REPAIR INSTRUCTION PRECAUTION


  1. BASIC REPAIR HINT


    1. HINTS ON OPERATIONS

      A01GWGYE01
      1 Attire

      • Always wear a clean uniform.

      • Hat and safety shoes must be worn.
      2 Vehicle protection Prepare a grille cover, fender cover, seat cover and floor mat before starting the operation.
      3 Safe operation

      • Use wheel chocks to secure the vehicle.

      • When working with the engine running, make sure to provide ventilation for exhaust fumes in the workshop.

      • When removing or installing heavy parts, such as the engine, transmission, differential, etc., before starting work make sure there are no problems with the equipment that will be used.

      • When working with 2 or more persons, be sure to check safety for one another.

      • If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others.
      4 Preparation of tools and measuring gauge Before starting operation, prepare a tool stand, SST, gauge, oil and parts for replacement.
      5 Removal and installation, disassembly and assembly operations

      • Diagnose with a thorough understanding of proper procedures and of the reported problem.

      • Before removing the parts, check the general condition of the assembly and for deformation and damage.

      • When the assembly is complicated, take notes. For example, note the total number of electrical connections, bolts, or hoses removed. Add matchmarks to ensure reassembly of components in the original positions. Temporarily mark hoses and their fittings if needed.

      • Clean and wash the removed parts if necessary and assemble them after a thorough check.
      6 Removed parts

      • Place the removed parts in a separate box to avoid mixing them up with the new parts or contaminating the new parts.

      • For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them with new ones as instructed in this manual.

      • Retain the removed parts for customer inspection, if requested.
      7* Checks to perform after work is finished

      • Make sure that removed and installed parts (oil filler cap, level dipstick, floor mat, etc.) are properly installed/tightened.

      • Make sure that none of the cloths or tools that were used have been left in the engine compartment or within the vehicle.

      • Check that there are no oil leaks.

      CAUTION:

      *:Be sure to perform these checks properly, not performing these checks properly after finishing work can lead to serious accident or injury.

    2. PRECOATED BOLTS


      1. A01H0LSE01

        Precoated bolts are bolts that have the thread area coated with seal lock adhesive.

      2. If a precoated bolt is retightened, loosened or moved, use the specified adhesive to coat it.

        Note

        Perform the torque check with the bolt tightened to the lowest permitted torque value.

      3. When precoated parts are reused, remove the old adhesive, clean them with non-residue solvent, and dry them with compressed air. Then apply new seal lock adhesive appropriate to those parts, and install them to the specified torque.

      4. The adhesive may take a specified amount of time until it hardens.

    3. GASKETS


      1. Gaskets are non-reusable. Always replace them with new ones.

      2. When necessary, use a sealer on gaskets to prevent leaks.

    4. BOLTS, NUTS AND SCREWS


      1. Carefully follow all the specifications for tightening torque. Always use a torque wrench.

      2. Make sure that no foreign matter (burrs, paint, etc.) gets trapped under the heads of the bolts and nuts when tightening them.

    5. FUSES


      1. When inspecting a fuse, check that the wire of the fuse is not broken.

      2. If the wire of a fuse is broken, confirm that there are no shorts in its circuit.

      3. A01GYGSE01

        When a fuse is replaced, a fuse with the same amperage rating must be used.

        Illustration Symbol Part Name Abbreviation
        A01H1Y6 A01H0JJ FUSE FUSE
        A01H29V A01H202 MEDIUM CURRENT FUSE M-FUSE
        A01GWN3 A01GX6S HIGH CURRENT FUSE H-FUSE
        A01GX89 A01H0X0 FUSIBLE LINK FL
        A01GYSP A01GYUF CIRCUIT BREAKER CB
        A01GYVE A01H0X0 FUSIBLE LINK ASSEMBLY FL

    6. CLIPS


      1. When prying a clip to remove it, always tape the tip of the tool with protective tape to protect the vehicle from damage.

      2. The removal and installation methods of typical clips used for vehicle body parts are shown in the table below.

        Tech Tips

        If clips are damaged during a procedure, always replace the clips with new clips.

        Shape (Example) Illustration Procedures
        A01GWTO A01H12L Remove clips with a clip remover or pliers.
        A01GWFK A01H1VB Remove clips with a clip remover or screwdriver.
        A01H1W9 A01H21Q Remove clips with a wide scraper to prevent panel damage.
        A01H16G A01GX02 Remove clips by pushing the center pin through and prying out the shell.
        A01GZLS A01H0VK Remove clips by unscrewing the center pin and prying out the shell.
        A01GYV4 A01GYUW Remove clips by prying out the pin and then prying out the shell.

    7. CLAWS


      1. When prying a claw to detach it, always tape the tip of the tool with protective tape to protect the vehicle from damage.

      2. The removal and installation methods of typical claws used for vehicle body parts are shown in the table below.

        Tech Tips

        If claws of caps or covers are damaged during a procedure, always replace the caps or covers with new ones.

        Shape (Example) Illustration Procedures
        A01H08B A01H273 Using a screwdriver, detach the claws and remove the caps or covers.
        A01GY2S A01GWI0 Using a screwdriver, detach the claws and remove the caps or covers.
        A01H09B A01GZZO Using a screwdriver, detach the claws and remove the caps or covers.

    8. HINGE, GUIDE, CLAMP, PIN ETC.


      1. The removal and installation methods of typical hinges, guides, clamps and pins used for vehicle body parts are shown in the table below.

        Tech Tips

        If clamps are damaged during a procedure, always replace the cap or cover that has damaged clamps with a new one.

        Shape (Example) Illustration Procedures
        A01H14S A01GXWN Disengage the pins by pulling.
        A01GXMX A01GYZG Disengage the pins by pulling.
        A01GWTV A01GXO0 Remove the clamps with pliers.
        A01H0S2 A01GYS5 Disengage the pins by pulling.

    9. NOTICE FOR ENGINE HOOD/DOOR ADJUSTMENT


      1. A01H09DE03

        If centering bolts are used for the hinges of the engine hood, door, luggage compartment door, etc., replace the centering bolts with standard bolts before performing the engine hood/door adjustment.

    10. JACKING UP AND SUPPORTING VEHICLE


      1. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations.

    11. REMOVAL AND INSTALLATION OF VACUUM HOSES


      1. A01GY86E01

        To disconnect a vacuum hose, pull and twist from the end of the hose. Do not pull from the middle of the hose as this may cause damage.

      2. A01H1GB

        When disconnecting vacuum hoses, use tags to identify where they should be reconnected.

      3. After completing any hose related repairs, double check that the vacuum hoses are properly connected. The label under the hood shows the proper layout.

      4. When using a vacuum gauge, never force the hose onto a connector that is too large. If a hose has been stretched, it may leak air. Use a step-down adapter if necessary.

    12. A01GZUZE01

      TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL


      1. A01H02EE01

        Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with a torque wrench.

        Note

        If an extension tool or SST is combined with a torque wrench and the wrench is used to tighten to a torque specification in this manual, the actual torque will be excessive and parts will be damaged.

      2. PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE


        1. Engineers must undergo special training to be able to perform high-voltage system inspection and servicing.

        2. All high-voltage wire harnesses are colored orange. The HV battery and other high-voltage components have "High Voltage" caution labels. Do not carelessly touch these wires and components.

        3. Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.

          Note

          After removing the service plug grip, turning the power switch on (READY) may cause a malfunction. Do not turn the power switch on (READY) unless instructed by the repair manual.

        4. After disconnecting the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals.

          A01GZ4DE01

          Tech Tips

          Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

        5. Be sure to install the service plug before starting the hybrid system. Starting the hybrid system with the service plug removed may damage the vehicle.

        6. A01GZMHE01

          Before wearing insulated gloves, make sure that they are not cracked, ruptured, torn, or damaged in any way. Do not wear wet insulated gloves.

        7. When servicing the vehicle, do not carry metal objects like mechanical pencils or scales that can be dropped accidentally and cause a short circuit.

        8. Before touching a bare high-voltage terminal, wear insulated gloves and use an electrical tester to ensure that the terminal is not charged with electricity (approximately 0 V).

        9. A01GW7R

          After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulation tape.

        10. The screw of a high-voltage terminal should be tightened firmly to the specified torque. Both insufficient and excessive torque can cause failure.

        11. Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION." sign to notify other engineers that a high-voltage system is being inspected and/or repaired.

        12. Do not place the HV battery upside down while removing and installing it.

        13. After servicing the high-voltage system and before reinstalling the service plug, check again that you have not left a part or tool inside, that the high-voltage terminal screws are firmly tightened, and that the connectors are correctly connected.

          A01GY32

      3. PRECAUTIONS TO BE OBSERVED WHEN INSPECTING OR SERVICING ENGINE COMPARTMENT

        A01GWOD

        The LEXUS LS600h L / LS600h automatically turns the engine ON and OFF when the READY light on the combination meter is ON. To avoid injury, Please make sure that both the indicator on the power switch and the READY lamp on the meter are off.

      4. ACTIONS TO BE TAKEN WHEN BATTERIES ARE DEPLETED

        Tech Tips

        The vehicle uses a 12 V auxiliary and a 288 V hybrid vehicle battery. Therefore, there are two recharging methods when the batteries are depleted.


        1. Perform this procedure when the auxiliary battery is fully depleted.

          Tech Tips

          The following problems indicate that the auxiliary battery is depleted:


          • No display appears on the instrument panel when the power switch is turned on (IG).

          • The hybrid system does not start.

          • The headlights are dim.

          • The sound from the horn is weak.

          Note

          Never use a quick charger.


          1. Move the shift lever to the P position and engage the parking brake.

          2. Turn the power switch off and remove the key from the interior detection area.

          3. A01GZYQE01

            Using booster cables, connect the 12 V battery of the rescue vehicle and the auxiliary battery of the stalled vehicle as shown in the illustration.

            Note

            Do not allow the booster cable to contact the seat vibration module assembly. The positive (+) terminal side of the auxiliary battery is close to the seat vibration module assembly. When charging the battery, it is extremely dangerous if the booster cable contacts the seat vibration module assembly, as sparks occur and the seat vibration module assembly may be damaged.

        5. Connecting Sequence Connecting Location
        1 Positive auxiliary battery terminal of stalled vehicle
        2 Positive battery terminal of rescue vehicle
        3 Negative battery terminal of rescue vehicle
        4 Negative auxiliary battery terminal of stalled vehicle

      5. Start the engine of the rescue vehicle and run the engine at a speed slightly higher than the idling speed for 5 minutes to charge the auxiliary battery of the stalled vehicle.

      6. A01H0RN

        Depress the brake pedal and push the power switch to start the hybrid system.

        Note

        If the hybrid system fails to start, the master warning light flashes, and the multi-information display is as shown in the illustration, the HV battery may be depleted.

      7. Disconnect the booster cable in the reverse order of the connection procedure.

        Note

        If the auxiliary battery needs to be replaced, replace it only with a 12 V battery specially designed for use with the LEXUS LS600h L / LS600h.

    13. When the HV battery is depleted, replace the HV battery.

      Tech Tips

      A01H0RN

      If the HV battery is depleted, the master warning light flashes, the multi-information display is as shown in the illustration, and DTC P3000-388, 389 or 603 is output.

  2. ACTIONS TO BE TAKEN FOR VEHICLE DAMAGED BY IMPACT


    1. Items to be prepared for operation at the site of the accident.


      • Protective clothing (insulated gloves, rubber gloves, goggles, and safety shoes)

      • Saturated boric acid solution 20 L (obtain 800 g of boric acid powder, put it into a container, and dissolve it in water)

      • Red litmus paper

      • ABC fire extinguisher (effective against both oil flames and electrical flames)

      • Shop rags (for wiping off electrolyte)

      • Vinyl tape (for insulating cables)

      • Electrical tester

    2. Actions to be taken at the accident site.


      1. Wear insulated or rubber gloves, goggles and safety shoes.

      2. Do not touch a bare cable that could be a high voltage cable. If the cable must be touched or if accidental contact is unavoidable, follow these instructions: 1) wear insulated or rubber gloves and goggles, 2) measure the voltage between the cable and the body ground using an electrical tester, and 3) insulate the cable using vinyl tape.

      3. If the vehicle catches on fire, use an ABC fire extinguisher to extinguish the fire. Trying to extinguish a fire using only a small amount of water can be more dangerous than effective. Use a substantial amount of water or wait for firefighters.

      4. Visually check the HV battery and immediate area for any electrolyte leakage. Do not touch any leaked liquid because it could be a highly alkaline electrolyte. Wear rubber gloves and goggles, and then apply red litmus paper to the leak. If the paper turns blue, the liquid must be neutralized before wiping. Neutralize the liquid using the following procedures: 1) apply saturated boric acid solution to the liquid, and 2) reapply red litmus paper and make sure it does not turn blue. Repeat steps 1 and 2 above until the paper does not turn blue. Then, wipe the neutralized liquid with a shop rag.

      5. If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the procedure below.

        A01H11ZE02
        A01GYY1E01

        1. Move the shift lever to the P position and engage the parking brake.

        2. Remove the key from the vehicle. Then disconnect the cable from the negative (-) terminal of the auxiliary battery.

        3. Remove the service plug while wearing insulated gloves.

          A01GZ4DE01

        CAUTION:

        Do not turn the power switch ON (READY) while removing the service plug.

        Note


        • A01GWKEE02

        • If the service plug cannot be removed due to damage to the rear portion of the vehicle, remove the IG2 relay from the engine room No. 2 junction block instead.

        • If the correct relay cannot be recognized, pull both relays in the fuse box.

    3. Moving the damaged vehicle

      Tech Tips

      If any of the following applies, tow the vehicle away using a tow truck.


      • One or more of the high-voltage components and cables are damaged.

      • The driving, traction, or fuel system is damaged.

      • A01H0BK

        The READY light is not illuminated when you start the engine.

      Note


      • Tow the damaged vehicle with its front and rear wheels lifted off the ground. In an emergency where a tow truck is not available, the vehicle may be temporarily towed using a cable or chain secured to the emergency towing eyelet. Also, make sure that the following conditions are met: 1) the towing should only be performed on paved roads for short distances at low speeds; 2) a driver must be in the vehicle to steer and operate the brakes; and 3) the vehicle's wheels, drive train, axles, steering and brakes must be operating normally.

      • Before towing the vehicle away using a tow truck, disconnect the cable from the negative (-) terminal of the auxiliary battery and remove the service plug. Only if none of the above applies and there are no problems that might affect driving, drive the vehicle away from the accident site to a safe place nearby.

      • Perform the procedure below if the READY light turns OFF, or there are abnormal noises, unusual smells, or strong vibrations while driving:


        1. Park the vehicle in a safe place.

        2. Move the shift lever to the P position and engage the parking brake.

        3. Disconnect the cable from the negative (-) terminal of the auxiliary battery.

        4. Remove the service plug while wearing insulated gloves.

    4. Actions required after moving the damaged vehicle. If you see any liquid on the road surface, it could be a highly alkaline electrolyte leakage.

      Wear rubber gloves and goggles, and apply red litmus paper to the leak. If the paper turns blue, the liquid must be neutralized before wiping. Neutralize the liquid using the following procedures: 1) apply saturated boric acid solution to the liquid, and 2) reapply red litmus paper and make sure it does not turn blue. Repeat steps 1 and 2 above until the paper does not turn blue. Then wipe the neutralized liquid with a shop rag.

    5. Items to be prepared (when repairing damaged vehicles).


      • Protective clothing (insulated gloves, rubber gloves, goggles, and safety shoes)

      • Saturated boric acid solution 20 L (obtain 800 g of boric acid powder, put it into a container, and dissolve it in water)

      • Red litmus paper

      • Shop rags (for wiping off the electrolyte)

      • Vinyl tape (for insulating cables)

      • Electrical tester

    6. Precautions to be observed when servicing the damaged vehicle.


      1. Wear insulated or rubber gloves, goggles, and safety shoes.

      2. Do not touch a bare cable that could be a high voltage cable. If the cable must be touched or if accidental contact is unavoidable, follow these instructions: 1) wear insulated or rubber gloves and goggles, 2) measure the voltage between the cable and the body ground using an electrical tester, and 3) insulate the cable using vinyl tape.

      3. Check the HV battery and immediate area for any electrolyte leakage. Do not touch any leaked liquid because it could be a highly alkaline electrolyte. Wear rubber gloves and goggles, and then apply red litmus paper to the leak. If the paper turns blue, the liquid must be neutralized before wiping. Neutralize the liquid using the following procedures: 1) apply saturated boric acid solution to the liquid, and 2) reapply red litmus paper and make sure it does not turn blue. Repeat steps 1 and 2 above until the paper does not turn blue. Then wipe the neutralized liquid with a shop rag.

      4. If the electrolyte adheres to your skin, wash the skin immediately using saturated boric acid solution or a large amount of water. If the electrolyte adheres to an article of clothing, take the clothing off immediately.

      5. If the electrolyte comes in contact with your eyes, call out loudly for help. Do not rub your eyes. Wash them with a large amount of water and seek medical care immediately.

      6. If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the procedure below.


        1. Move the shift lever to the P position and engage the parking brake.

        2. Remove the key from the vehicle. Then disconnect the cable from the negative (-) terminal of the auxiliary battery.

        3. Wear insulated gloves, and then remove the service plug.

        Note

        If the service plug cannot be removed due to damage to the rear portion of the vehicle, remove the IG2 relay from the engine room No. 2 junction block instead.

    7. Precautions to be taken when disposing of the vehicle.

      When scrapping the vehicle, remove the HV battery from the vehicle and return it to the location specified by the manufacturer. The same applies to any damaged HV battery.

    8. After removing the battery, keep it away from water. Water may heat the battery, which results in a fire.

    9. Do not tow the vehicle with its 4 wheels on the ground.

      Note

      In an emergency where a tow truck is not available, the vehicle may be temporarily towed using a cable or chain secured to the emergency towing eyelet. Also, make sure that the following conditions are met: 1) the towing should only be performed on paved roads for short distances at low speeds; 2) a driver must be in the vehicle to steer and operate the brakes; and 3) the vehicle's wheels, drive train, axles, steering and brakes must be operating normally.

  3. FOR VEHICLES WITH SUPPLEMENTAL RESTRAINT SYSTEM

    The LEXUS LS600h L / LS600h is equipped with a Supplemental Restraint System (SRS). The SRS of this vehicle consists of the following:


    1. Steering pad

    2. Driver side knee airbag assembly

    3. Front passenger side knee airbag assembly

    4. Front passenger airbag assembly

    5. Curtain shield airbag assembly

    6. Front seat side airbag assembly

    7. Rear seat side airbag assembly

    8. Center airbag sensor assembly

    9. Rear seat cushion airbag assembly

    10. Active headrest inflator

    11. Front airbag sensor

    12. Door side airbag sensor

    13. Side airbag sensor

    14. Rear airbag sensor

    15. Seat position airbag sensor

    16. Front seat outer belt assembly with pretensioner

    17. Rear seat outer belt assembly with pretensioner

    CAUTION:


    • Failure to carry out service procedures in the correct sequence could cause SRS parts to unexpectedly deploy and possibly lead to serious injuries. Furthermore, if a mistake is made when servicing SRS parts, they may fail to operate when required. Before performing servicing (including installation/removal, inspection and replacement of parts), be sure to read the following precautions.

    • Before starting work, wait at least 90 seconds after the power switch is turned OFF and after the cable of the negative (-) auxiliary battery terminal is disconnected. (SRS parts are equipped with a backup power source. If work is started within 90 seconds of turning the power switch OFF and disconnecting the cable from the negative (-) auxiliary battery terminal, SRS parts may deploy.)

    • Do not expose SRS parts directly to hot air or flames.

    Note


    • Malfunction symptoms of SRS parts are difficult to confirm. DTCs are the most important source of information when troubleshooting. During troubleshooting, always confirm DTCs before disconnecting the cable from the negative (-) auxiliary battery terminal.

    • For minor collisions where SRS parts do not deploy, always inspect the SRS parts.

    • Before performing repairs, remove airbag sensors as necessary if any kind of impact is likely to occur to an airbag sensor during repairs.

    • Never use SRS parts from another vehicle. When replacing SRS parts, replace them with new ones.

    • Never disassemble or attempt to repair SRS parts.

    • When replacing a deployed active headrest inflator, always replace it together with the headrest.

    • If an SRS part has been dropped, or if there are any cracks, dents or other defects in the case, bracket or connector, replace the SRS part with a new one.

    • Use an ohmmeter/voltmeter with high impedance (10 kΩ/V minimum) for troubleshooting the electrical circuits.

    • Information labels are attached to the periphery of SRS parts. Follow the cautions and instructions on the labels.

    • After work on SRS parts is completed, perform the SRS warning light check.

    • When the cable is disconnected from the negative (-) auxiliary battery terminal, the memory settings of each system will be cleared. Because of this, be sure to write down the settings of each system before starting work. When work is finished, reset the settings of each system as before. Never use a backup power supply from outside the vehicle to avoid erasing the memory in a system.

    • An airbag or pretensioner may be activated by static electricity. To prevent this, be sure to touch a metal surface with bare hands to discharge static electricity before performing this procedure.


    1. SPIRAL CABLE


      1. The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, as cable disconnection and other problems may occur. Refer to the information about correct installation of the steering wheel.

    2. AIRBAG ASSEMBLY


      1. Airbag assembly with pad:

        Always place a removed or new airbag assembly with the pad surface facing upward. Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag inflates. Also, do not place anything on top of the airbag assembly.

      2. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause a serious injury.

      3. Grease or detergents of any kind should not be applied to the airbag assembly.

      4. Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.

      5. When using electric welding anywhere on the vehicle, disconnect the center airbag sensor connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring.

      6. When disposing of the vehicle or the airbag assembly by itself, the airbag should be deployed using SST before disposal. Activate the airbag in a safe place away from electrical noise.

    3. SEAT OUTER BELT ASSEMBLY WITH PRETENSIONER


      1. Never measure the resistance of the seat outer belt. This may cause the pretensioner of the seat outer belt to activate, which could cause a serious injury.

      2. Never install the seat outer belt on another vehicle.

      3. Store the seat outer belt in an area where the ambient temperature is below 80°C (176°F), the humidity is not high and there is no electrical noise.

      4. When using electric welding anywhere on the vehicle, disconnect the center airbag sensor connectors (2 pins). These connectors contain shorting springs. This feature reduces the possibility of the pretensioner deploying due to currents entering the squib wiring.

      5. When disposing of a vehicle or the seat outer belt by itself, the pretensioner should be activated before disposal. Activate the pretensioner in a safe place away from electrical noise.

      6. As the seat outer belt is hot after the pretensioner is activated, allow some time for it to cool down sufficiently before disposal. Never apply water to try to cool down the seat outer belt.

      7. Grease, detergents, oil or water should not be applied to the seat outer belt.

    4. AIRBAG SENSOR ASSEMBLY


      1. Never reuse an airbag sensor assembly that has been involved in a collision where the SRS has deployed.

      2. The connectors to the airbag sensor assembly should be connected or disconnected with the sensor placed on the floor. If the connectors are connected or disconnected while the airbag sensor assembly is not placed on the floor, the SRS may activate.

      3. Work must be started at least 90 seconds after the power switch is turned OFF and the cable is disconnected from the negative (-) auxiliary battery terminal, even if only loosening the set bolts of the airbag sensor assembly.

    5. WIRE HARNESS AND CONNECTOR


      1. The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are yellow. If the SRS wire harness becomes disconnected or the connector becomes broken, repair or replace it.

  4. ELECTRONIC CONTROL


    1. A01H1KKE01

      REMOVAL AND INSTALLATION OF AUXILIARY BATTERY TERMINAL

      Note


      • Always remove the service plug to cut off the high-voltage circuit when servicing or inspecting high-voltage parts and wiring.

      • Carry the removed service plug grip in your pocket to prevent other technicians from reinstalling it while servicing the vehicle.

      • The high-voltage wiring and connectors are all colored orange.

      • Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) auxiliary battery terminal.

      • After the power switch is turned off, the multi-media module receiver assembly records various types of memory and settings. As a result, after turning the power switch off, be sure to wait for the time specified in the following table before disconnecting the cable from the negative (-) auxiliary battery terminal.

        Waiting Time before Disconnecting Cable from Negative (-) Auxiliary Battery Terminal
        Condition Waiting Time
        Vehicle enrolled in G-BOOK system 6 minutes
        Vehicle not enrolled in G-BOOK system 1 minute

      1. Before performing electronic work, disconnect the cable from the negative (-) auxiliary battery terminal to prevent component and wire damage caused by accidental short circuits.

      2. When disconnecting the cable, turn the power switch OFF and headlight dimmer switch OFF and loosen the cable nut completely. Perform these operations without twisting or prying the cable. Then disconnect the cable.

      3. Clock settings, radio settings, audio system memory, DTCs and other data are erased when the cable is disconnected from the negative (-) auxiliary battery terminal. Write down any necessary data before disconnecting the cable.

      4. Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) auxiliary battery terminal.

    2. HANDLING OF ELECTRONIC PARTS


      1. A01H1OEE01

        Do not open the cover or case of the ECU unless absolutely necessary. If the IC terminals are touched, the IC may be rendered inoperative by static electricity.

      2. Do not pull the wires when disconnecting electronic connectors. Pull the connector.

      3. Be careful not to drop electronic components, such as sensors or relays. If they are dropped on a hard surface, they should be replaced.

      4. When cleaning the engine with steam, protect the electronic components, air filter and emission-related components from water.

      5. Never use an impact wrench to remove or install temperature switches or temperature sensors.

      6. When measuring the resistance of a wire connector, insert the tester probe carefully to prevent terminals from bending.

      7. Do not expose electronic parts to high temperatures and humidity.

      8. Do not touch the terminals of the connectors, as a malfunction due to static electricity and/or deformation may occur.

  5. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS


    1. PLACE FOR REMOVING AND INSTALLING FUEL SYSTEM PARTS


      1. Work in a location with good air ventilation that does not have welders, grinders, drills, electric motors, stoves, or any other ignition sources.

      2. Never work in a pit or near a pit as vaporized fuel will collect in those places.

    2. REMOVING AND INSTALLING FUEL SYSTEM PARTS


      1. Prepare a fire extinguisher before starting the operation.

      2. To prevent static electricity, install a ground wire to the fuel changer, vehicle and fuel tank, and do not spray the surrounding area with water. Be careful when performing work in this area, as the work surface will become slippery. Do not clean up gasoline spills with water, as this may cause the gasoline to spread, and possibly create a fire hazard.

      3. Avoid using electric motors, working lights and other electric equipment that can cause sparks or high temperatures.

      4. Avoid using iron hammers as they may create sparks.

      5. Dispose of fuel-contaminated cloths separately using a fire resistant container.

  6. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS


    1. A01GWN2

      If any metal particles enter inlet system parts, they may damage the engine.

    2. When removing and installing inlet system parts, cover the openings of the removed parts and engine openings. Use gummed tape or other suitable materials.

    3. When installing inlet system parts, check that no metal particles have entered the engine or the installed parts.

  7. HANDLING OF HOSE CLAMPS


    1. Before removing the hose, check the clamp position so that it can be reinstalled in the same position.

    2. Replace any deformed or dented clamps with new ones.

    3. When reusing a hose, attach the clamp on the clamp track portion of the hose.

    4. A01H1SGE01

      For a spring type clamp, you may want to spread the tabs slightly after installation by pushing in the direction of the arrows as shown in the illustration.

  8. FOR VEHICLES EQUIPPED WITH MOBILE COMMUNICATION SYSTEMS


    1. A01GZUG

      Install the antenna as far away from the ECU and sensors of the vehicle electronic systems as possible.

    2. Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle electronic systems. For details about ECU and sensor locations, refer to the section of the applicable components.

    3. Keep the antenna and feeder separate from other wiring as much as possible. This will prevent signals from the communication equipment from affecting vehicle equipment and vice versa.

    4. Check that the antenna and feeder are correctly adjusted.

    5. Do not install a high-powered mobile communication system.

  9. HEADLIGHT INSPECTION MAINTENANCE


    1. for HID Headlight


      1. When the headlight dimmer switch assembly is set to HEAD, do not touch the discharge headlight's high-voltage socket area.

    2. for LED


      1. When the headlight dimmer switch assembly is set to HEAD, do not touch the LED.

    3. A01H0QLE01

      When the headlights are illuminated, do not cover the headlights for 3 minutes or more.

      Note


      • As the headlight's outer lens is made of resin, the resulting heat created when covering the headlight for an extended period of time may deform the headlight.

      • When performing inspection maintenance, the discharge headlight's precautions must be followed.

  10. FOR VEHICLES EQUIPPED WITH TRC (TRACTION CONTROL) SYSTEM AND VSC (VEHICLE STABILITY CONTROL) SYSTEM


    1. Notices for when using a chassis dynamometer.


      1. Position the front wheels on free rollers or support the vehicle with rigid racks and make sure the front wheels can rotate freely.

      2. When testing with a speedometer tester, a combination tester for the speedometer and brake, a chassis dynamometer or similar, be sure to enter "Test mode" and prohibit the TRC and VSC controls.

      3. A01GWP0E03

        After completing the inspection, be sure to exit "Test mode".

        Note

        Never drive the vehicle while in "Test mode".

        CAUTION:


        • If the vehicle is tested in normal mode on the drum tester, TRC and VSC operation may cause the vehicle to jump out from the drum tester.

        • When switching to VSC OFF mode, the VSC OFF switch must be held for 3 seconds or more with the vehicle stopped. TRC and VSC operation must both be turned off before beginning testing.

        • During VSC OFF mode, TRC OFF is displayed in the multi-information display, and the combination meter's VSC OFF indicator light illuminates.

        • Fix the vehicle in place with chains for safety.

    2. NOTICES FOR VSC RELATED PROCEDURES


      1. For VSC related parts, adjustments are required after removal and installation. Therefore, perform removal and installation only when necessary.

      2. When performing VSC related procedures, be sure to strictly follow the preparation and completion procedures.

      3. When performing removal and installation or replacement of VSC related parts, first disconnect the cable from the negative (-) auxiliary battery terminal.

  11. PRECAUTIONS FOR TOWING ALL WHEEL DRIVE VEHICLES


    1. Use one of the following methods to tow the vehicle.

    2. If the vehicle has trouble with the chassis or drivetrain, use method 1 (flatbed truck).

      A01GXL8E04
      Text in Illustration
      *1

      Note

      If the vehicle is tilted after parking on a level surface, the braking force may be insufficient as the electric parking brake determines how much braking force to using the yaw rate sensor value for the slope of the road.

      		 *2

      Tech Tips

      Press the electric parking brake switch twice to apply the parking brake with the maximum braking force.

      Note

      Do not use any towing method other than those shown above.

    3. If a tow truck is not available, in an emergency the vehicle may be temporarily towed using a cable or chain secured to the emergency towing eyelet(s).

      This should only be attempted on hard surfaced roads for distances of less than 80 km, and at speeds below 30 km/h (19 mph).

      A driver must be in the vehicle to steer and operate the brakes. The vehicle's wheels, drivetrain, axles, steering and brakes must be in good condition.

      Note

      If the towing speed or distance exceeds the above limits, or the vehicle is towed in a backward direction with any of the wheels on the ground, the drivetrain may be damaged.


      1. Emergency towing procedure


        1. Turn the power switch ON (IG).

        2. Depress the brake pedal and move the transmission shift lever to N.

        3. Release the parking brake.

        4. Release the brake pedal slowly.

        Note


        • Use extreme caution when towing the vehicle. Avoid sudden starts or erratic driving maneuvers which place excessive stress on the emergency towing eyelet and the cables or chains.

        • Do not turn off the power switch. Turning off the power switch may result in engagement of the steering lock, resulting in a hazardous situation or accident.

    4. The towing methods shown below are dangerous and can damage the vehicle, so do not use them.

      A01GZL9

      1. Do not tow the vehicle with only 2 wheels on the ground.

        Note

        If the vehicle is towed with only the 2 wheels on the ground, the drivetrain may overheat and be damaged or the wheels may come off the dollies.

      2. Do not use a sling-type towing method either from the front or rear.

        Note

        If a sling-type tow truck is used, damage may occur to the vehicle body.

  12. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER

    CAUTION:

    If a large amount of unburned gasoline or gasoline vapors flow into the converter, it may cause overheating and create a fire hazard. To prevent this, observe the following precautions.


    1. Use only unleaded gasoline.

    2. Perform the spark test and cylinder compression check only when necessary, and as quickly as possible.

    3. Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter.

  13. INSPECTION AND ADJUSTMENT OF JOINT ANGLE DURING REMOVAL AND INSTALLATION OF PROPELLER SHAFT


    1. When performing operations which involve the removal and installation of the propeller shaft, always check the joint angle. Make adjustments if necessary.

      A01H185E01