A1–1

1 IMPORTANT SAFETY INSTRUCTIONS

1-1 GENERAL DESCRIPTION
1. The large number of components in a motor vehicle alone represents a certain risk potential. In
addition to the correct installation of the parts, correct settings are also required to ensure operational
safety. For this reason, the maintenance and repair of motor vehicles requires extensive expertise.
2. Correct service methods and repair procedures are very important, not only for the safe ty and
reliability of a vehicle, but also for the safety of maintenance personnel.
3. The procedures and procedures discussed in this manual generally describe the techniques
recommended by the manufacturer. Following the instructions given here is a prerequisite for the
reliability of the vehicle. The maintenance and repair of vehicles includes numerous work techniques.
In addition, the various types of work require a wide variety of processes, tools and components.
4. In the context of this manual, it is impossible to explain all the techniques, procedures, components,
tools and handles that are required for all work steps. Therefore, everyone who receives this manual
is expected to make a responsible selection of techniques, tools and spare parts that are neces sary
for the proper maintenance of the defective vehicle. In addition, he must take responsibility for his
work in connection with his own safety.
5. The manual was created for trained car mechanics. No work should be carried out on the vehicle if
the instructions described here have not been understood or assigned.

1-2 WARNINGS, PRECAUTIONS AND NOTES

1. The following terms are used to describe safety instructions that relate to the various risks.

WARNING
• WARNING contains information that must be strictly observed for the safety of the mechanic and
bystanders. Failure to comply results in a risk of injury.

ATTENTION
• Under CAUTION there are instructions that must be observed in order to avoid damage and to
ensure proper functioning of the affected parts.

NOTE
• In order to make the working method effective, additional instructions relating to the working method
are given in this section.
A1–2
1-3 GENERAL WARNINGS
1-3-1 WARNING REGARDING ALL MAINTENANCE AND REPAIR WORK
1. Always wear eye protection.
2. Always secure a jacked up vehicle with jack stands.
3. Make sure that the ignition switch is in the “OFF” position, unless otherwise stated in the step.
4. Always apply the handbrake before working on the vehicle.
5. Only run the engine in a well-ventilated area to reduce the risk of carbon monoxide poisoning.
6. When the engine is running, keep sufficient distance from moving parts such as fans and belts so that
no parts of your body or clothing are caught.
7. Never touch hot metal parts such as the radiator, exhaust manifold, exhaust pipe, catalytic converter
and muffler. There is a risk of serious burns. Let the parts cool down sufficiently before starting work.
8. Do not smoke while working on the vehicle.
9. Remove rings, watches, necklaces, bracelets, etc. before work and wear tight-fitting clothing to avoid
injury.
10. Do not come near the fan blades with your hands or tools! The electric fan on the radiator is
temperature-controlled and can also be switched on when the ignition is switched off due to a sudden
increase in temperature. In vehicles with air conditioning, the fan can suddenly start working when the
air conditioning is switched on. The electric fan is also mounted on the condenser for the air
conditioning and starts rotating whenever the air conditioning is switched on. You should therefore
disconnect the electric fan motors from the electrical system before working under the bonnet.
 A1–3
2 HOW TO USE THIS MANUAL
2-1 PREPARATION TOOLS
If a special tool (SST), tool, measuring instrument, type of grease or oil has to be prepared before carrying
out the operation, these are listed in the table as tools to be prepared at the beginning of a description.
General tools, jacks, and inventory that can be assumed in any workshop are usually left out.

2-2 PROCEDURE FOR REMOVAL AND INSTALLATION

1. Exploded drawings show the installation status of the component.
2. The application of a type of grease or oil as well as sealants are marked with an arrow in the
illustration. Notes on tightening torque and parts that must not be used again are also listed. The
individual components are described under the corresponding exploded drawing.
3. A list of the removal and installation procedures can be found directly below the component
illustration. The removal procedures (dismantling), the installation procedures (assembly) and the
names of the spare parts are listed in the order starting from the left. The letter in front of a spare part
name matches the one in the illustration / corresponding component.
4. When installing (assembling) one proceeds in the opposite direction to dismantling (dismantling).
NOTE
• Installation (assembly) is only described separately in cases in which installation (assembly) cannot
be carried out in the opposite direction to dismantling (dismantling).
5. If a special procedure is required in one operation, the number for dismantling is marked with “j /”.
Further explanations are given under “Main points for removal (dismantling)” or “Main points for
installation (assembly)”. The mark “j” indicates “main points for removal (disassembly)” additional
information, while the mark “/” indicates “main points for installation (assembly)”.
A1–4
2-2-1- SAMPLE EXAMPLE
(1) COMPONENTS

~n
H

k: rubber grease
~: Not reusable Part unit: Nm
{kgf,; cm}

(2) REMOVAL AND INSTALLATION

PROCEDURES
1 a pin bushing, saddle guide pin 8th H Shoe, brake lining guide
2 b bolt, saddle guide, number 1 9 i Cuff, cylinder
3 c brake pad, disc brake, No. 2 10 j Piston, disc brake
4 d spacer, anti-squeak washer No. 1 11 k Piston seal, piston
5 e brake pad, disc brake with indicator no.1 12t l Cuff, bolt
h
6 f spacer, anti-squeak washer No. 1 13 m Bolt, saddle guide, No. 1
7 g shoe, brake lining guide 14t n Bushing, saddle guide
h

2-3 DESCRIPTION OF THE MAINTENANCE REFERENCE VALUES

The required maintenance reference values for inspections and maintenance work are described in bold
letters in the text as a target value and permissible limit value. Details of the benchmarks can be found in
the section "Explanation of benchmarks".

2-4 OPERATIONS NOT LISTED IN THIS MANUAL

The description of the following basic work steps can be omitted in this maintenance manual; please do this
during the actual work step anyway.
1. Steps for jacking up and lifting
2. Cleaning and cleaning of removed parts - to be carried out as required
3. Visual inspection
 A1–5
2-5 EXPLANATION OF REFERENCE VALUES

SET VALUE This mark shows the target value at the time of testing or adjustment.

LIMIT This mark shows the maximum or minimum value at the time of the test or setting.

DEVIATION This value stands for the difference between the maximum game and the minimum game.

WARNING This note draws attention to possible risks of injury for the mechanic or bystanders in the event that the
mechanic is unable to use the working method described in the manual.

ATTENTION This note draws attention to possible damage to the component to be repaired in the event that the mechanic
is unable to use the working method described in the manual.

NOTE Supplementary explanations to facilitate the work are given separately from the other descriptions. Difficulties in
taking measurements to determine limit values mean that in some cases, if malfunctions are unlikely, limit
values for simple measuring methods are given.
A1–6
3 ABBREVIATIONS
The abbreviations used in this manual represent the following.

ABBREVIATION TERM ABBREVIATION TERM

S S
2WD Two-wheel drive LHD Left-hand drive vehicle
4WD all wheel drive LSPV Load-dependent brake force regulator
SECTION Anti-lock braking system MGC Magnetic clutch relay
A/C air conditioning MP Multipurpose
ON 1 Relay ABS M/T Manual transmission
ON 2 Relay for heated rear window N/A Natural ventilation
API American Petroleum Institute NOx Nitrogen oxides
AT automatic transmission OPT Optional
ATDC After top dead center O/S Oversize
ATF Automatic transmission fluid PCV Closed crankcase ventilation
Ay Composite component PR Tire load capacity
BTDC Before top dead center PTO drive
D-LOCK Door locking / central locking RH right side
DLC Diagnostic connector RHD Right-hand drive vehicle
DLI Distributorless ignition system RR Rear / rear
DVS system Daihatsu Vehicle Stability System S/A Component made from firmly connected
individual parts
DVVT Dynamic, variable distributor control SAE Society of Automotive Engineers
EBD Electronic brace force distribution / ABS SFR Detonator
ECU Electronic control unit SIO Diagnostic circuit
EFI Electronic fuel injection SST Special tool
EGR Exhaust gas recirculation system HOURS default
EPS Electronic power steering SW counter
ESA Electronic ignition timing T Tightening torque
EX Exhaust gas T/C Exhaust gas turbocharger
F/L Melting strip fuse TAIL Tail / taillights
FR Front TDC Top Dead Center
G sensor Gravity sensor U/S Undersize
GND Body mass VSV Vacuum switching valve
HC Hydrocarbon VTV Vacuum transfer valve
H/L High beam / low beam W/ With
IG ignition bolt
IN Suction / inlet screw
ISC Idle speed control mother
ITC Integrated timer control Washer
LED light emitting diode Clip
LH Left side
 A1–7
4 UNIT
The SI units (international system of units) are listed below. (The previously valid units are also given.
Example: 33.25 & 13.25N; m {340 & 135kgf; cm}

4-1 NEW UNIT DUE TO THE INTRODUCTION OF THE SI UNIT

1. The SI unit is an international system of units that was created to gently advance communication in the
field of technology by unifying earlier systems of units that were internationally different so that there
is a value per unit. The target value is described in this maintenance manual in accordance with the
SI system of units.
object SI units Common units Conversion table
force N kgf 1 kgf = 9.80665 N
Torque N·m kgf cm 1 kgf · cm = 0.0980665 N · m
print kPa kgf / cm2 1 kgf / cm2 = 98.0665 kPa
MmHg 1mmHg = 0.133322 kPa
Spring constant N / mm kgf / mm 1 kgf / mm = 9.80665 N / mm
volume cc 1000cc = 1
force kW PS 1 hp = 0.735499 kW
A1–8
5 GENERAL MAINTENANCE INSTRUCTIONS
1. Use fender covers, seat covers, and floor carpets so that the vehicle does not get dirty or scratched.
2. (1) If only the front or rear of a vehicle is jacked up, ensure that chocks are placed in front of the
wheels to ensure safe operation.
(2) Jacked up vehicles must be supported with jack stands at the specified points.
(3) When the vehicle has been raised, make sure that the fork of the lift is placed in the specified
position and raise it. After lifting, ensure that safety devices are used.
3. Connecting and disconnecting the battery terminal
(1) Before doing any electrical work, ensure that the earth terminal is disconnected from the negative
(-) terminal of the battery.
(2) Before disconnecting the earth cable from the negative pole (-) of the battery, ensure that the
fault code of the EFI system is read out, if any.
(3) After reconnecting the earth cable to the battery, set the clock or re-program the radio's preset
stations, if the clock or radio is available.
(4) If it becomes necessary to disconnect the battery power supply to carry out tests and repairs,
always disconnect the earth cable from the negative (-) terminal of the battery first.
(5) To avoid damage to the battery poles, first loosen the terminal nut and then pull the earth cable
straight up. Never turn or pry off the connection terminal.
(6) In the event of difficulties, ensure that a battery terminal puller (commercially available) is used to
loosen the ground cable from the negative terminal of the battery.
(7) Clean the battery poles or the earth cable terminals with a cloth. Never use a file or any other
abrasive material.
(8) After loosening the nuts, fasten the cable clamps to the battery poles and tighten the nuts after
assembly. Never hit the terminals of the battery poles with a hammer or something similar.
(9) Do not forget to put the cover of the positive terminal (+) back on correctly.
4. Repairs to the fuel system
(1) Do not work near open flames.
(2) Before loosening the fuel line, place a suitable container or a cleaning rag under the connection
area.
(3) Before loosening the fuel line, unscrew the tank cap to reduce the pressure in the fuel tank.
(4) When loosening or loosening banjo bolts or union nuts on the fuel lines, use a cloth or similar to
prevent fuel from spraying out.
(5) Tighten connections with the prescribed torque.
(6) Attach the specified clips to each port.
5. Use special tools to ensure efficient workflow and accuracy.
 A1–9
6. REMOVAL, DISASSEMBLY
(1) When working in hard-to-reach places, markings should be made where they have no effect on
the function, so that assembly is easy.
(2) Each time parts are removed, check the condition in which they were installed, deformation,
breakage, unevenness or the presence of scoring.
(3) Arrange the removed parts in order and divide them into one group that will be replaced and
another that will be reused.
(4) Any reused part should be adequately cleaned.
7. INSPECTION AND MEASUREMENT OF PARTS
(1) Detailed testing and measurement should be performed as necessary for the parts that are to be
reused.
8. INSTALLATION, ASSEMBLY
(1) Mount the parts that can still be used according to the correct procedure and observing the
specified target value (value for the setting, tightening torque).
(2) Use original parts when replacing parts.
(3) Make sure that sealant and grease are applied to the appropriate locations.
(4) Make sure that new sealing rings, gaskets or the like, split pins etc. are used.
(5) When using sealing screws, use the specified liquid gasket and gasket sealant.
(6) Use the specified screw and nut. Unless otherwise specified, the side for which a tightening
torque is specified should be tightened to the specified value with a torque wrench. Use a ring or
hook wrench to prevent the counterpart from turning.
9. ADJUSTMENT, REVIEW OF WORK STEPS
(1) Set to the specified maintenance set point using a gauge or tester.
10. HANDLING HOSES or the like.
(1) Make sure that the fuel hose, water hose or similar are properly seated after installation and
cannot slip out or are leaking.
(2) Make sure that no fuel drips onto neighboring parts when removing the fuel hose (special care
should be taken with rubber mountings of the engine or similar parts, as there is a possibility that
the material will wear out more quickly through contact with fuel)
11. REPAIR
(1) If a screw or the like is removed while screwing the body or similar work, the scratch on the
painted surface on the body and screw should be repaired according to the body color.
A1–10
6 ATTACHMENT POINTS FOR JACKS AND BASES
6-1 STARTING POINTS FOR JACKS
ATTENTION
• The vehicle must always be jacked up on a horizontal and level surface.
• Never jack up the vehicle at the front and back at the same time.
• Make sure that the jack is positioned so that the bumper is not damaged.
 A1–11
6-2 ATTACHMENT POINTS FOR BASES
ATTENTION
• Do not jack up the vehicle at points other than those specified.
A1–12
7 STARTING POINTS FOR LIFTS
ATTENTION
• Front view: Align the support blocks of a two-armed lift, as shown in the illustration on the previous
page, with the attachment points for jack stands.
• Rear view: align the support blocks of a two-armed lift with the rear spring as shown in the illustration
below.
 A1–13
8 TOWING INSTRUCTIONS Towing with the tow rope
8-1 TOWING BY ROPE (ONLY IN AN EMERGENCY)
Release the parking brake, switch the ignition to the ACC
position and move the selector lever to neutral.
ATTENTION
• Never tow with a rope if the engine and / or drive system
appears to be defective.
• When driving with the engine switched off, the braking
force decreases because the brake booster does not L21S 5016E T 10

work. The brake pedal must be pressed harder than

usual.
• For vehicles with automatic transmissions, ensure that a
low loader is always used.

8-2 USE OF A LOW LOADER Transport on a low loader

The vehicle With more dressed Parking brake trans-
port and secure the vehicle.
ATTENTION
• Make sure that the vehicle is transported on a low loader
if the engine and / or drive system appears to be
defective.

L21S 5017E T 10
A1–14
9 DIAGNOSTIC INSTRUCTIONS
9-1 DIAGNOSIS
9-1-1 PERFORMING THE DIAGNOSTICS
1. Any electronic control system installed in the vehicle is an important tool in troubleshooting. These
systems also have self-diagnostic functions to check the defective part in the corresponding system.
A battery backup (the function of the power source for the fault code memory is guaranteed even
when the ignition is switched off) is set up for the self-diagnosis function of the electronic control
system and is designed in such a way that the fault code is stored in each system. Since the function
of the malfunction code memory is different for each system, checking / erasing the code memory
should be performed according to the correct working procedures only after checking the built-in
malfunction code memory function.

Entry of the vehicle with malfunction

Ask the customer about the conditions

Diagnosis through question and and circumstances under which the
answer malfunction occurred.

Check and record the diagnostic code

Deletion of the diagnosis code

Acknowledge the malfunction

Re-examine the error symptoms
phenomenon and understand the
malfunction situation.

Check the diagnostic code again

Abnormal code Normal code

Isolate the faulty systems.

Baseline review
Troubleshooting
based on fault codes
Troubleshooting based on
the error symptoms

Repair or replace

NO Confirm that the problem described by

Check (is the vehicle working properly again?) the customer has been resolved.

YES

end
L11E7008ES35
 A1–15
9-1-2 SYMPTOM CHECK
1. When performing troubleshooting, it is necessary to check the phenomenon yourself to determine the
cause. For this purpose, it is essential to reproduce the malfunction phenomenon based on the
information from the customer, to create circumstances and environment similar to those that caused
the malfunction. In the case of phenomena described by the customer that are difficult to reproduce, it
is necessary to simulate circumstances that come as close as possible to the original disturbance
circumstances (road conditions, weather conditions, driving conditions). To this end, it is extremely
important to try to persistently reproduce the disturbance phenomenon by removing external factors
such as vibration (moving wiring harnesses and relays by hand), heat (blowing hot air), Water
(bringing in moisture) can be added. While the trouble phenomenon is being reproduced, it is
important to check the displayed diagnostic codes before and after confirming the trouble. Checking
whether the code that was issued before confirmation is the same or not is also an important step in
isolating the source of interference.

9-1-3 CUSTOMER PROBLEM ANALYSIS

1. For a vehicle that malfunctions, first check the malfunction phenomenon, then find out the cause and
remove the cause. There is a possibility that the vehicle will not function normally again even if many
work steps are carried out without investigating the cause. The question about problems is used to
gather information from the customer before examining the fault phenomenon and is an important
clue for trying to repeat the fault. When asking about problems, it is necessary to concentrate on the
things that relate to the fault described so that the information gathered becomes a useful reference
for troubleshooting when asked about problems.
A1–16
10 DIAGNOSTIC CONNECTOR
10-1 ARRANGEMENT OF THE TERMINALS OF THE DIAGNOSTIC CONNECTOR

1 2 3 4th 5 6t 7th 8th

h
9 10 11 12t 13 14t15t 16
h h h

Diagnostic
connector

L21S5020ES16

No Terminal code No. Terminal code

.

E (signal ground)
E (body mass)

10-2 CONNECTION METHOD FOR THE DIAGNOSTIC CONNECTOR

Establish a connection by connecting the engine control system (SST) test lead to the diagnostic
connector. The system check for each system by using the short-circuit terminal (SST), the terminal for
determining the engine speed and the terminal for VF output monitoring (SST).
10-3 CONNECTION METHOD FOR EACH SYSTEM
1. Diagnostic code output for engine control system
: Short circuit between T (EFI) - E
2. Function check O2 sensor for engine control system
: Measure between VF - E
3. Engine speed check of the engine control system
: Measure between REV - body ground
4. Diagnostic code output for automatic transmission system
: Short circuit between T (ECU) - E
5. Diagnostic code output for ABS system
: Short circuit between T (ECU) - E
6. Diagnostic code output for airbag system
: Short circuit between T (ECU) - E
7. Function check of body integration control
: Short circuit between T (ECU) - E
8. Diagnostic code output for immobilizer
: Short circuit between T (ECU) - E
9. Diagnostic code output for EPS system
: Short circuit between T (ECU) - E
 A1–17
11 SYSTEM CHECK
INSTRUCTIONS
11-1 INSTRUCTIONS FOR HANDLING THE
CONNECTOR
1. The connection and disconnection of the connector and
each terminal should only be done after disconnecting
the negative pole of the battery. However, the
malfunction code may be cleared if the negative pole of
the battery is disconnected, so the malfunction code G 07E 5017T10

should be confirmed first, if necessary, before the

negative pole of the battery is disconnected.
2. Ensure that the connector is released by pulling on the
connector housing itself rather than the cable harness,
with the connector's locking claw released. When
connecting, press it together until it audibly clicks into
place.
3. When holding a test probe on the connector, hold it from
the back of the connector (harness).
4. For objects that cannot be accessed from the rear, such
as waterproof plugs, the test probe should be inserted
carefully without bending anything.
5. Never touch the terminal of the connector directly with
your hand. Test
probe
6. Be careful not to cause a short circuit by touching two
test probes when voltage is applied to the test probe.

Do not insert the test tip all the way.

G 07E 5024ET 10
A1–18
11-2 TESTING PROCEDURES FOR WIRING HARNESS AND CONNECTOR
Perform the wiring harness and connector test in the discrimination system test in accordance with the following
items.
11-2-1 CONTINUITY CHECK Sensor side Computer side
1. Remove the connector of the corresponding wiring
harness on both sides.
2. Measure the electrical resistance between the
corresponding terminal of the connector at both ends.
TARGET VALUE: Not more than 1+ +

ATTENTION
• Measure the electrical resistance during the cabletree is
moved slightly up and down or left and right. G07E5020ET10

NOTE
• In the event of a break, it is rare that the break is in the
middle of the wiring, the majority of the breaks are near
the connector. Check especially the connector of the
sensor part carefully.
11-2-2 SHORT CIRCUIT TEST Sensor side Computer side
1. Remove the connector of the corresponding wiring
harness on both sides.
2. Measure the electrical resistance between the
corresponding terminal of the connector and the body
ground connection. In addition to the above, perform the +

test on the connector on each side.

TARGET VALUE: Not less than 1 M +
ATTENTION G07E5019ET10

• Measure the electrical resistance while gently moving the Sensor side Computer side
wire harness up and down and right and left.
3. Measure the electrical resistance between the terminals
in the same connector with the connector of the
corresponding terminal (except between the respective
power supply and earth lines). Additionally to the + +

above mentioned the exam at

thePass through connectors on both sides. TARGET
VALUE: Not less than 1 M + G07E5021ET10

ATTENTION
• Make sure there is wiringcannot get caught anywhere in
the passenger compartment and that a short circuit is not
accidentally caused by a terminal.
11-2-3 VISUAL INSPECTION, CONTACT FORCE INSPECTION
1. Remove the connector of the corresponding wiring pull
harness on both sides.
slightlyLoose
2. Visually check the formation of rust or intermingling with
foreign bodies on the connector terminals. ning
3. Check whether there is any loosening or damage to the
joint and check that it has been released from the
connector by pulling gently on the wiring harness.
 A1–19
4. Check the tensile force through a prepared plug contact
of the connector and plugging it together with the
sockets. There is a possibility of poor contact for a socket
with less tensile force compared to the other sockets.
ATTENTION
• If there is rust formation, mixing with foreign bodies or the
loss of contact force between the plug and the socket, it
Plug side of the test contact
is possible that the contact properties change due to
disconnection and reconnection. If the inspection of the G 07E 5023ET 10

wire harness and connector shows no malfunction, the

malfunction phenomenon can be confirmed. Then, if the
fault phenomenon cannot be reproduced, a loose contact
between the plug and the socket could be regarded as
the cause.

11-3 CIRCUIT CHECK OF COMPUTER UNIT

Perform the circuit test of the computer unit. If there is a malfunction, repair the appropriate connector,
circuit, and if normal, replace the computer unit.
1. VISUAL INSPECTION OF THE CONNECTOR, INSPECTION OF THE CONTACT FORCE
Visually inspect the connector of the computer unit and check the contact force as described on the
previous page.
2. CHECK THE EARTH LINE OF THE COMPUTER UNIT
Remove the computer unit connector, and then measure the applied voltage between each power
source terminal, each ground connector, and the body ground terminal.
SET POINT: VOLTAGE OF EACH POWER SUPPLY

ATTENTION
• During the circuit test of the computer unit, there may be a case that “no abnormality” is displayed if
the contact condition changes due to the removal and installation of the connector. So if the result of
the circuit test of the computer unit shows “no discrepancy”, the computer unit classifies the computer
unit as defective after confirming the fault again by reconnecting the connector to the computer unit.

11-4 INSTRUCTIONS FOR USING THE SYSTEM

1. The computer unit, any sensor or similar parts are precision parts. No great effort should be exerted
during removal and installation. Do not reuse parts that have been subjected to a large force (e.g. if a
part has fallen on the floor).
2. Make sure that no water gets inside the vehicle and that no water gets on the computer unit, a sensor
or similar parts when testing in the rain or when washing the vehicle.
3. If the computer unit is determined to be defective and a vehicle returns to normal after it has been
replaced, reinstall this computer unit (which has been judged to be defective) and ensure that the
previous malfunction is reproduced again. Then finally classify the computer unit as defective.
A1–20
12 INFORMATION ON INSTALLING MOBILE
COMMUNICATION SYSTEMS
ATTENTION
• For vehicles equipped with a mobile communication system such as amateur radio or mobile phone,
observe the following precautionary measures.

1. Mount the antenna as far away as possible from the electronic control system.
2. Since electromagnetic waves are radiated from the antenna lead, do not lay the antenna lead less
than 30 cm away from the computer unit and the ECU wiring harness. Do not lay both lines parallel to
each other over a longer distance
3. Never tie the antenna lead to the engine wiring harness with adhesive tape.
4. Adjust / lay the antenna and the supply line in such a way that radio interference is excluded.
5. Do not install a radio device or similar devices with high transmission power (more than 10 kW).
 A1–21
12 INSTRUCTIONS FOR HANDLING VEHICLES WITH CATALYST
WARNING
• If a large amount of unburned gas gets into the catalytic converter, it can overheat the catalytic
converter and create a fire hazard. To avoid such hazards, be sure to observe the following
precautions. Also make sure that such precautions are explained to customers.

1. Only use unleaded petrol on vehicles with a catalytic converter.

2. Make sure that the following points are observed when performing the spark test.
(1) Carry out spark tests only when absolutely necessary. Make sure to complete the test as soon as
possible.
(2) Do not rev up the engine during the test.
(3) Turn off the fuel supply before performing any spark test.
3. Do not run the engine with the fuel tank almost empty. Failure to do so can result in misfiring. The
catalyst would be exposed to excessive loads, which in turn leads to catalyst damage.
4. Do not dispose of used catalytic converters with components to which gasoline or oil has adhered.
A1–22
14 PRECAUTIONS FOR VEHICLES WITH SRS AIRBAG AND BELT
TENSIONER
14-1 INSTRUCTIONS FOR MAINTENANCE WORK
Ensure that servicing vehicles equipped with an airbag and pretensioner is performed using the correct
procedures and methods, otherwise the airbag or pretensioner may be damaged and cause serious injury
during the work. Also, ensure that maintenance on vehicles equipped with airbags and pretensioners is
performed according to the correct procedures and methods outlined in this manual by carefully reading
the following items.
14-1-1 PRECAUTIONS BEFORE MAINTENANCE WORK
1. Before starting maintenance on airbag and belt tensioner components, the following work steps must
be observed.
(1) Check the status of the airbag warning light.
(2) Check and save the diagnosis codes.
(3) Switch off the ignition and disconnect the battery earth cable.
(4) Wait at least 60 seconds to prevent the airbag from deploying.
WARNING
• There is a possibility that the airbag will deploy if the operation is started within 60 seconds of
disconnecting the earth cable from the battery.
NOTE
• Since airbag systems have an emergency power capacitor (for triggering)60 seconds are required as
a discharge time, although the ground cable of the battery has already been disconnected (natural
discharge).
ATTENTION
• Note that the memory of the computer or another system (such as the engine control) can also be
erased if the earth cable is disconnected from the battery.
2. Ensure that a digital circuit tester that meets the following standard is used to electrically test vehicles
with airbags and seatbelt pretensioners.
WARNING
• Make sure that the electrical current value of the circuit tester used for the work step is measured and
check that it corresponds to the following target value. If a circuit tester that is out of specification is
used, there is a possibility that the airbag may malfunction or deteriorate. In addition, measure the
electrical current o

TARGET VALUE: Notmore than approx. 50 mA (0.05A)

14-1-2 PRECAUTIONS TO AVOID MALFUNCTION

1. Be careful not to drop parts of the airbag system during removal and installation.
2. Make sure that when removing parts of the airbag system, they are not exposed to any force or
damage.
3. Ensure that the passenger-side impact absorber and airbag unit are held with the unfolding side
facing up during the operation, even though this is a temporary operation. Never stack the impact
pots on top of each other (there is a possibility of serious accidents if the metal surface faces up in an
emergency).
4. Store the parts of the airbag system where the effects of electrosmog, high temperatures (no more
than an outside air temperature of 85 ° C) and high humidity can be avoided.
 A1–23
5. Do not expose parts of the airbag system directly to high temperatures and naked flames.
6. In view of the fact that an air bag is deployed in an emergency, if possible, carry out maintenance
work in such a way that the body does not get near the expanding part of the air bag.

14-1-3 GENERAL MAINTENANCE INSTRUCTIONS

1. Observe the information on the warning labels on the components that make up the airbag.
2. When installing, make sure that the spiral contact connector is aligned with the center of the steering
wheel.
3. Make sure that the spiral contact plug is aligned with the center and mark the removed parts in the
appropriate place. If the position / location of parts is changed, the wire harness of the spiral contact
plug could tear off when the steering wheel is turned. These instructions also apply to the parts listed
below.

(1) CONCERNING THE STEERING

1. Steering wheel, steering column, steering gear or the like.
(2) CONCERNING THE VEHICLE BODY
1. Instrument panel or similar.
2. Body electrics defective
3. Combination switch or the like
(3) CONCERNING THE TRANSMISSION
1. Can be the case when the connection to the steering gear is disconnected when removing and
installing the engine, gearbox, etc.

14-1-4 PRECAUTIONS BEFORE BODY AND PAINTING

1. As an inflator in the middlePart of the steering wheel, the upper part of the instrument panel, the foot
of the A-pillar, the foot of the B-pillar and the rear of the front seat, make sure that no force is applied
during the repair, e.g. with a hammer, or that high temperatures occur.
2. If an electric welder is used, do not operate until after removing the parts of the air bag system.
3. If the application of high force or temperatures cannot be avoided, only carry out the work after
removing parts of the airbag system.
4. Do not bring the painted surfaces near the airbag to temperatures of more than 85 ° C while it is
drying.
5. Make sure that parts belonging to the airbag are replaced with new ones if they are externally
scratched or deformed.
A1–24
15 VEHICLE IDENTIFICATION
15-1 BODY COLOR CODE
Body color Color
code
White W09
Black mica N05
red R29
Blue mica metallic B51
Silver metallic S28
Lavender opal metallic P10
Champagne opal metallic T17
Rose opal metallic R41

Body color
White
Black mica
red
Blue-mica
metallic
Silver metallic
Lavender opal
metallic
Champagne
opal metallic
Rose opal
metallic

Vehicle identification number (EU

15-2 CHASSIS SERIAL NUMBER version)
1. The The stamped chassis serial numbers can be found in
the positions shown in the illustration.

Chassis number L21S1102ET10

15-3 ENGINE TYPE AND ENGINE NUMBER

1. The engine type and number can be found on the
locations shown in the figure.

Engine type Engine number

L21S1104ET10
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15-4 NAME PLATE POSITION
1. The The nameplate is at the position shown in the
illustration.

type label
L21S 1103E T 10

15-4-1 INFORMATION ON THE IDENTIFICATION PLATE