repeat the same steps described in (1) above with the polarity of the tester probes reversed this time.
(3)Ensure that continuity exists either in the step (1) or in the step (2) and no continuity exists at the other test. If not, replace the rectifier holder.
2.Inspection of rectifier at negative side
(1)While using an ohmmeter, connect one tester probe to each negative terminal. Also, connect the other probe to each rectifier terminal.
(2)Repeat the same steps described in (1) above with the polarity of the tester probes reversed this time.
(3)Ensure that continuity exists either in the step (1) or in the step (2) and no continuity exists at the other test. If not, replace the rectifier holder.
Bearing
1.Inspection of front bearing
Ensure that the front bearing turns smoothly. Replace the front bearing, if necessary.
CH–13
2.Replacement of front bearing
(1)Remove the four screws and retainer plate.
JCH00051-00045
(2)Remove the front bearing from the drive end frame, using a suitable socket wrench in conjunction with a press.
CAUTION:
• Be very careful not to damage the coil and stud bolts during the front bearing removal.
JCH00052-00046
(3)Press a new front bearing into the drive end frame, using a suitable socket wrench in conjunction with a press.
CAUTION:
• Be sure to hold the outer race of the new front bearing during the installation. Holding of the inner race or side cover will cause the front bearing to be damaged.
JCH00053-00047
(4)Attach the retainer plate to the drive end frame with the four screws.
3.Inspection of rear bearing
Ensure that the rear bearing turns smoothly. Replace the rear bearing, if necessary.
JCH00054-00048 JCH00055-00049
4.Replacement of rear bearing
(1)Remove the rear bearing cover from the rotor, using an armature bearing puller.
CAUTION:
• Be very careful not to damage the fan during the removal.
SST:09820-00021-000
(2)Place the parts on the rotor in the following order. Spacer New rear bearing New bearing cover
(3)Press the assembled parts into the rotor, using a hydraulic press in combination with a suitable attachment.
NOTE:
• Care must be exercised so that the point where the rear bearing is assembled to the rotor shaft may not deform an bearing cover. Therefore, be sure to select a suitable attachment to assemble the bearing cover.
5.Inspection/replacement of stud bolt
Visually inspect the thread portion of the stud bolt. If any damage exists, replace the stud bolt.
ASSEMBLY
1.Install the rotor in the drive end frame assembly.
2.Installation of rectifier end frame on drive end frame
(1)Place the wave washer on the rear bearing.
(2)Install the rectifier end frame on the drive end frame with the four attaching nuts.
CAUTION:
• Be very careful not to damage the coil cord during the installation.
3.Installation of rectifier holder, IC regulator and brush holder
(1)Attach the rectifier holder to the rectifier end frame with the coil wires passed through the aperture of the rectifier holder.
(2) Secure the rectifier holder to the rectifier end frame by installing the attaching bolt with washer.
(3)Connect the coil wires to the rectifier holder with the attaching screws.
(4)Install the rectifier holder and IC regulator with the attaching screws.
NOTE:
• Make sure that the IC regulator has been installed properly with the attaching screws.
(5)Install the brush holder in such a way that a gap of at least 1 mm is provided between the brush holder and the IC regulator. Secure the brush holder with the two screws.
Screw
Bolt wit washer
JCH00061-00055
JCH00000-00056
JCH00062-00057
JCH00064-00059
JCH00065-00060
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CH–17
4.Installation of rear end cover.
(1)Install the rear end cover on the alternator.
(2)Secure the rear end cover with the three attaching nuts.
(3)Install the insulator terminal.
(4)Secure the insulator terminal attaching nut.
5.Attach the alternator pulley and spacer collar to the rotor shaft.
6.Tighten the pulley lock nut to the specified tightening torque.
Tightening Torque:94.0 - 127.0 N·m
7.Ensure that the rotor turns smoothly.
CH–18
SERVICE SPECIFICATIONS
Specific gravityStandard
Rated output
Alternator:
Amperage Resistance Standard Minimum Standard Minimum Adjusting voltage
SST
M101 (Except Europe hot area specifications), M111
J102, J122 (Except tropical, general and A/T specifications)
M101 (Europe hot area specifications)
J102, J122 (Tropical, general and A/T specifications)
09820-00021-000Alternator bearing puller
09286-87701-000Alternator adjusting bar
TIGHTENING TORQUE
70 A
80 A
TO INDEX
COOLING SYSTEM
CHECK & CHANGE OF ENGINE
COOLANT
PRECAUTIONS
WARNING:
• If the coolant gets to the vehicle body, immediately flush away the coolant using water.
• Never open the radiator cap when the engine is still hot. Failure to observe this caution will cause you to get scalded.
• The inside of the radiator is under a pressurized condition when the cooling water is hot. Therefore, if the radiator cap should be removed, the cooling water will blow off, possibly causing injuries such as scald.
CAUTION:
• Here, the coolant refers to the mixture of water and antifreeze of a reliable brand that has been mixed in accordance with the instructions of the antifreeze manufacturer.
CHECK OF ENGINE COOLANT QUALITY
There should be no excessive deposits of rust or water scales around the radiator cap or the radiator filler hole. Also, the coolant should be free of oil.
Change the coolant if it is excessively dirty.
CHECK OF ENGINE COOLANT LEVEL
Check to see if the coolant level is between the L and F lines of the reserve tank. If the coolant level is near the low level or below the low level, add the coolant up to the full level.
NOTE:
• If no coolant is present in the reserve tank or the coolant level is very low, check for water leakage, using a radiator cap tester. (Refer to the page CO–13.)
CHANGE OF ENGINE COOLANT
CAUTION:
• Be sure to perform the coolant change after the engine has cooled down.
Furthermore, with regard to the engine coolant changing procedure, be sure to refer to the engine service information label affixed to the body.
1.DRAIN ENGINE COOLANT
M101 & M201 Series
(1)Remove the radiator cap.
(2)Drain the coolant by loosing the radiator drain plug.
J102 Series
(1)Remove the radiator cap.
(2)Loosen and remove the cocks (white) of the air bleeding valves A and B
(3)Drain the coolant by loosing the radiator drain plug.
S221 Series
(1)Remove the radiator cap.
(2)Drain the coolant by loosening the radiator drain plug.
(3)Loosen the bleeder plug located at the top of the engine water outlet housing.
2.FILL ENGINE COOLANT
M101 & M201 Series
(1)Tighten the drain plug of the radiator. Fill the radiator with water.
CAUTION:
• As regards water to be used as cooling water, use soft water which does not contain salts of minerals, calcium, magnesium, and so forth.
NOTE:
• The operations described in steps (1) through (5) are to completely expel any deteriorated coolant remaining in the cooling system.
(2)Tighten the radiator cap.
(3)Start the engine, and keep warming up the engine and then stop the engine and allow it to cool down.
(4)Drain the water. (Refer to page CO–3.)
(5)Repeat the steps (1) through (4) two to three times.
(6)Tighten the drain plug of the radiator. Fill the radiator with coolant in accordance with the instructions of the manufacturer of the antifreeze solution.
CAUTION:
• Use a reliable brand of ethylene-glycol base antifreeze solution.
Coolant Capacity:3.8R(W/heater, W/O reserve tank)
Reserve Tank Capacity:
Full:0.45R
Low:0.25R
(7)Tighten the radiator cap. Also add the coolant to the reserve tank.
(8)Warm up the engine until the cooling fan operates twice, and then stop the engine.
(9)After the engine has cooled down, fill the radiator with coolant and add the coolant up to the full level of the reserve tank.
J102 Series
(1)Tighten the drain plug of the radiator. Fill the radiator with water.
CAUTION:
• As regards water to be used as cooling water, use soft water which does not contain salts of minerals, calcium, magnesium, and so forth.
NOTE:
• The operations described in steps (1) through (7) are to completely expel any deteriorated coolant remaining in the cooling system.
(2)Tighten the cock A when the water starts to overflow from the air bleeding valve A
(3)Tighten the cock B when the water starts to overflow from the air bleeding valve B
(4)Tighten the radiator cap when the water starts to overflow from the radiator.
(5)Start the engine, and keep warming up the engine and then stop the engine and allow it to cool down.
(6)Drain the water. (Refer to page CO–3.)
(7)Repeat the steps (1) through (6) two to three times.
(8)Tighten the drain plug of the radiator. Fill the radiator with coolant in accordance with the instructions of the manufacturer of the antifreeze solution.
CAUTION:
• Use a reliable brand of ethylene-glycol base antifreeze solution.
Coolant Capacity:(W/heater, W/O reserve tank)
MT:5.80R
AT:5.72R
Reserve Tank Capacity:0.95R
(9)Tighten the cock A when the coolant starts to overflow from the air bleeding valve A.
(10)Tighten the cock B when the coolant starts to overflow from the air bleeding valve B
(11)Tighten the radiator cap when the coolant starts to overflow from the radiator. Also add the coolant to the reserve tank.
(12)Warm up the engine until the cooing fan operates twice, and then stop the engine.
(13)After the engine has cooled down, fill the radiator with the coolant and add the coolant up to the full level of the reserve tank.
NOTE:
If no coolant overflows from the air bleeding valves A or B, or no coolant overflows from both valves A and B in steps (9) and (10) above, tighten the cocks of the air bleeding valves after coolant overflows from the radiator.
S221 Series
(1)Tighten the drain plug of the radiator. Fill the radiator with water.
CAUTION:
• As regards water to be used as cooling water, use soft water which does not contain salts of minerals, calcium, magnesium, and so forth.
NOTE:
• The operations described in steps (1) through (6) are to completely expel any deteriorated coolant remaining in the cooling system.
(2)Tighten the bleeder plug when the water starts to overflow from the bleeder plug.
(3)Tighten the radiator cap when the water starts to overflow from the radiator.
(4)Start the engine, and keep warming up the engine and then stop the engine and allow it to cool down.
(5)Drain the water. (Refer to page CO–3.)
(6)Repeat the steps (1) through (5) two to three times.
(7)Tighten the drain plug of the radiator. Fill the radiator with coolant in accordance with the instructions of the manufacturer of the antifreeze solution.
CAUTION:
• Use a reliable brand of ethylene-glycol base antifreeze solution.
Coolant Capacity:(W/heater, W/O reserve tank)
MT:6.50R
AT:6.70R
Reserve Tank Capacity:0.7R
(8)Tighten the bleeder plug when the coolant starts to overflow from the bleeder plug.
(9)Tighten the radiator cap when the coolant starts to overflow from the radiator. Also add the coolant to the reserve tank.
(10)Warm up the engine until the cooing fan operates twice, and then stop the engine.
(11)After the engine has cooled down, fill the radiator with the coolant and add the coolant up to the full level of the reserve tank.
Engine coolant
Bleeder plug
sCO00072-00000
sCO00073-00052
sCO00074-00053
sCO00075-00000
WATER PUMP COMPONENTS
:Tightening torque
★ :Non-reusable parts
Unit:N·m
q Power steering pump drive belt
w V-ribbed belt
e Water pump pulley
r Water pump Assy
t Water pump gasket
REMOVAL
1.Drain the engine coolant. (Refer to page CO–3.)
2.Remove the drive belt. (Refer to the CH section.)
3.Remove the power steering pump drive belt. (J102 only)
(1)Loosen the bolts A and B
(2)Remove the power steering pump drive belt by moving the power steering pump.
4.Remove the water pump pulley while preventing it from turning, using a screwdriver or the like, as indicated in the right figure.
5.Remove the water pump Assy and gasket.
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INSPECTION
1.Check the water pump pulley for damage or deformation. Replace the water pump pulley if it exhibits damage or deformation.
2.Visually inspect the water pump rotor for damage or deformation.
Replace the water pump if the water pump rotor exhibits damage or deformation.
3.Ensure that the water pump rotates smoothly by hand. Replace the water pump if it will not rotate smoothly.
4.Visually inspect the water pump pulley seat for damage or deformation.
Replace the water pump if it exhibits damage or deformation.
INSTALLATION
1.Install the water pump assembly and gasket.
Tightening Torque:7.2 - 10.8 N·m
2.Install the water pump pulley while preventing it from turning, using a screwdriver or the like, as indicated in the right figure.
Tightening Torque:8.1 - 15.0 N·m
3.Install the power steering pump drive belt. (J102 only)
(1)Install the power steering pump drive belt between the water pump pulley and the power steering pump pulley.
(2)Adjust the tension by moving the power steering pump.
(3)Tighten the bolts A and B
Tightening Torque:34.4 - 52.0 N·m
CO–8
(4)Check the tension of the power steering pump drive belt.
Specified Value
Belt deflection amount
Belt tension
NOTE:
New beltUsed belt
7.0 - 9.0 mm9.0 - 11.0 mm
294 - 392 N196 - 294 N
• When the belt deflection amount is measured, the measurement should be carried out with a force of 98N applied between the designated pulleys in the right figure.
• As regards the belt that has been used for more than five minutes, it should be adjusted according to the specified value for the used belt.
4.Install the drive belt. (Refer to the CH section.)
5.Fill engine coolant. (Refer to page CO–3.)
Power steering pump pulley Measuring section
Water pump pulley Engine coolant
JCO00027-00025
JCO00028-00026
THERMOSTAT
COMPONENTS
S221 Series
M101, M201 & J102 Series 1
:Tightening torque Unit:N m
q Hose w Water inlet e Thermostat
:Tightening torque Unit:N·m
3
11.2 - 16.8
q Radiator No. 3 hose w Water outlet e Thermostat
REMOVAL
M101, M201 & J102 Series
1.Drain the engine coolant. (Refer to CO–3.)
2.Disconnect the radiator thermo control switch connector. (Only for EU spec.)
3.Remove the water inlet from the cylinder head.
4.Remove the thermostat from the cylinder head.
S221 Series
1.Drain the engine coolant (Refer to CO–3.)
2.Remove the water outlet from the cylinder head.
3.Remove the thermostat from the cylinder head.
CO–10
INSPECTION
1.Ensure that the thermostat valve is closed at room temperature of 20°C and the spring has no play. Replace the thermostat if the valve is open or the spring has a play.
2.Check the rubber grommet of the thermostat for damage or crack.
Replace the thermostat if the rubber grommet exhibits damage or crack.
3.Check of thermostat valve opening temperature (1)Immerse the thermostat in water, as indicated in the right figure. Heat the water gradually. Ensure that the temperature at which the valve begins to open conforms to the specified value.
Specified Valve Opening Temperature:
M101, M201 & J102 Series:80 ±2°C
S221 Series:88 ±1.5°C
If the temperature fails to conform to the specification, replace the thermostat with a new one.
(2) M101, M201 & J102 Series
Under the condition described in the step (1), heat the water to 93°C. At this time, ensure that the valve lift is the specified value or more.
Specified Value:More than 8.5 mm
S221 Series
Under the condition described in the step (1), heat the water to 100°C. At this time, ensure that the valve lift is the specified value or more.
Specified Value:More than 8.0 mm
CAUTION:
• Be very careful not to get scalded, for the heated thermostat will be very hot.
than 8.0 mm
More than 8.5 mm
M101, M201 & J102 Series
More
S221 Series
INSTALLATION
M101, M201 & J102 Series
1.Install the thermostat to the water inlet. NOTE:
• Be sure to assemble the thermostat at the position indicated in the right figure.
2.Install the water inlet to the cylinder head. Tightening Torque:7.2 - 10.8 N·m
3.Connect the radiator thermo control switch connector. (Only for EU spec.)
4.Fill the engine coolant. (Refer to page CO–3.)
5.Start the engine. Ensure that no water leakage is present.
S221 Series
1.Assemble the thermostat to the water outlet with its jiggle pin facing upward.
2.Install the water outlet to the water outlet housing. Tightening Torque:11.2 - 16.8 N·m
3.Install the water outlet housing to the cylinder head. Tightening Torque:16.0 - 24.0 N·m
4.Fill the engine coolant. (Refer to page CO–5.)
5.Start the engine. Ensure that no water leakage is present.
CO–10-1
Jiggle pin locating protrusion
Jiggle pin
Protruding section
Cutout section
Jiggle pin
Bleeder plug
YCO00076-00054
YCO00077-00055
YCO00040-00032
YCO00042-0003
RADIATOR
COMPONENTS
M101 & M201 Series
:Tightening torque Unit:N·m
J102 Series
q Radiator reserve tank
w Radiator inlet hose
e Radiator outlet hose
:Tightening torque Unit:N·m
q Radiator reserve tank w Radiator inlet hose e Radiator outlet hose
r Radiator bracket t Fan motor assy y Radiator assy
r Radiator bracket t Fan motor assy y Radiator assy
YCO00043-00035
RADIATOR (S221) COMPONENTS (S221)
:Tightening torque Unit:N·m
q Radiator fan motor
w Radiator reserve tank
e Radiator No. 1 hose
r Radiator No. 2 hose
t Radiator bracket
y Radiator support member
u Radiator assy
i Fan motor assy with shroud
REMOVAL
M101, M201 & J102 Series
WARNING:
• Never remove the radiator cap and drain plug when the engine coolant is still hot.
1.Disconnect the cable from the negative (–) terminal of the battery. NOTE:
• It should be noted that the diagnosis results and memory in the radio, etc. will be erased when the cable is disconnected from the negative (–) terminal of the battery.
2.Remove the engine undercover.
3.Drain the engine coolant. (Refer to page CO–3.)
4.Remove the front bumper.
5.Remove the condenser. (air conditioner.)
NOTE:
• Be very careful not to disconnect the pipes that have been connected to the condenser.
6.On automatic transmission vehicles, disconnect the oil cooler hose.
7.Disconnect the radiator inlet hose and radiator outlet hose at the radiator side.
8.Remove the radiator bracket and coupler of the fan motor.
9.Remove the fan motor assembly and radiator assembly as a set.
S221 Series YCO00046-00036
S221 Series
WARNING:
• Never remove the radiator cap and drain plug when the engine coolant is still hot.
1.Disconnect the cable from the negative (–) terminal of the battery.
NOTE:
• It should be noted that the memories of diagnosis results, radio, etc. will be erased at same time when the cable is disconnected from the negative (–) terminal of the battery.
2.Drain the coolant.
3.Remove the front grille and front bumper.
4.Remove the hood lock.
5.Disconnect the oil cooler hose. (A/T)
6.Disconnect the radiator hoses No. 1 and No. 2.
7.Remove the radiator bracket.
8.Remove the radiator support upper member.
9.Remove the radiator assembly.
10.Remove the fan motor assembly with shroud.
NOTE:
• When the radiator assembly is removed, be sure to lift the radiator assembly while pulling the condenser (for air conditioner) toward your side.
• Do not disconnect the pipes of the condenser (for air conditioner).
INSTALLATION
M101, M201 & J102 Series
1.Install the fan motor assembly and radiator assembly as a set.
2.Install the radiator bracket.
3.Install the coupler of the fan motor.
4.Connect the radiator inlet hose and radiator outlet hose to the radiator.
5.On automatic transmission vehicles, connect the automatic transmission oil cooler hose to the radiator. (Refer to the A/T section.)
6.Install the condenser. (air conditioner.)
7.Fill engine coolant. (Refer to page CO–3.)
8.Install the front bumper.
9.Install the engine undercover.
10.Connect the cable to the negative (–) terminal of the battery.
11.Check the radiator for leakage.
S221 Series
1.Install the fan motor assembly and radiator assembly as a set.
2.Install the radiator.
3.Install the radiator bracket.
4.Install the coupler of the fan motor.
5.Connect the radiator No. 1 hose and radiator No. 2 hose to the radiator.
6.On automatic transmission vehicles, connect the automatic transmission oil cooler hose to the radiator. (Refer to the A/T section.)
7.Install the hood lock.
8.Install the front grille and bumper.
9.Fill engine coolant. (Refer to page CO–3.)
10.Connect the cable to the negative (–) terminal of the battery.
11.Check the radiator for leakage.
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CLEANINGOF RADIATOR
Using water or steam cleaner, remove mud and dirt from the radiator core.
CAUTION:
• When using a high-pressure type cleaner, be very careful not to deform the radiator core fins.
• Keep a distance of more than 40 - 50 cm between the radiator core and the cleaner nozzle when the cleaner nozzle pressure is 2.9 - 4.9 MPa.
• Also, the injection angle of pressurized water should be right angles to the radiator.
• Failure to observe this caution will cause the radiator fins to be deformed.
INSPECTION OF RADIATOR
1.Check of radiator cap
(1)Check the seal packing of the radiator cap for damage.
Replace the radiator cap with a new one, if any damage exists.
(2)Lift the valve at the vacuum side with your fingers. Ensure that the valve is functioning properly. Replace the radiator cap with a new one, if the valve fails to function.
(3)Check the radiator cap by means of a radiator cap tester to see if the relief valve opens at a pressure of 108 ±15 kPa.
If the radiator cap fails to conform to the specification, replace the radiator cap.
CAUTION:
• Never open the radiator cap when the engine is still hot.
• Failure to observe this caution will cause you to get scalded.
2.Check of cooling system for leakage
(1)Fill the radiator with coolant. Attach a radiator cap tester.
(2)Warm up the engine.
(3)Apply a pressure of 122.7 kPa to the cooling system by means of the radiator tester. If the pressure drops, check the hoses, radiator, water pump and heater for evidence of leakage. If no external leakage is found, check the heater core, cylinder block, cylinder head and throttle body for evidence of leakage. Check the hoses for deterioration, cracks, bulge or damage.
Replace the defective part(s) if necessary.
(4)Remove the radiator cap tester from the radiator.
WARNING:
• Never open the radiator cap and/or drain cap when the coolant is still hot. Failure to observe this caution will cause you to get scalded.
CO–14
ELECTRIC COOLING FAN
IN-VEHICLE INSPECTION
1.If the fan motor is rotating when the coolant temperature is below 80°C and the ignition switch is at the off position, check the RAD FAN relay and the wiring harness for short.
(1)Disconnect the RAD FAN relay from the relay Block (R/B).
(2)If the fan motor stops, check the RAD FAN relay.
(3)If the fan motor is rotating, check the wiring harness for short.
2.Turn on the ignition key switch. Ensure that the fan is not rotating when the coolant is cold (below 80°C). If the fan motor is rotating, check the engine coolant temperature sensor and radiator thermo control switch (EC spec.).
3.Warm the engine, until the radiator coolant temperature rises above 100°C. Ensure that the fan motor is rotating. If the fan motor is not rotating, check the RAD FAN relay, wiring harness, radiator fan motor fuse, radiator fan motor, water temperature sensor and radiator thermo control switch (EC spec.).
Radiator fan motor check
1.Disconnect the connector of the radiator fan motor.
2.Check resistance between the terminals of the radiator fan motor.
Specified Value:Approx. 1.0 Ω
Radiator fan motor relay check
The radiator fan motor relay employs the same relay as the starter relay. Therefore, for the unit inspection, refer to the ST section.
Engine coolant temperature sensor check
Refer to the “EF” section.
Radiator thermo control switch check
(EC specifications only)
1.Ensure that continuity exists between the terminals when the water temperature is 94°C or above. If there is no continuity, replace the radiator thermo control switch.
2.Allow the water temperature to drop. When the temperature becomes 83°C or below, ensure that no continuity exists between the terminals. If there is continuity, replace the radiator thermo control switch.
SPECIFICATIONS
Coolant capacity (R) (w/heater, W/O reserve tank)
Reserve tank capacity (R)
Thermostat
TIGHTENING TORQUE
Water pump × Cylinder block
Water pump × Water pump pulley
Water inlet × Cylinder head
Water inlet pipe × Cylinder block Water outlet housing × Water outlet
motor × Fan shroud
motor × Fan
shroud × Radiator
shroud × Radiator
reserve tank × Fan shroud Radiator bracket × Support upper member
M101, M201
J102
S221
M101, M201
J102
S221
M101, M201
J102
S221
M101, M201
J102
S221
M101, M201, J102
S221
M101, M201, J102
S221
Remarks
M101, M201, J102
S221 only
S221 only
M101, M201
S221, J102
TO INDEX
EMISSION CONTROL SYSTEM
1. OUTLINE OF EMISSION CONTROL SYSTEM ..............................EC–-12
2-1. FOREU SPECIFICATIONS OF M101, M201 ANDJ102 ............................EC–-13
2-2. FORAUS GENERAL SPECIFICATIONS OF M101, M201 ANDJ102 ...........EC–-14
2-3. FORLEADED SPECIFICATIONS OF J102 .........................................EC–-15
2-4. FOR EU SPECIFICATIONS OF S221 .........................................EC–5-1
2-5. FOR AUS AND GENERAL SPECIFICATIONS OF S221 ...........EC–5-2
2-6. FOR LEADED SPECIFICATIONS OF S221 .........................................EC–5-3
3. INSPECTION OF POSITIVE CRANKCASE VENTILATION SYSTEM ........................EC–-16
4. INSPECTION OF FUEL EVAPORATIVE EMISSION CONTROL SYSTEM ............EC–-17
4-1. COMPONENT LAYOUT .................EC–-17
4-2. INSPECTION OF FUEL VAPOR LINES, FUEL TANK & FILLER CAP ............EC–-17
4-3. INSPECTION OF VSV FOR EVAP ..EC–-18
JEC00001-00000
1. OUTLINE OF EMISSION CONTROL SYSTEM
1-1. PURPOSE OF SYSTEM
Pollutants to be controlled
Blow-by gas recirculation
Three-way catalyst
Feedback control (EFI)
Electronic ignition timing control (ESA)
Deceleration fuel cut
Dynamic variable valve timing control (DVVT)
Fuel evaporative emission control
Purpose and function
A system whereby the blow-by gas generated inside the engine is introduced to the intake manifold, instead of releasing it to the atmosphere, in order that it may be burnt again in the combustion chamber.
A device whereby HC and CO contained in the exhaust gas are oxidized and NOx is deoxidized by the monolithic type catalytic converter, thereby reducing those emissions of HC, CO and NOx to be released to the atmosphere.
The feedback control system ensures a proper air-to-fuel ratio required by the engine. Also it ensures an optimum amount of oxygen to be contained in the exhaust gas so as to obtain high purification rate of the three-way catalyst.
In this electronic ignition timing control, based on signals sent from various sensors, the emission control computer always keeps the ignition timing at an optimum timing according to the engine conditions.
A device which prevents the fuel supply during deceleration period in order to reduce HC and CO emissions.
A system whereby HC emitted from the fuel tank is absorbed to a charcoal canister, thereby preventing HC from being released to the atmosphere. This controller reduces NOx and HC emission by controlling the opening/closing of the intake valves to a timing best suited to running conditions.
3. INSPECTION OF POSITIVE CRANKCASE VENTILATION SYSTEM
Visual inspection of hoses and connections
Check the hoses and connections for cracks, leakage or damage.
If any parts exhibit fault, replace or repair them, as required.
Inspection of PCV Valve
1.Disconnect the PCV hose from the PCV valve.
2.Remove the PCV valve.
3.Install clean hose to PCV valve.
4.Inspect PCV value operation.
(1)Blow air into the cylinder head side, and check that air passes through easily.
CAUTION:
• Do not suck air through the value. Petroleum substances inside the value are harmful.
(2)Blow air into the intake manifold side, and check that air passes through with difficulty.
NOTE:
• If operation is not as specified, replace the PCV valve.
Cylinder Head Side
Manifold Side
4. INSPECTION OF FUEL EVAPORATIVE EMISSION CONTROL SYSTEM
4-1. COMPONENT LAYOUT
Purging line
Check valve 1
Check valve 3
Check valve 2
4-2. INSPECTION OF FUEL VAPOR LINES, FUEL TANK & FILLER CAP
1.Visual inspection of fuel vapor lines and connections for loose connections, kinks or damage
If any damage is present, repair or replace the parts, as required.
2.Visual inspection of fuel tank
Check the fuel tank for deformation, cracks or fuel leakage.
If any damage is present, repair or replace the part, as required.
3.Inspection of the fuel filler cap
Check the fuel filler cap and gasket for damage or deformation.
Also check that air continuity with some resistance exists on the fuel filler cap. Replace the cap, if necessary.
NOTE:
• If the fuel tank is deformed by negative and positive pressure, be sure to replace the fuel filler cap with a new one after replacing the fuel tank.
4.Inspection of charcoal canister
(1)Detach the hose band from the charcoal canister.
(2)Disconnect the rubber hoses from the charcoal canister.
NOTE:
• Prior to the disconnection of the rubber hose, put a tag on each of the rubber hoses so that they may be reconnected correctly to the original position.
(3)Remove the charcoal canister from the vehicle by pulling up the charcoal canister case.
Combustion chamber
Purge port Throttle body
tank vapor line
(4)Visually inspect the charcoal canister case for cracks or damage.
If any damage is found, replace the charcoal canister with a new one.
(5)Check of charcoal canister for air leakage
Ensure that no air leakage is present when ensure that no air leakage is present when compressed air of 29.4kPa is applied to the atmosphere side pipe C with the throttle body side A and fuel tank side B pipes plugged.
If air leakage is present, replace the charcoal canister with a new one.
(6)Ensure that no air continuity exists when blowing your breath into the purge side A pipe of the charcoal canister.
If air continuity exists, replace the charcoal canister with a new one.
(7)Check of charcoal canister for restriction
q Ensure that air continuity exists on the atmosphere side C pipe, when blowing your breath into the fuel tank side pipe B while the purge side A pipe is plugged.
If no air continuity exists, replace the charcoal canister with a new one.
w Ensure that air continuity exists when a negative pressure to is applied the purge side pipe A using a MityVac.
If no air continuity exists, replace the charcoal canister with a new one.
(8)Install the charcoal canister to the vehicle.
(9)Reconnect the rubber hoses and attach new hose bands.
Terios Spec. other than EU spec.
4-3. INSPECTION OF VSV FOR EVAP
Refer to Mention EF.
EFI SYSTEM
1. GENERAL PRECAUTIONARY MEASURES .........EF–-1 2
1.1 INSTRUCTIONS ON USE OF THIS SERVICE MANUAL ........................................EF–-1 2
1.2 HANDLING INSTRUCTIONS ON CATALYTIC CONVERTER-EQUIPPED VEHICLES ............EF–-1 3
1.3 ITEMS TO BE OBSERVED WHEN MOBILE COMMUNICATION SYSTEM IS MOUNTED ..EF–-1 3
3. SYSTEM DESCRIPTION ........................................EF–-1 9
3.1 LOCATION OF ELECTRONIC CONTROL PARTS .........................................EF–-1 9
3. SYSTEM DESCRIPTION (S221) ............................EF–13-1
3.1 LOCATION OF ELECTRONIC CONTROL PARTS (S221) .............................EF–13-1
3. SYSTEM DESCRIPTION (M201) ............................EF–13-4
3.1 LOCATION OF ELECTRONIC CONTROL PARTS (M201) .............................EF–13-4
3.2 SYSTEM DIAGRAM .......................................EF–-114
3.2 SYSTEM DIAGRAM (S221) ...........................EF–16-1
3.3
1. GENERAL PRECAUTIONARY MEASURES
1.1 INSTRUCTIONS ON
USE OF THIS SERVICE MANUAL
This service manual has been compiled in such a way that the manual may be used both in regions where the type certification is implemented based on the EC exhaust emission approval, and other regions. Hence, with regard to the assignment, reading, erasing of trouble codes and those steps of checks, repairs and confirmation, the service manual contains the procedures for both cases; One is a procedure that uses the DS-21 diagnosis tester or the OBD II generic scan tool, and the other is a procedure that does not use this tester or tool.
Therefore, the following instructions given below must be observed.
1.About Use of DS-21 Diagnosis Tester or OBD II Generic Scan Tool
• Regions where type certification is implemented based on EC exhaust emission approval Make sure to use the DS-21 diagnosis tester or the OBD II generic scan tool.
• Other regions
You may use or not use the DS-21 diagnosis tester or the OBD II generic scan tool. You may perform the operation, employing whichever method that will be easier to you.
2.Instructions To Be Followed Concerning Trouble Codes
Trouble codes, such as P0105/31 (4-digit code/2-digit code) are posted additionally.
• Regions where type certification is implemented based on EC exhaust emission approval
Make sure to use only 4-digit trouble codes (e.g. P0105) which have been assigned according to the ISO regulations.
• Other regions
You may perform the operation using the 4-digit code, employing the DS-21 diagnosis tester or the OBD II generic scan tool. Or you may perform the operation using the 2-digit codes (e.g.31), without the use of the tester or tool.
You may perform the operation, employing whichever method that will be easier to you.
NOTE:
• The OBD II generic scan tool means a scan tool complying with the ISO 14230 (KWP2000) format.
• In cases where the OBD II generic scan tool is employed, not all malfunction codes (4-digit codes) can be read out. It should be noted that only those trouble codes in which “zero” follows after “P”, for example, P0XXX, can be read out.
• The accuracy of the 2-digit codes in diagnosing malfunctioning components is slightly inferior to that of the 4-digit codes.
• Hereinafter, those regions where the type certification is implemented based on the EC exhaust emission approval, is referred to as the “EU specifications.”
1.2 HANDLING INSTRUCTIONS ON CATALYTIC CONVERTER-EQUIPPED VEHICLES
WARNING:
• When a great amount of unburnt gas is admitted into the catalytic converter, overheating is prone to occur, resulting in a fire hazard.
To avoid such trouble in advance, be certain to observe the following precautions. Also, be sure to explain such precautions to your customers.
1.Use only unleaded gasoline to catalytic converter-equipped vehicles.
2.Avoid idling the engine for a prolonged length of time.
Do not run the engine continuously at idle speed for more than 20 minutes.
WARNING:
• Immediately check and repair the vehicle if the fast idle speed or idle speed is unstable or the system exhibits malfunction. Failure to observe this warning may result in a fire hazard.
3.Be sure to observe the following points when performing the spark jump tests.
(1)The spark jump test must be limited to cases where such test is absolutely necessary. Also, be sure to finish the test in the shortest possible time.
(2)Never race the engine during the test.
(3)Be sure to shut off the fuel supply when performing the spark jump test in advance.
4.Do not run the engine when the fuel tank becomes nearly empty.
Failure to observe this caution will cause misfiring. Also, it will apply excessive load to the catalytic converter, even leading to catalyst damage.
5.Be sure to avoid coasting with the ignition switch turned OFF. Moreover, be certain to avoid applying the brake for a prolonged period of time.
6.Do not dispose of the waste catalyst along with parts contaminated with gasoline or oil.
JEF00002-00000
1.3 ITEMS TO BE OBSERVED WHEN MOBILE COMMUNICATION SYSTEM IS MOUNTED
For those motor vehicles equipped with a mobile communication system, such as a bidirectional wireless telephone and cellular phone, be sure to observe the following precautionary measures.
1.Install the antenna as far away as possible from the ECU and sensors of the electronically-controlled system of the vehicle.
2.The wire of the antenna should be routed at least 30 cm away from the ECU and sensors of the electronically-controlled system of the vehicle. For details concerning the arrangement of the ECU and sensors, refer to the arrangement diagram of the components in the relevant section.
3.Do not wind the antenna feeder line together with other wires. Avoid routing the antenna feeder in parallel with other harnesses whenever possible.
4.The antenna and feeder line should be properly adjusted.
5.Never install a strong mobile communication system.
JEF00003-00000
1.4 IMMOBILIZER SYSTEM-EQUIPPED VEHICLES
1.The immobilizer system is formed by communication between the Immobilizer ECU and the EFI ECU by means of the rolling code. The rolling code will be automatically retained both in the immobilizer ECU and in the EFI ECU when the engine is started once with the key of the immobilizer system. The engine will not start if the rolling code in the immobilizer ECU and EFI ECU are not identical. Therefore, the engine will not start when using the EFI ECU which was mounted before on another vehicle with the immobilizer system without resetting the rolling code.
2.When the EFI ECU of a vehicle equipped with the immobilizer system was replaced, based on the results of the trouble shooting, and related troubles have been remedied, it is impossible, due to its construction, to confirm that the malfunction was caused by the former EFI ECU by installing the EFI ECU again. Incidentally, this confirmation is possible in the case of vehicles without the immobilizer system. Therefore, it is not necessary to install the former EFI ECU again to carry out the reconfirmation. In the case of vehicles without the immobilizer system, be sure to carry out this re-installation and reconfirmation.
3.In the case of vehicles equipped with the immobilizer system, once the engine is started for the confirmation test, etc. after the malfunction has been remedied, that EFI ECU can not be used for other vehicles with the immobilizer system, unless a measure is taken.
NOTE:
• When you would like to use each ECU of the vehicle concerned on vehicles equipped with other immobilizer system, initialize the ECU, using the diagnosis tester (DS-21), before removing the ECU from the vehicle. Then, remove the ECU and install it on another vehicle. If you perform the key registration, using the master key of this vehicle, each ECU can be used separately or as a set.
• When the EFI ECU is to be replaced with a new one, it is possible to start the engine by using the master key with the terminal T for immobilizer ECU (ECU-T) of the data link connector grounded with a jump wire.
• Please refer to Section BE of the service manual.
1.5 ITEMS TO BE OBSERVED DURING SYSTEM CIRCUIT CHECK
1.Before connecting and disconnecting the connectors and terminals, be sure to turn OFF the ignition switch or disconnect the negative (–) terminal from the battery. Otherwise, the harness is judged to have an open wire, and the fail-safe function will be applied. On the other hand, when the negative (–) terminal of the battery is disconnected, the diagnosis code will be erased. Therefore, if it is necessary to confirm the diagnosis code, be sure to perform the confirmation in advance.
2.When disconnecting the connector, never pull the harness. Rather, hold the connector properly with the connector unlocked and pull it. When connecting the connector, be sure to positively insert the connector, until you hear a clicking sound when the lock is engaged.
3.Do not directly touch the terminals of parts which incorporate a microcomputer.
4.When a test probe is applied to the terminal to which a voltage is applied, care must be exercised so that two test probes may not come in contact with each other, so that short circuit may not take place.
5.When the connector is connected to the ECU, never connect an ohmmeter between the ECU connector and the sensor or actuator. Failure to observe this caution may damage the ECU or sensor or actuator.
6.When a test probe is applied to the connector, be sure to bring it from the rear side (harness side) of the connector. In the case of connectors where it is impossible to apply a test probe from the rear side, such as water-proof connectors, apply the test probe from the connector side. At this time, be very careful not to bend the male terminal of the connector or open the female terminal.
7.Be sure to use a voltmeter/ohmmeter whose internal impedance is at least 10 kΩ/V. When a voltmeter/ohmmeter whose internal impedance is less than 10 kΩ/V is used, it may cause the ECU to malfunction or give a wrong evaluation.
8.When checking the terminal for the connecting condition, be sure to check the male terminal for a bend and the female terminal for an excessive opening. Furthermore, check both terminals for locking (looseness), rust formation, dust adhesion, etc.
9.Prior to the measurement of the voltage of each terminal, make sure that the battery voltage is 11 V or more. If the terminal voltage is checked with a low battery voltage, it may lead to a wrong diagnosis.
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