Service Precautions
General
Observe all safety precautions and notes while working.

NOTE: The following information are general precautions when servicing the vehicle and some features mentioned may not apply.

Protect all painted surfaces and seats against dirt and scratches with a clean cloth or vinyl cover.
Work safely and give your work your undivided attention. When either the front or rear wheels are to be raised, block the remaining wheels. Communicate as frequently as possible when work involves two or more workers. Do not run the engine unless the shop or working area is well ventilated.
When starting the engine or running the drive system with the vehicle lifted, pay attention to your surroundings and watch out for other worker's safety.
Before removing or disassembling parts, they must be inspected carefully to isolate the cause for which service is necessary. Observe all safety notes and precautions and follow the proper procedures as described in this manual.
Mark or place all removed parts in order in a parts rack so they can be reassembled in their original places.
Use the special tool when use of such a tool is specified.
Power tools must be used appropriately.
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Follow instructions and precautions carefully per the tool's manufacturer.
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Do not use power tools for tightening. Only use them during removals of fasteners.
Parts must be assembled with the proper torque according to the established maintenance standards.
When tightening a series of bolts or nuts, begin with the center or large diameter bolts and tighten them in a crisscross pattern in two or more steps.
Use new packings, gaskets, O-rings, and cotter pins whenever reassembling.
Do not reuse parts that require replacement. Always replace them.
Use genuine parts and lubricants or equivalents. When parts are to be reused, they must be inspected carefully to make sure they are not damaged or deteriorated and are in good usable condition.
Coat or fill parts with specified grease as indicated. Clean all removed parts with solvent upon disassembly.
Brake fluid and hydraulic components
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When replenishing the system, use extreme care to prevent dust and dirt from entering the system.
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Do not mix different brands of fluid as they may not be compatible.
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Do not reuse drained brake fluid.
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Because brake fluid can cause damage to painted and resin surfaces, be careful not to spill it on such materials. Quickly wash the brake fluid off the painted or resin surface using water or warm water if spilled.
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After disconnecting brake hoses or pipes, be sure to plug the openings to prevent loss of brake fluid.
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Clean all disassembled parts only in clean BRAKE CLEANER. Blow open all holes and passages with compressed air.
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Keep disassembled parts from air-borne dust and abrasives.
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Check that parts are clean before assembly.
Avoid oil or grease getting on rubber parts and tubes, unless specified.
Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves.
When spraying any agents that contain silicone, cover all the connectors, terminals, and switches in the area with a protective cloth or plastic sheet.
Upon assembling, check every part for proper installation and operation.
When disassembling and/or reassembling parts, do the service below.
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Check the proper parts are installed.
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Check the installed parts operate properly.
If harmful materials to human body come in contact with eyes, skins, or the mouth, take appropriate treatments and seek immediate medical attention.
Auto Idle Stop System (If Equipped)
Some models are equipped with an Auto Idle Stop System. Before servicing the vehicle, especially inside the engine compartment, turn the vehicle to the OFF (LOCK) mode, then keep the key away from the vehicle.

Before doing any service on the powertrain system, read the following precautions. See also "Auto Idle Stop System Description - Operation Conditions" for additional information.

Precaution for Disposal of EDLC Module (If Equipped)
Vehicles with the Auto Idle Stop System are equipped with the EDLC (Electric Double Layer Capacitor) module.
Because the EDLC module accumulates high voltage, it must be discharged completely before waste disposal of the vehicle and/or module itself. See "EDLC Module Removal and Installation" for more detail.
There is electrolyte liquid in the EDLC module, and it is harmful physically and environmentally. If the electrolyte liquid is leaking due to a collision, etc., make sure to wear protective goggles and gloves when handling the EDLC.
Real Time 4WD/AWD (Intelligent Control System) (If Equipped)
The 4WD/AWD system distributes driving torque between the front and rear wheels when accelerating and when wheel spin occurs.

The 4WD/AWD with Intelligent Control does not have a manual switch to disable the 4WD/AWD system. Whenever service work requires spinning the front or rear wheels with the engine, always lift and support the vehicle so all four wheels are off the ground.
Electric Powertrain System (If Equipped)
The Electric Powertrain System used in hybrid models uses high voltage circuits and a lithium-ion battery module. The high voltage cables are identified by orange cabling. The safety labels are attached to high voltage and other related parts. Touching, disassembling, removing, or replacing high voltage parts or cables can cause severe electric shock that may result in serious injury or death. You must be familiar with Electric Powertrain System before working around it. Make sure you have read the Electric Powertrain Service Precautions in the Electric Powertrain section before doing repairs or service.
Electrical Troubleshooting Information
Before Troubleshooting
1.
Check applicable fuses in the appropriate fuse/relay box.

2.
Check the 12 volt battery charge and whether the 12 volt battery has been damaged, and clean and tighten the connections.
Do not quick-charge a 12 volt battery unless the 12 volt battery ground cable has been disconnected, otherwise you will damage the alternator diodes.
Do not attempt to crank the engine with the 12 volt battery ground cable loosely connected or you will severely damage the wiring.

3.
Check the drive belt tension.
Handling Connectors
Make sure the connectors are clean and have no loose wire terminals.
Make sure multiple cavity connectors are packed with dielectric grease (except waterproof connectors).
Most of the connectors have push-down release type locks (A).
Some connectors have a clip on their side used to attach them to a mounting bracket on the body or on another component. This clip has a pull type lock.
Some mounted connectors cannot be disconnected unless you release the lock first and remove the connector from its mount bracket (A).
Never try to disconnect connectors by pulling on their wires; pull on the connector halves instead.
Always reinstall plastic covers.
Before connecting connectors, make sure the terminals (A) are in place and not bent.
Check for loose retainers (A) and rubber seals (B).
The backs of some connectors are packed with dielectric grease. Add grease if necessary. If the grease is contaminated, replace the connector (if available) or the wire harness.
Insert the connector all the way and make sure it is securely locked.
Position wires so that the open end of the cover faces down.
Handling Wires and Harnesses
Secure wires and wire harnesses to the frame with their respective wire ties at the designated locations.
Remove clips carefully; don't damage their locks (A).
Slip pliers (A) under the clip base and through the hole at an angle, then squeeze the expansion tabs to release the clip.
After installing the harness clips, make sure the harness doesn't interfere with any moving parts.
Keep the wire harnesses away from exhaust pipes and other hot parts, from sharp edges of brackets and holes, and from exposed screws and bolts.
Seat grommets in their grooves properly (A). Do not leave grommets distorted (B).
Testing and Repairs
Do not use wires or harnesses with broken insulation. Replace them or repair them by wrapping the break with electrical tape.
Never attempt to modify, splice, or repair SRS wiring. If there is an open or damage on SRS wiring or terminals, replace the harness.
After installing parts, make sure that no wires are pinched under them.
When using electrical test equipment, follow the manufacturer's instructions and those described in this manual.
If possible, insert the probe of the tester from the wire side (except for waterproof connectors).
Use a probe with a tapered tip.
Puncturing the insulation on a wire can cause poor or intermittent electrical connections.
For testing at connectors, bring the tester probe into contact with the terminal from the connector side of wire harness connectors in the engine compartment.
For female connectors, just touch lightly with the tester probe and do not insert the probe.

When checking any control module(s) or unit(s) connector terminals, gently slide the sharp tester probe from the wire side into the connector until it comes in contact with the terminal end of the wire.
Some vehicles may use an aluminum wire harness. Special attention is needed to protect the harness from corrosion and damage during disconnecting of connectors.
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Do not break up the connectors of the aluminum wire harnesses.
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Never attempt to modify and repair the aluminum wire harnesses. Replace the wire harnesses if they are damaged.
Five-step Troubleshooting
1.
Verify the Complaint

Turn on all the components in the problem circuit to verify the customer's complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area.

2.
Analyze the Schematic

Look up the schematic for the problem circuit. Determine how the circuit is supposed to work by tracing the current paths from the power feed through the circuit components to ground. If several circuits fail at the same time, the fuse or ground is a likely cause.

Based on the symptoms and your understanding of the circuit operation, identify one or more possible causes of the problem.

3.
Isolate the Problem by Testing the Circuit

Make circuit tests to check the diagnosis you made in step 2. Keep in mind that a logical, simple procedure is the key to efficient troubleshooting. Test for the most likely cause of the failure first. Try to make tests at points that are easily accessible.

4.
Fix the Problem

Once the specific problem is identified, make the repair. Be sure to use proper tools and safe procedures.

5.
Make Sure the Circuit Works

Turn on all components in the repaired circuit in all modes to make sure you've fixed the entire problem. If the problem was a blown fuse, be sure to test all of the circuits on the fuse. Make sure no new problems turn up and the original problem does not reoccur.
Wire Color Codes
The following abbreviations are used to identify wire colors in the circuit schematics:

WHT...
White
YEL...
Yellow
BLK...
Black
BLU...
Blue
GRN...
Green
RED...
Red
ORN...
Orange
PNK...
Pink
BRN...
Brown
GRY...
Gray
PUR...
Purple
TAN...
Tan
LT BLU...
Light Blue
LT GRN...
Light Green
LT PUR...
Light Purple

The wire insulation has one color or one color with another color stripe. The second color is the stripe.
Precaution for Handling Sodium-Filled Exhaust Valves (If Equipped)
Read all of the instructions before disposing of sodium-filled exhaust valves.
Sodium requires extreme caution in handling and disposal. Sodium is highly flammable and it reacts with water and oxygen in the air. Sodium reacts with water vigorously and may cause an explosion.
Make sure to wear protective tools (such as goggles and gloves) when handling sodium. Keep sodium away from eyes and skin as it may cause caustic skin burns, and contact with eyes may cause blindness.
When handling sodium, be sure to do so in a well-ventilated area as it reacts with water to form hydrogen gas.
If you come in contact with sodium, flush thoroughly with a large amount of water and seek immediate medical attention.

Determination method of Sodium-Filled Exhaust Valves
Identification marks (A) for sodium-filled exhaust valves are located on the valve head and/or valve stem.
NOTE: The illustration is a typical sample of the sodium-filled valve.

Waste Disposal of Sodium-Filled Valves
1.
When the sodium-filled exhaust valves are NOT damaged

NOTE: You can dispose sodium-filled exhaust valves as you would with normal valves unless the sodium in the valve stem is exposed. If they are exposed, the valve stem must be neutralized using the Neutralization Procedure.

Do not destroy the valves intentionally to expose sodium.

2.
When the sodium-filled exhaust valves are damaged

NOTE: Do the neutralization procedure before disposal.
Make sure to wear protective goggles and gloves, and do this procedure in a well-ventilated area.
When you do this procedure, make sure to have a fire extinguisher (dry powder type) on hand.
Handle the damaged valves with tweezers or tongs, not with bare hands.
Neutralization Procedure
1.
Prepare a large container filled with 10 L (2.64 US gal) of water.
2.
Soak the damaged valves into the water.
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Soak the damaged valves completely.
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Keep all cigarettes, sparks, and flames away from the container. Chemical reaction of sodium and water generates hydrogen gas.
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Stay a few meters away from the container as this procedure may cause severe reaction of chemicals.
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This procedure can neutralize a maximum of six damaged valves at the same time.

3.
When the procedure is finished after 4-5 hours, pick up the damaged valves with tweezers or tongs, and dispose of them as normal valves.
The waste liquid after neutralization procedure contains highly-concentrated sodium hydroxide. It is very harmful physically and environmentally. Dispose the waste liquid according to your local regulations.

A.
Damaged valves
B.
Water solution of sodium hydroxide (waste liquid)