Follow the procedures shown in the table below.
Static Checks Just After Vehicle Receipt
|
Operation |
Check point |
|
1. Appearance check |
(1) If the vehicle is covered with protective coating, visually check the vehicle body for damage and dents. If the protective coating has been removed, visually inspect the body paints for small areas of damage or rust. (2) Visually check the glass and light lenses for any damage, cracks or excessive gaps between body sheet metal. (3) Visually check the plated parts for any damage. |
|
2. Tire check |
(1) Check the tires for damage, defective, and dents on wheels. (2) Check the tire air pressure. |
|
3. Fuse installation |
If the vehicle is about to be delivered to customer, attach a room light fuse. |
|
4. Air conditioner harness connection |
If the vehicle is about to be delivered to customer, connect the air conditioner harness. |
|
5. Lock/unlock and open/close operation checks of doors. |
(1) Using the key, check the trunk lid can be locked or unlocked normally. (2) Open and close all doors to check that there are no defective. |
|
6. Double lock operation check |
Check that double lock operates normally. |
|
7. Operation check of child safety lock system |
Check the child safety lock system operates normally. |
|
8. Lock/unlock and open/close operation checks of the rear doors. |
(1) Check if the rear gate can be unlocked normally through the emergency hole. (2) Open and close the rear gate to see that there are no abnormal conditions. (3) Operate the power door lock switch to check that the rear gate is locked and unlocked normally. |
|
9. Operation check of fuel lid opener lock release lever |
Operate the fuel lid opener to check that the fuel lid is unlocked normally. |
|
10. Accessory check |
Check that the following accessories are provided. • Owner’s manual • Warranty booklet • Maintenance note • Spare key • Jack • Tool set • Spare tire |
|
11. Operation check of front hood lock release system |
Operate the front hood lock release lever to check that the front hood opens normally. |
|
12. Battery |
Check the battery for any abnormal conditions such as rust and trace of battery fluid leaks. |
|
13. Brake fluid |
Check the fluid amount. |
|
14. Engine oil |
Check the oil amount. |
|
15. Transmission fluid |
Check the fluid amount. |
|
16. AT front differential oil |
Check the AT front differential oil amount. |
|
17. Engine coolant |
Check the engine coolant amount. |
|
18. Clutch fluid |
Check the clutch fluid amount. |
|
19. Window washer fluid |
Check the window washer fluid amount. |
|
20. Front hood latch check |
Check that the hood is closed and latched completely. |
|
21. Keyless entry system |
Check that the keyless entry system operates normally. |
|
22. Seat |
(1) Check the seat surfaces for stains or dirt. (2) Check the seat installation conditions and functionality. |
|
23. Seat belt |
Check the seat belt installation conditions and functionality. |
Checks with the Engine Running
|
Operation |
Check point |
|
24. Test mode connector |
Test mode connector |
|
25. Immobilizer system |
(1) Check that the engine starts with all keys that are equipped on vehicle. (2) 60 seconds after turning ignition switch from ON to ACC or OFF, or immediately after removing the key, check that the security indicator light blinking. |
|
26. Starting condition |
Start the engine and check that the engine starts smoothly. |
|
27. Exhaust system |
Check that the exhaust noise is normal and no leaks are found. |
|
28. Indicator and warning lights |
Check that all indicator lights and warning lights operate normally. |
|
29. Clock |
Check that the clock operates normally. |
|
30. Audio |
Check the radio, CD player for normal operation. |
|
31. Navigation System |
(1) Check all display functions for normal operation. (2) Check the map disc (DVD) are provided on vehicle. (3) Check that the navigation system operates normally. |
|
32. Front accessory power supply socket |
Check that the front accessory power socket operates normally. |
|
33. Lighting system |
Check that the lighting system operates normally. |
|
34. Window washer |
Check that the window washer system operates normally. |
|
35. Wiper |
Check that the wiper system operates normally. |
|
36. Power window operation check |
Check that the power window operations normally. |
Dynamic Test with the Vehicle Running
|
Operation |
Check point |
|
37. Brake test |
Check the foot brake for normal operations. |
|
38. Parking brake |
Check the parking brake for normal operations. |
|
39. AT shift control |
Check that the AT shift patterns are correct. |
|
40. Heater & ventilation |
Check that the heater & ventilation system operates normally. |
|
41. Air conditioner |
Check that the air conditioner operates normally. |
|
42. Cruise control |
Check that the cruise control operates normally. |
Checks after Dynamic Test
|
Operation |
Check point |
|
43. ATF level |
Check that the ATF level is correct. |
|
44. Power steering fluid level |
Check that the power steering fluid level is normal. |
|
45. Fluid leak check |
Check for fluid/oil leaks. |
|
46. Water leak check |
Spray the vehicle with water and check for water leaks. |
|
47. Appearance check 2 |
(1) Remove the protective coating (if any). (2) Check the body paints for damage and stain. (3) Check the plated parts for damage and rust. |
1. If the vehicle is covered with protective coating, visually check the vehicle body for damage and dents.
2. When there is no protective coating, check the body paints for damage or stains in detail and repair as necessary.
3. Check the window glass, door glass, and lights for any cracks or damage and replace the parts as necessary.
4. Check the plated parts, such as the grilles and door knobs, for damage or loss of gloss and replace the parts as necessary.
1. Check the outer side surface of the tire damage.
2. Check the tire air pressure by referring to the following table.
|
Tire size |
Tire inflation pressure kPa (kgf/cm2, psi) | |
|
Front |
Rear | |
|
215/60R16 |
200 (2.0, 29) |
190 (1.9, 28) |
|
215/55R17 |
220 (2.2, 32) |
210 (2.1, 30) |
Fuses for the room light circuit are removed immediately after vehicle delivery to prevent battery discharge. Attach a 15 A fuse (A) as shown in the figure.
4. AIR CONDITIONER HARNESS CONNECTION
The air conditioner harness is disconnected immediately after vehicle delivery to protect the air conditioner compressor. Connect the harness as shown in the figure.
5. CHECK THE DOORS FOR LOCK/UNLOCK AND OPEN/CLOSE OPERATIONS
1. Using the key, lock and unlock the door several times to check for normal operation. Open and close the door several times for smooth movement.
|
(A) |
Unlock |
|
(B) |
Lock |
2. Close the door of driver seat completely, and place the door lock knob (A) to the lock position. Then pull the inner remote (B) to ensure that doors will not open.
For other doors, place the door lock knob (A) to lock position and then pull the inner remote (B) to ensure that doors will not open.
|
(A) |
Door lock knob |
|
(B) |
Inner remote |
3. Press the driver’s side power door lock switch to lock side. Check that all doors including rear gate are locked.
4. Press the driver’s side power door lock switch to unlock side. Check that all doors including rear gate are unlocked.
6. DOUBLE LOCK OPERATION CHECK
1. Fully open all windows.
2. Remove the key.
3. Lock the doors using key or keyless transmitter.
4. Check that all doors including rear gate are not unlocked when pressing the power door lock switch to unlock side.
5. Place the door lock knob to the unlock position, then pull inner remote to ensure that doors will not open. For other doors, ensure that the doors will not open.
6. Check that double lock is unlocked for all doors and all doors are unlocked then rear gate is unlocked when ignition key is turned ON at double lock status.
7. CHECK THE OPERATION OF CHILD SAFETY LOCK
1. Set the child safety lock on both rear doors to the lock position.
2. Close the rear doors completely.
3. Check that the lock levers of the rear doors are in the unlock position. Then, pull inner remote of rear doors to ensure that doors will not open.
4. Pull the outer handles to ensure that doors will open.
|
(A) |
Unlock |
|
(B) |
Lock |
|
(C) |
Child safety lock |
8. CHECK THE REAR GATE FOR LOCK/UNLOCK AND OPEN/CLOSE OPERATIONS
1. Open and close the rear gate several times for smooth movement.
2. Operate the rear gate emergency lever to check that the rear gate is locked and unlocked normally.
(1) Remove the cover inside the rear gate.
(2) Operate the driver to check that the rear gate is locked and unlocked normally.
|
(A) |
Lock |
|
(B) |
Unlock |
9. OPERATION CHECK OF FUEL LID OPENER LOCK RELEASE LEVER
Operate the fuel lid opener to check that the fuel lid opens normally. Check that the filler cap is securely closed.
Check that the following accessories are provided.
• Owner’s manual
• Warranty booklet
• Maintenance note
• Spare key
• Jack
• Tool set
• Spare tire
|
(A) |
Jack |
|
(A) |
Jack handle |
11. OPERATION CHECK OF FRONT HOOD LOCK RELEASE SYSTEM
1. Operate the front hood release knob to check that the front hood is locked normally.
2. Operate the lever (A) and check that the front hood is opened normally. Support the front hood with hood stay.
Check the battery terminals to make sure that there are no rust or corrosions due to fluid leaks. Check that the battery caps are securely tightened.
|
(A) |
Cap |
|
(B) |
Upper level |
|
(C) |
Lower level |
Check the brake fluid amount. If the amount is insufficient, carry out a brake line test to identify brake fluid leaks and check the brake operation. After that, refill the brake fluid tank with the specified type of fluid.
Check the engine oil amount. If the amount of oil is insufficient, check that no leaks are found. Then, add the necessary amount of the specified engine oil.
|
(A) |
Engine oil level gauge |
|
(B) |
Engine oil filler cap |
|
(C) |
Upper level |
|
(D) |
Lower level |
|
(E) |
Approx. 1 L (1.1 US qt, 0.9 Imp qt) |
Check the transmission fluid amount. If the amount of fluid is inappropriate, check that no leaks are found. Then, add the necessary amount of specified fluid.
|
(A) |
Oil level gauge |
|
(B) |
Upper level |
|
(C) |
Lower level |
Check the AT front differential oil amount. If the amount of oil is inappropriate, check that no leaks are found. Then, add the necessary amount of the specified AT front differential oil.
|
(A) |
Oil level gauge |
|
(B) |
Upper level |
|
(C) |
Lower level |
Check the coolant amount on the reservoir. If the amount of engine coolant is insufficient, check that no leaks are found. Then, add the necessary amount of coolant with the specified concentration.
Check the clutch fluid amount. If the amount of fluid is insufficient, check that no leaks are found. Then, add the necessary amount of specified fluid.
|
(A) |
Reservoir tank |
|
(B) |
MIN. level |
|
(C) |
MAX. level |
Check the window washer fluid amount. If the amount is insufficient, check that no leaks are found. Then, add the necessary amount of washer fluid commercially available.
|
(A) |
Window washer tank |
|
(B) |
FULL level |
Retract the front hood stay and close the front hood. Check that the front hood is completely latched.
Check the keyless entry system operations as follows:
• Fully open all the door windows.
• Remove the key from the ignition switch and close all the doors including rear gate.
• Press the LOCK side button once on the keyless transmitter. Check if all the doors are locked, and hazard light blinks once.
• Press the UNLOCK side button once on the keyless transmitter. Check if all the doors are unlocked, and hazard light blinks twice.
• Close all the doors and rear gate, and press the LOCK side button on the keyless transmitter. Press UNLOCK side button on the keyless transmitter, then wait for 30 seconds. Check if all the doors and rear gate are locked automatically. (without model with double lock)
Check that each seat provides full functionality in sliding and reclining. Check all of the functions of the rear seat.
Pull out the seat belt and then release it. Check that the belt retracts smoothly.
Turn the ignition switch to ON and check that the malfunction indicator light starts blinking. If the light blinks, return the ignition key to LOCK and disconnect the test mode connector. Then, turn the ignition key to ON again. If the malfunction indicator light blinks at that time in spite of the disconnected test mode connector, carry out an engine diagnosis.
|
(A) |
Test mode connector (green) |
1. Check that the engine starts with all keys that are equipped on vehicle.
2. 60 seconds after turning ignition switch from ON to ACC or OFF, or immediately after removing the key, check that the security indicator light blinking.
NOTE:
If malfunctions occur, refer to “IMMOBILIZER (DIAGNOSIS)”.
Start the engine and check that the engine starts smoothly. If the battery voltage is low, recharge or replace the battery. If any noises are observed, immediately stop the engine and check and repair the abnormal components.
Listen to the exhaust noise to see if no noises are observed.
28. INDICATOR AND WARNING LIGHTS
Check that all the indicator and warning lights are off.
Check the clock for normal operations and enough accuracy.
Check the radio for full functionality and normal noise level. Check the CD player operations.
1. Check all display functions for normal operation. (Refer to operating manuals for operation procedures.)
2. Check the map disc (DVD) are provided on vehicle.
3. Check that the navigation system operates normally.
32. FRONT ACCESSORY POWER SUPPLY SOCKET
Check the operation of the front accessory power socket.
1. Check the headlight operations.
2. Check the stop light operation.
3. Check the headlight levelizer operations on models with the manual headlight levelizer.
4. Check other lights for normal operations.
Check that the window washer system injects washer fluid to the specified area of the windshield shown in the figure.
Front injection position:
(A): 350 mm (13.78 in)
(B): 150 mm (5.91 in)
(C): 275 mm (10.83 in)
(D): 600 mm (23.62 in)
Rear injection position:
A: 35 mm (1.38 in)
B: 72°
|
(1) |
Nozzle |
Check the front and rear wipers for normal operations.
36. POWER WINDOW OPERATION CHECK
Operate the power window switches one by one to check that each of the power windows goes up and down without noises.
Check the foot brake for normal operations.
Check the parking brake for normal operations.
1. Turn the ignition switch to ON.
2. While brake pedal is not depressed, check if the select lever does not move from “P” range.
3. While brake pedal is depressed, check if the select lever moves from “P” range.
4. Set the select lever to other than “P” range.
5. When the ignition switch is turned to OFF, check if the ignition key switch cannot be removed.
6. Set the AT selector lever to each gear position while checking that the demanded gear position is correctly attained.
|
(1) |
RHD model |
|
(2) |
LHD model |
|
Selector position |
Gear position | |||
|
1st |
2nd |
3rd |
4th | |
|
D |
OK |
OK |
OK |
OK |
|
3 |
OK |
OK |
OK |
— |
|
2 |
OK |
OK |
— |
— |
|
1 |
OK |
— |
— |
— |
7. For model with SPORT shift, check that gear position can be changed to intended position with steering shift switch and select lever at SPORT shift mode.
• LHD model
• RHD model
|
(1) |
Steering shift switch |
|
Selector position |
Gear position | |||
|
1st |
2nd |
3rd |
4th | |
|
D |
OK |
OK |
OK |
OK |
|
SPORT shift |
OK |
OK |
OK |
OK |
Operate the heater & ventilation system to check for normal airflow outlet control, air inlet control, airflow capacity and heating performance.
Operate the air conditioner. Check that the A/C compressor operates normally and enough cooling is provided.
Operate the cruise control system. Check that the system is activated and deactivated correctly.
After selecting all positions (P, R, N, D), set the select lever in “P” range. Idle the engine for 1 — 2 minutes, and measure the ATF level. If the amount is insufficient, check that no leaks are found. Then, add the necessary amount of the specified ATF.
|
(A) |
Level gauge |
|
(B) |
Check position when “HOT” [70 to 80°C (158 to 176°F)] |
|
(C) |
Upper level |
|
(D) |
Lower level |
|
(E) |
Check position when “COLD” [20 to 30°C (68 to 86°F)] |
44. POWER STEERING FLUID LEVEL
Check that the power steering fluid level is normal. If insufficient, check for leaks. Then add the necessary amount of the specified power steering fluid.
|
(A) |
Reservoir tank |
|
(B) |
MIN. level |
|
(C) |
MAX. level |
Check entire areas of the vehicle for any trace of coolant/oil/fluid leaks.
Spray the vehicle with water using a hose and check that no water enters the passenger compartment.
• Before performing the water leakage test, remove anything that may obstruct the operation or which must be kept dry.
• Close all the windows and doors securely. Close the hood before starting the test.
• Connect a hose to a tap, and spray water on the vehicle. The rate of water spray must be approx. 20 to 25 L (5.3 — 6.6 US gal, 4.4 — 5.5 Imp gal) per minute.
When spraying water on areas adjacent to the floor and wheel house, increase the pressure. When spraying water on areas other than the floor and wheel house, decrease the pressure. But the force of water must be made strong occasionally by pressing the end of the hose.
NOTE:
Be sure to keep the hose at least 10 cm (3.9 in) away from vehicle.
Check the following areas.
• Front window and body framework mating portion
• Door mating portions
• Glass mating portions
• Rear quarter window mating portions
• Rear window and body framework mating portion
• Around roof drips
If any dampness in the compartments is discovered after the water has been applied, carefully check all the areas that may have possibly contributed to the leak.
1. When vehicle body is covered with protective film (wrap guard), peel it off.
NOTE:
• It is easier to remove the wrap guard using steam.
• For the vehicle left for a long time or at low temperature, sprinkle some water heated 50 — 60°C (122 — 140°F) over the vehicle to raise its surface temperature before peeling off the wrap guard. Do not use the water heated to over 60°C (140°F).
• If the adhesive remains exist on the coated surface, soak a flannel rag, etc. with a small amount of coating wax or solvent such as oil benzene and IPA, put the soaked cloth on the remains lightly, and then wipe them off with a flannel rag etc.
• Keep solvent from touching the resin or rubber parts. Do not use coating wax or solvent while the component surface temperature is high due to hot weather etc.
• If the coated surface is swollen out due to seams or moisture, expose the vehicle to the sunlight for a few hours or heat the seam and swollen portions using a dryer etc.
• Dispose of the peeled wrap guard as burnable industrial garbage.
2. Check the whole vehicle body for flaking paint, damage by transportation, corrosion, dirt, cracks or blisters.
NOTE:
• It is better to determine an inspection pattern in order to avoid missing an area, since the total inspection area is wide.
• Do not repair the body paint unless absolutely necessary. Also, if the vehicle is in need of repair to remove scratches or corroded paint, the repair area must be limited to the minimum. Re-painting and spray painting must be avoided as possible.
3. Check each window glass for scratches carefully. Slight damage may be removed by polishing with cerium oxide. (Fill a cup half with cerium oxide, and add warm water to it. Then agitate the content until it turns to wax. Apply this wax to a soft cloth, and polish the glass with it.)
4. Check each portion of the vehicle body and underside components for the formation of rust. If rust is discovered, remove it with sandpaper of #80 to #180 and treat the surface with rust preventive. After this treatment is completed, flush the portion thoroughly, and prepare the surface for repair painting.
5. Check each portion of body and all of the assembly parts for deformation or distortion. Also, check each light lens for cracks.