BASIC REPAIR HINT
HINTS ON OPERATIONS
1 | Attire |
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2 | Vehicle protection | Prepare a grille cover, fender cover, seat cover and floor mat before starting work. |
3 | Safety procedures |
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4 | Preparation of tools and measuring equipment | Before starting work, prepare a tool stand, SST, measuring equipment, oil, and any replacement parts required. |
5 | Removal and installation, disassembly and assembly operations |
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6 | Removed parts |
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JACKING UP AND SUPPORTING VEHICLE
Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations.
*1 | Seal Lock Adhesive |
PRECOATED PARTS
Precoated parts are bolts and nuts that are coated with seal lock adhesive at the factory.
If a precoated part is retightened, loosened or moved in any way, it must be recoated with the specified adhesive.
When reusing a precoated part, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriately to that part.
Some seal lock agents harden slowly. You may have to wait for the seal lock adhesive to harden.
GASKETS
When necessary, use a sealer on gaskets to prevent leaks.
BOLTS, NUTS AND SCREWS
Carefully follow all the specifications for tightening torque. Always use a torque wrench.
*1 | INCORRECT |
*2 | CORRECT |
FUSES
When inspecting a fuse, check that the wire of the fuse is not broken.
If the wire of a fuse is broken, confirm that there are no shorts in its circuit.
When a fuse is replaced, a fuse with the same amperage rating must be used.
Illustration | Symbol | Part Name | Abbreviation |
---|---|---|---|
FUSE | FUSE | ||
MEDIUM CURRENT FUSE | M-FUSE | ||
HIGH CURRENT FUSE | H-FUSE | ||
FUSIBLE LINK | FL | ||
CIRCUIT BREAKER | CB |
CLIPS
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 damaged clips with new ones.
Shape (Example) | Removal/Installation |
---|---|
Remove the clips with a clip remover or pliers. |
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Remove the clips with a clip remover or screwdriver. |
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Remove the clips with a wide scraper to prevent panel damage. |
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Remove the clips by pushing the center pin through and prying out the shell. |
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Remove the clips by unscrewing the center pin and prying out the shell. |
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Remove the clips by prying out the pin and then prying out the shell. |
CLAWS
The removal and installation methods of typical claws used for vehicle body parts are shown in the table below.
Tech Tips
If claws are damaged during a procedure, always replace the cap or cover that has damaged claws with a new one.
Shape (Example) | Illustration | Procedure |
---|---|---|
Using a screwdriver, disengage the claws and remove the cap or cover. | ||
Using a screwdriver, disengage the claws and remove the cap or cover. | ||
Using a screwdriver, detach the claws and remove the cap or cover. |
HINGES, GUIDES, CLAMPS, PINS, ETC.
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) | Removal/Installation |
---|---|
REMOVAL AND INSTALLATION OF VACUUM HOSES
*1 | INCORRECT |
*2 | CORRECT |
To disconnect a vacuum hose, pull and twist it from the end of the hose. Do not pull it from the middle of the hose as this may damage the hose.
When disconnecting vacuum hoses, use tags to identify where they should be reconnected.
After completing any hose related repairs, double-check that the vacuum hoses are properly connected. The label under the hood shows the proper layout.
When using a vacuum gauge, never force the hose onto a connector that is too large. If a hose has been stretched, air may leak. Use a step-down adapter if necessary.
TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL
Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with a torque wrench.
Formula
T' = (L2/(L1 + L2))*T
T' | Reading of torque wrench {N*m (kgf*cm, ft.*lbf)} |
T | Torque {N*m (kgf*cm, ft.*lbf)} |
L1 | Length of SST or extension tool {cm (in.)} |
L2 | Length of torque wrench {cm (in.)} |
Note
If an extension tool or SST is combined with a torque wrench and used to tighten to a torque specification in this manual, the actual torque will be excessive and parts will be damaged.
PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE
CAUTION:
The vehicle has a hybrid system that operates at voltages up to 650 V. The hybrid system uses an HV battery that contains an electrolyte which is a strong alkali solution that includes potassium hydroxide. Be sure to follow the instructions in this manual to handle the system correctly. Failure to do so may result in serious injury or electrocution.
Technicians must undergo special training to be able to service and inspect the high-voltage system.
All high-voltage wire harnesses and connectors are colored orange. The HV battery and other high-voltage components have "High Voltage" caution labels. Do not carelessly touch these wires or components.
When there is a problem with the wire harness or connector of a high-voltage circuit, repairs to the harness or connector should not be attempted. Replace damaged or malfunctioning high voltage cables or connectors.
Before inspecting or servicing the high-voltage system, be sure to follow all safety measures, such as wearing insulated gloves and removing the service plug to prevent electrocution. Carry the removed service plug in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.
*1 | Battery Service Hole Cover |
Note
After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.
After removing the service plug, wait 10 minutes before touching any of the high-voltage connectors and terminals.
Tech Tips
Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.
Before using insulated gloves, be sure to check them for cracks, tears and other types of damage by performing the following procedure.
Place the glove on its side.
Roll the opening up 2 or 3 times.
Fold the opening in half to close it.
Confirm that there are no air leaks.
When servicing the vehicle, do not carry metal objects like mechanical pencils or rulers that can be dropped accidentally and cause a short circuit.
Before touching a bare high-voltage terminal, wear insulated gloves and use a tester to make sure that the terminal voltage is 0 V.
After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulating tape.
Bolts and nuts high-voltage terminals should be tightened firmly to the specified torque. Both insufficient and excessive torque can cause failure.
Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION" sign to notify other technicians that the high-voltage system is being inspected and/or repaired.
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 terminals are firmly tightened, and that the connectors are correctly connected.
When installing hybrid system components such as the HV battery, make sure that the polarity of all connections is correct.
PRECAUTIONS TO BE OBSERVED WHEN INSPECTING OR SERVICING ENGINE COMPARTMENT
The vehicle automatically turns the engine on and off when the READY light on the instrument panel is illuminated. To avoid injury, make sure that both the indicator on the power switch and the READY light on the meter are off.
ACTIONS TO BE TAKEN WHEN A WARNING LIGHT IS LIT
*1 | READY Light | *2 | Master Warning Light |
*3 | MIL | *4 | Charge Warning Light |
*5 | Multi-information Display | - | - |
If one of the warning lights (2) to (4) illuminates, connect the intelligent tester to the DLC3 to check the DTCs (Diagnostic Trouble Codes). Then, refer to the applicable troubleshooting steps in this manual to inspect and repair the affected area. The foregoing actions are also required if the READY light does not illuminate when attempting to turn the power switch on (READY).
Indicator Light | Vehicle Condition |
---|---|
(1) READY (TO DRIVE) | Illuminates when the power switch is turned on (READY), indicating that the vehicle is ready to be driven. |
(2) Master Warning Light | The master warning light comes on or flashes to indicate that a warning is currently being displayed on the multi-information display. Depending on the warning, the buzzer may also sound. When any malfunction occurs in the hybrid system or hybrid battery system, the master warning light comes on or flashes along with a buzzer, and a warning, "CHECK HYBRID SYSTEM", is displayed on the multi-information display. |
(3) MIL | Illuminates when there is a malfunction in the engine control system. (Also illuminates when the power switch is turned on.) |
(4) Charge Warning Light | Illuminates when there is a malfunction in the charging system. (Be sure to check the DTC (Diagnostic Trouble Code) if this light illuminates together with the master warning light.) |
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.
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.
Move the shift lever to P and engage the parking brake.
Turn the power switch off and remove the key from the interior detection area.
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.
Tech Tips
Use the booster terminal in the engine compartment.
Connecting Sequence | Connecting Location |
---|---|
1 | Positive booster terminal of stalled vehicle |
2 | Positive battery terminal of rescue vehicle |
3 | Negative battery terminal of rescue vehicle |
4 | Bracket on the cylinder head cover |
Start the engine of the rescue vehicle and run the engine at a speed slightly higher than usual.
Turn the power switch on (READY).
Note
Immediately disconnect the booster cables in the reverse order of connection after the hybrid system and the engine have started. Do not leave the booster cables connected because they are not designed for recharging purposes.
If the hybrid system fails to start and the HV battery warning illuminates, the HV battery may be discharged.
*1 | Master Warning Light | *2 | Multi-information Display |
When the hybrid vehicle battery is depleted:
Replace the hybrid vehicle battery.
Tech Tips
When the hybrid vehicle battery is discharged or low, Low Traction Battery is displayed, and DTC P3000-388, 389, P0AF8-816 is stored in the power management control ECU (HV CPU).
ACTIONS TO BE TAKEN FOR VEHICLES DAMAGED BY IMPACT
CAUTION:
The vehicle has a hybrid system that operates at voltages up to 650 V. The hybrid system uses an HV battery that contains an electrolyte which is a strong alkali solution that includes potassium hydroxide. Be sure to follow the instructions in this manual to handle the system correctly. Failure to do so may result in serious injury or electrocution.
Items to be prepared for the accident site
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)
A shop rag or piece of cloth (for wiping off the electrolyte)
Insulating tape (for insulating cable)
Electrical tester
Actions to be taken at the accident site
CAUTION:
Do not touch any bare cables that may have high-voltage. If a cable must be touched or if accidental contact is possible, wear insulated gloves and insulate the cable using insulating tape.
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.
Visually check the HV battery and the immediate area for any electrolyte leakage. Do not touch any leaked liquid because it could be highly alkaline electrolyte.
Work on the vehicle only after the vehicle has been pulled out of the water.
Check the vicinity of the hybrid vehicle battery for any leakage of the electrolyte.
CAUTION:
Do not touch any leaked liquid because it could be highly alkaline electrolyte. Wear rubber gloves and goggles, neutralize the liquid with saturated boric acid solution, and then apply red litmus paper to the liquid. Check that the paper does not turn blue. Wipe the neutralized liquid with a shop rag or piece of cloth.
If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the following procedure.
CAUTION:
Be sure to wear insulated gloves, goggles, and safety shoes.
*1 | Inverter with Converter Assembly | *2 | Engine Room Junction Block Assembly |
*3 | Engine Room Relay Block No. 2 | *4 | Power Steering Converter Assembly |
*5 | HV battery Assembly | *6 | Auxiliary Battery |
*7 | Rear Traction Motor with Transaxle Assembly | *8 | No. 3 Wire Frame |
*9 | Hybrid Vehicle Transaxle Assembly | *10 | Engine Room Relay Block No. 3 |
*11 | Oil Pump with Motor Assembly | *12 | Water Pump with Motor Assembly |
*13 | Compressor with Motor Assembly | - | - |
*1 | IG2 MAIN Fuse |
*2 | Engine Room Junction Block Assembly |
Turn the power switch off.
Tech Tips
If the power switch cannot be turned off, remove the IG2 MAIN fuse from the engine room junction block assembly. Confirm that the READY Light is OFF.
Disconnect the cable from the negative terminal of the auxiliary battery.
Wear insulated gloves, and then remove the service plug.
Note
After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.
Moving the damaged vehicle
If any of the following conditions are met, tow the vehicle away using a tow truck.
One or more of the high-voltage components and cables are damaged.
Components related to driving, the transaxle, or the fuel system are damaged.
The master warning light is on.
The READY light does not come on when attempting to turn the power switch on (READY).
CAUTION:
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.
Note
Perform the procedure below if the READY light turns off , or there are abnormal noises, unusual smells, or strong vibrations while driving:
Park the vehicle in a safe place.
Move the shift lever to P, and apply the parking brake.
Turn the power switch off, and disconnect the power cable from the negative (-) terminal of the auxiliary battery.
Remove the service plug while wearing insulated gloves.
Actions required after moving the damaged vehicle
Procedure
If you see any liquid on the road surface, it could be highly alkaline electrolyte leakage.
Wear rubber gloves and goggles, neutralize the liquid with saturated boric acid solution, and then apply red litmus paper to the liquid. Check that the paper does not turn blue. Wipe the neutralized liquid with a shop rag or piece of cloth.
Items to be prepared (when repairing a damaged vehicle)
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
A shop rag or piece of cloth (for wiping off the electrolyte)
Insulating tape (for insulating cables)
Electrical tester
Precautions to be observed when servicing a damaged vehicle
CAUTION:
Always follow instructions to ensure safety.
Wear insulated or rubber gloves, goggles, and safety shoes.
Check the HV battery and immediate area for any electrolyte leakage.
CAUTION:
Do not touch any leaked liquid because it could be highly alkaline electrolyte. Wear rubber gloves and goggles, neutralize the liquid with saturated boric acid solution, and then apply red litmus paper to the liquid. Check that the paper does not turn blue. Wipe the neutralized liquid with a shop rag or piece of cloth.
If the electrolyte comes in contact with your skin, use a saturated boric acid solution or a large amount of water to wash it off. If the electrolyte comes in contact with an article of clothing, take it off immediately.
If the electrolyte comes in contact with your eyes, call out loudly for help. Do not rub your eyes. Wash them immediately with a large amount of water and seek medical care.
Do not touch any bare cables that could be high voltage cables. If a cable must be touched or if accidental contact is possible, follow the following instructions: 1) wear insulated gloves and goggles, 2) measure the voltage between the cable and body ground using an electrical tester, and 3) insulate the cable using insulating tape.
If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the procedure below.
CAUTION:
Do not touch any bare cables that may have high-voltage. If a cable must be touched or if accidental contact is possible, wear insulated gloves and insulate the cable using insulating tape.
*1 | IG2 MAIN Fuse |
*2 | Engine Room Junction Block Assembly |
Turn the power switch off.
Tech Tips
If the power switch cannot be turned off, remove the IG2 MAIN fuse from the engine room junction block assembly. Confirm that the READY Light is OFF.
Disconnect the cable from the negative terminal of the auxiliary battery.
Wear insulated gloves, and then remove the service plug.
Note
After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.
Precautions to be taken when disposing of the vehicle
Disposing of HV battery
When scrapping the vehicle, remove the HV battery from the vehicle and return it to the location specified by the manufacturer. Any damaged HV battery should also be returned to the specified location.
CAUTION:
After removing the HV battery, keep it away from water. Water may heat the battery, resulting in a fire.
Accidents such as electric shocks could result if the vehicle and its HV battery are disposed of improperly or abandoned. Therefore, make sure to return any HV battery using the prescribed recovery route through a LEXUS dealer.
Precautions to be observed when towing
Tow the damaged vehicle with its front and rear wheels lifted off the ground.
CAUTION:
Towing the damaged vehicle with its wheels on the ground will cause the motor to generate electricity. This electricity could, depending on the nature of the damage, leak and cause a fire.
Towing with the 4 wheels on the ground
CAUTION:
If the vehicle needs to be towed using a rope with all 4 wheels on the ground, do not exceed 30 km/h (19 mph) and tow only for a short distance and then have the vehicle towed by a truck.
Turn the power switch on (IG) and move the shift lever to N.
If any abnormality is present in the damaged vehicle during towing, stop towing immediately.
FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER
This vehicle is equipped with a Supplemental Restraint System (SRS).
CAUTION:
Before performing pre-disposal deployment of any SRS component, review and closely follow all applicable environmental and hazardous material regulations. Pre-disposal deployment may be considered hazardous material treatment.
Failure to carry out the service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing and lead to serious injury. Furthermore, if a mistake is made when servicing the SRS, it is possible that the SRS may fail to operate properly. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following section carefully.
GENERAL NOTICE
As malfunctions of the SRS are difficult to confirm, the Diagnostic Trouble Codes (DTCs) become the most important source of information when troubleshooting. When troubleshooting the SRS, always check for DTCs before disconnecting the battery.
Work must be started at least 90 seconds after the power switch is turned off and after the cable is disconnected from the negative (-) battery terminal.
The SRS is equipped with a back-up power source. If work is started within 90 seconds after turning the power switch off and disconnecting the cable from the negative (-) battery terminal, the SRS may deploy.
When the cable is disconnected from the negative (-) battery terminal, the clock and audio system memory will be cleared. Before starting work, make a note of the settings of each memory system. When work is finished, reset the clock and audio system as before.
CAUTION:
Never use a back-up power source (battery or other) to avoid clearing the system memory. The back-up power source may inadvertently power the SRS and cause it to deploy.
If the vehicle has been involved in a minor collision where the SRS does not deploy, the steering pad, front passenger airbag assembly, knee airbag assembly, seat side airbag assembly, curtain shield airbag assembly and seat outer belt assembly should be inspected before further use of the vehicle.
Never use SRS parts from another vehicle. When replacing parts, use new parts.
Before repairs, remove the airbag sensor assemblies if impacts are likely to be applied to the sensor during repairs.
Never disassemble and attempt to repair any airbag sensor assemblies or airbag assemblies.
Steering pad
Front passenger airbag assembly
Knee airbag assembly
Seat side airbag assembly
Curtain shield airbag assembly
Seat outer belt assembly
Replace the airbag sensor assemblies and the airbag assemblies if: 1) damage has occurred from being dropped, or 2) cracks, dents or other defects in the case, bracket or connector are present.
Do not directly expose the airbag sensor assemblies or airbag assemblies to hot air or flames.
Use a voltmeter/ohmmeter with high impedance (minimum = 10 kΩ) for troubleshooting electrical circuits.
Information labels are attached to the SRS components. Follow the instructions on the labels.
After work on the SRS is completed, check the SRS warning light.
*1 | Alignment Mark |
SPIRAL CABLE
The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position. Otherwise, cable damage and other problems may occur. Refer to the information about correct installation of the steering wheel Click here.
STEERING PAD
Always place a removed or new steering pad with the surface facing upward as shown in the illustration. Placing the steering pad with the pad surface facing downward could cause a serious accident if the airbag deploys. Also, do not place anything on top of the steering pad.
*1 | CORRECT | *2 | INCORRECT |
Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury.
Grease or detergents of any kind should not be applied to the steering pad.
Store the steering pad in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.
Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
When disposing of the vehicle or the steering pad by itself, the airbag should be deployed using SST before disposal Click here. Deploy the airbag in a safe place away from electrical noise.
FRONT PASSENGER AIRBAG ASSEMBLY
Always place a removed or new front passenger airbag assembly with the pad surface facing upward as shown in the illustration. Placing the airbag assembly with the airbag deployment direction facing downward could cause a serious accident if the airbag deploys.
*1 | CORRECT | *2 | INCORRECT |
Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury.
Grease or detergents of any kind should not be applied to the front passenger airbag assembly.
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.
Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
When disposing of the vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal Click here. Deploy the airbag in a safe place away from electrical noise.
KNEE AIRBAG ASSEMBLY
Always place a removed or new knee airbag assembly with the airbag deployment direction facing upward as shown in the illustration. Placing the airbag assembly with the airbag deployment direction facing downward could cause a serious accident if the airbag deploys.
*1 | CORRECT | *2 | INCORRECT |
Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury.
Grease or detergents of any kind should not be applied to the knee airbag assembly.
Store the knee 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.
Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
When disposing of a vehicle or knee airbag assembly unit by itself, the airbag should be deployed using SST before disposal Click here (for driver side), Click here (for front passenger side)). Deploy the airbag in a safe place away from electrical noise.
SEAT SIDE AIRBAG ASSEMBLY
Always place a removed or new seat side airbag assembly with the airbag deployment direction facing upward.
Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury.
Grease or detergents of any kind should not be applied to the seat side airbag assembly.
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.
Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal Click here (for front side), Click here (for rear side)). Deploy the airbag in a safe place away from electrical noise.
CURTAIN SHIELD AIRBAG ASSEMBLY
Always place a removed or new curtain shield airbag assembly in a clear plastic bag, and keep it in a safe place.
*1 | CORRECT | *2 | INCORRECT |
*3 | Clear Plastic Bag | - | - |
CAUTION:
The plastic bag should be disposed of after use.
Note
Never disassemble the curtain shield airbag assembly.
Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury.
Grease or detergents of any kind should not be applied to the curtain shield airbag assembly.
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.
Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal Click here. Deploy the airbag in a safe place away from electrical noise.
SEAT OUTER BELT ASSEMBLY (SEAT BELT PRETENSIONER)
Never measure the resistance of the seat outer belt assembly. This may cause the pretensioner of the seat outer belt assembly to activate, which could cause serious injury.
Never disassemble the seat outer belt assembly.
Never install the seat outer belt assembly on another vehicle.
Store the seat outer belt assembly in an area where the ambient temperature is below 80°C (176°F), the humidity is not high and there is no electrical noise.
Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
When disposing of a vehicle or the seat outer belt assembly unit by itself, the seat outer belt assembly should be activated before disposal Click here (for front side), Click here (for rear side)). Activate the seat outer belt assembly in a safe place away from electrical noise.
As the seat outer belt assembly is hot after being activated, allow some time for it to cool down sufficiently before disposal. Never apply water to cool down the seat outer belt assembly.
Grease, detergents, oil or water should not be applied to the seat outer belt assembly.
CENTER AIRBAG SENSOR ASSEMBLY
Never reuse a center airbag sensor assembly that has been involved in a collision where the SRS has deployed.
The connectors to the center airbag sensor assembly should be connected or disconnected with the sensor installed to the vehicle. If the connectors are connected or disconnected while the center airbag sensor assembly is not installed, the SRS may activate.
Work must be started at least 90 seconds after the power switch is turned off and the cable is disconnected from the negative (-) battery terminal, even if only loosening the bolts of the center airbag sensor assembly.
WIRE HARNESS AND CONNECTOR
All the connectors in the system are a standard yellow color. If an SRS wire harness has an open circuit or a connector is broken, replace it.
ELECTRONIC CONTROL
*1 | Cable |
*2 | Negative (-) Battery Terminal |
Note
Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
After the power switch is turned off, the display and navigation module display (HDD navigation system) records various types of memory and settings. As a result, after turning the power switch off, make sure to wait for the time specified in the following table before disconnecting the cable from the negative (-) battery terminal.
Specification | Waiting Time |
---|---|
w/o Telematics transceiver | 60 sec. |
w/ Telematics transceiver | 120 sec. |
DISCONNECTING AND RECONNECTING NEGATIVE BATTERY CABLE
Before performing work on electronic components, disconnect the cable from the negative (-) battery terminal to prevent damage to the electrical system or components.
When disconnecting the cable, turn the power switch and headlight switch off and loosen the cable nut completely. Perform these operations without twisting or prying the cable. Then, disconnect the cable.
Clock settings, radio settings, audio system memory, DTCs and other data will be cleared when the cable is disconnected from the negative (-) battery terminal. Write down any necessary data before disconnecting the cable.
*1 | INCORRECT |
HANDLING OF ELECTRONIC PARTS
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.
Do not pull on the wires when disconnecting electronic connectors. Pull on the connector itself.
Do not drop electronic components, such as sensors or relays. If they are dropped on a hard surface, they should be replaced.
When cleaning the engine compartment with steam, protect the electronic components, air filter and emission-related components from water.
Never use an impact wrench to remove or install temperature switches or temperature sensors.
When measuring the resistance between terminals of a wire connector, insert the tester probe carefully to prevent the terminals from bending.
WARNING NOTIFICATION FUNCTION (VEHICLES WITH G-BOOK SERVICE CONTRACT)
Note
Before performing inspections or repairs which may cause warning messages or DTC to occur, such as a simulation test or road test, it is necessary to activate warning notification restraint mode so that the G-BOOK center does not recognize the warnings as real ones.
Warning notification restraint mode can be entered by using the intelligent tester or operating the multi-display.
Tech Tips
The warning notification function sends a warning message signal, received from the combination meter assembly via CAN communication, to the G-BOOK center using the G-BOOK device if a warning is displayed due to a vehicle malfunction.
Warning notification restraint mode
Tech Tips
Performing the following procedure will select warning notification restraint mode.
After warning notification restraint mode is entered, driving the vehicle 10 km (6 mile) will cancel the mode.
Warning notification restraint mode (Using the intelligent tester)
Turn the power switch off.
Connect the intelligent tester to the DLC3.
Start the engine.
Enter the following menus: Powertrain / Engine / DTC.
Warning notification restraint mode (Operating the multi-display)
Enter diagnostic mode of the navigation system (for HDD).
REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
PLACE FOR REMOVING AND INSTALLING FUEL SYSTEM PARTS
Work in a location with good air ventilation that does not have welders, grinders, drills, electric motors, stoves, or any other ignition sources nearby.
Never work in a pit or near a pit as fuel vapors will collect there.
REMOVING AND INSTALLING FUEL SYSTEM PARTS
Prepare a fire extinguisher before starting work.
To prevent static electricity, install a ground wire between the fuel changer and vehicle, and do not spray the surrounding area with water. Be careful when performing work in this area, as the floor 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.
Avoid using electric motors, work lights and other electric equipment that can cause sparks or high temperatures.
Avoid using iron hammers as they may create sparks.
Dispose of fuel-contaminated cloth separately using a fire resistant container.
REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS
If any metal particles enter intake system parts, this may damage the engine.
When removing and installing intake system parts, cover the openings of the removed parts and engine openings. Use adhesive tape or other suitable materials.
When installing intake system parts, check that no metal particles have entered the engine or installed parts.
HANDLING OF HOSE CLAMPS
*1 | Clamp Track |
*2 | Spring Type Clamp |
Before removing a hose, check the clamp position so that it can be reinstalled in the same position.
Replace any deformed or dented clamps with new ones.
When reusing a hose, attach the clamp on the clamp track portion of the hose.
For a spring type clamp, it may be necessary to spread the tabs slightly after installation by pushing them in the direction of the arrows as shown in the illustration.
FOR VEHICLES EQUIPPED WITH MOBILE COMMUNICATION SYSTEMS
Install an antenna as far away from the ECU and sensors of the vehicle electronic systems as possible.
Install an antenna and 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 on the applicable components.
Keep the antenna and feeder separate from other wiring as much as possible. This will prevent signals sent from the communication equipment from affecting vehicle equipment and vice versa.
Check that the antenna and feeder are correctly adjusted.
Do not install a high-powered mobile communication system.
HEADLIGHT INSPECTION OR MAINTENANCE
When the headlight dimmer switch assembly is set to head, do not touch the discharge headlight high-voltage socket area.
Note
When performing inspection or maintenance, the discharge headlight precautions must be followed.
*1 | Illumination for 3 minutes or more prohibited if covered |
When the headlights are illuminated, do not cover the headlights for 3 minutes or more.
Note
As the headlight outer lens is made of resin, the resulting heat created when covering the headlight for an extended period of time may deform the headlight.
FOR VEHICLES EQUIPPED WITH AIR SUSPENSION SYSTEM
Before raising the vehicle using a jack or lift, or working under the vehicle, make sure to disable vehicle height control using the height control OFF switch.
Tech Tips
When vehicle height control is disabled using the height control OFF switch, "HEIGHT CONTROL OFF" will be shown on the multi-information display in the combination meter.
The history that vehicle height control has been disabled using the height control OFF switch will remain even if the cable is disconnected from the negative (-) battery terminal.
Vehicle height control disabled using the height control OFF switch will resume when the vehicle speed reaches 30 km/h (19 mph).
In order to resume vehicle height control disabled using the height control OFF switch, push the height control OFF switch again with the engine running and the power switch on (IG).
FOR VEHICLES EQUIPPED WITH TRACTION CONTROL (TRC) AND VEHICLE STABILITY CONTROL (VSC) SYSTEMS
NOTICES FOR WHEN TESTING WITH DRUM TESTER
When testing with a 2-wheel drum tester such as a speedometer tester, a combination speedometer and brake tester, or a chassis dynamometer, perform the following procedure to enter inspection mode and disable the TRC and VSC systems Click here.
Note
If the vehicle is tested in normal mode on the tester, TRC and VSC operation may cause the vehicle to jump out from the tester.
Check that "FWD Maintenance Mode" is displayed on the multi-information display.
Secure the vehicle with chains for safety.
Tech Tips
Pressing the VSC OFF switch (for vehicles with a VSC OFF switch) does not disable TRC and VSC operation completely.
NOTICES FOR VSC RELATED PROCEDURES
For VSC related parts, adjustments are required after removal and installation. Therefore, perform removal and installation only when necessary.
When performing VSC related procedures, be sure to strictly follow the preparation and completion procedures.
When performing removal and installation or replacement of VSC related parts, first disconnect the cable from the negative (-) battery terminal.
WHEN INSPECTING VEHICLES
Note
If the vehicle is run in the inspection mode, for such as a speedometer test, a DTC may be set. Therefore, if the warning light comes on, after canceling the inspection mode, check for DTCs using the intelligent tester and clear the DTCs.
VEHICLE CONDITIONS
Before activating inspection mode, turn the air conditioning off, start the engine with the shift lever in P, and check the engine stops within several seconds after starting (engine warm up check).
Activate inspection mode and inspect the vehicle Click here.
The shift position for each test is as follows:
Test Item | Inspection Mode | Shift Position |
---|---|---|
1. Vehicle straight travelling test (side slip inspection) | FWD maintenance mode, AWD maintenance mode or normal | D |
2. Braking force test | Normal | N |
3. Speedometer test | FWD maintenance mode or AWD maintenance mode | D |
4. Exhaust gas test (idling) | FWD maintenance mode or AWD maintenance mode | P |
5. Headlight test | FWD maintenance mode, AWD maintenance mode or normal | P |
Reset inspection mode immediately after completion of inspection.
Note
Driving the vehicle without resetting inspection mode may damage the transaxle.
WHEN USING A BRAKE TESTER
Tech Tips
When inspecting the brakes using the brake tester, the braking force of the rear wheels may be reduced. When the vehicle speed is 0 km/h (0 mph), the brake control system of the vehicle limits the rear brake fluid pressure to approximately 50% of the normal brake fluid pressure when driving the vehicle, in order to reduce energy consumption.
Note
A high-speed type brake tester cannot be used.
Vehicle speed should be less than 0.5 km/h (0.3 mph).
Follow all usage and safety procedures in the operator's manual for the brake tester.
Place the wheels to be tested (front or rear) onto the rollers.
Move the shift lever to N.
Start the engine to allow normal brake booster operation.
Operate the brakes to perform the test.
WHEN USING A SPEEDOMETER TESTER
CAUTION:
Be sure to perform the test in the FWD inspection mode.
Note
Do not use a chassis dynamometer to perform rapid starting or quick acceleration/deceleration without first setting the proper load on the dynamometer. Failing to set the load may damage the transaxle.
Depress the accelerator pedal slowly and gradually accelerate the vehicle. Make a measurement.
After the measurement, use the brakes to gradually decelerate the vehicle.
WHEN USING A CHASSIS DYNAMOMETER
Always set an appropriate load before starting the test.
Note
Sudden acceleration or deceleration of the vehicle on a chassis dynamometer under minimal load may damage the transaxle.
WHEN USING AN ON-VEHICLE BALANCER
Raise the vehicle until all 4 wheels are off the ground.
Support the vehicle with safety stands at an appropriate height. Make sure that vehicle does not lean in any direction, and that the tires are completely clear of the floor.
Place the vibration pick-up unit into position for the wheel to be measured*1.
Release the parking brake.
Check that no dragging force exists when turning each wheel by hand.
Put the wheel balancer in position.
Wheel balance measurement should be done by using both the engine and the wheel balancer drive roller to spin the wheels.
Tech Tips
*1: Different on-vehicle wheel balancers have different requirements for mounting the vibration pick-up unit(s). Refer to the operator's manual for the wheel balancer to confirm requirements for use.
Note
Be sure to perform the test in FWD maintenance mode.
Start the engine and then increase the vehicle speed gradually with the shift lever in D.
Do not accelerate or decelerate suddenly.
Deceleration should be done by braking gradually.
Make sure that no one is standing in-line with the spinning wheels.
Measurement should be done quickly.
Confirm that the vehicle is securely immobilized.
Follow all usage and safety procedures in the operator's manual for the wheel balancer.
WHEN TOWING AWD VEHICLES
Use one of the following methods to tow the vehicle.
If the vehicle has trouble with the chassis or drive train, use method 1 (flat bed truck).
Note
Do not use any towing method other than those shown above.
If a tow truck is not available, in an emergency 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 short distances below 30 km/h (19 mph).
A driver must be in the vehicle to steer and operate the brakes. The vehicle's wheels, drive train, axles, steering and brakes must be in good condition.
Emergency towing procedure
Release the parking brake.
Shift the shift lever to N.
Turn the power switch on (IG).
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.
If the hybrid system is off, the power assist for the brakes and steering will not function, making steering and braking more difficult.
The following towing methods shown below are dangerous and can damage the vehicle, so do not use them.
Do not tow the vehicle with only two wheels on the ground.
Do not use a sling-type towing method either from the front or rear.
Note
If these towing methods are used either from the front or rear, the following may occur.
The drive train may overheat and be damaged and the wheels may come off the dolly.
If a sling-type tow truck is used, damage may occur to the vehicle body.
WHEN TOWING FWD VEHICLES
Use one of the following methods to tow the vehicle.
If the vehicle has trouble with the chassis or drive train, use method 1 (flat bed truck).
Note
Do not use any towing method other than those shown above.
If a tow truck is not available, in an emergency 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 short distances below 30 km/h (19 mph).
A driver must be in the vehicle to steer and operate the brakes. The vehicle's wheels, drive train, axles, steering and brakes must be in good condition.
Emergency towing procedure
Release the parking brake.
Shift the shift lever to N.
Turn the power switch on (IG).
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.
If the hybrid system is off, the power assist for the brakes and steering will not function, making steering and braking more difficult.
The following towing methods shown below are dangerous and can damage the vehicle, so do not use them.
Do not tow the vehicle with only front wheels on the ground.
Do not use a sling-type towing method either from the front or rear.
Note
If these towing methods are used either from the front or rear, the following may occur.
The drive train may overheat and be damaged.
If a sling-type tow truck is used, damage may occur to the vehicle body.
ALARM NOTIFICATION FUNCTION (VEHICLES WITH G-BOOK SERVICE CONTRACT)
If the vehicle's automatic alarm is activated, the G-BOOK center makes a phone call to the customer.
Note
When servicing the vehicle, ensure that the vehicle does not experience any conditions that cause a telephone call to be made by a G-BOOK operator.
Before performing inspections or repairs which may activate the alarm notification function, be sure to inform the customer that they may receive a telephone call from a G-BOOK operator.
Tech Tips
Customers can cancel the alarm notification on the display and navigation module display screen.
STRICT PROHIBITION OF MANUAL EMERGENCY CALL USING EMERGENCY CALL SERVICE (VEHICLES WITH G-BOOK SERVICE CONTRACT)
Do not make an emergency call when not in emergency situations. For inspections, use the manual maintenance check.
Note
If the emergency call service is used to connect to the G-BOOK center when not in an emergency situation, an unnecessary workload will be generated at the G-BOOK center. This may cause a delayed response by the G-BOOK center to other emergency calls.
If emergency vehicles are dispatched due to an accidental operation of the telephone switch assembly, you may be charged for the vehicle or punished according to related laws.
If an accidental operation of the telephone switch assembly is made:
Contact the G-BOOK center to tell that the call was made by mistake.
The emergency call cannot be halted or finished from the vehicle. Only the G-BOOK center can halt or finish the call.
If the G-BOOK center cannot be informed that the call was made by mistake, the center will report to authorities, emergency facilities and dealerships in compliance with its agreements. As a result, emergency vehicles may be dispatched.
FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER
CAUTION:
If a large amount of unburned gasoline or gasoline vapors flow into the converter, it may cause converter overheating and create a fire hazard. To prevent this, observe the following precautions:
Use only unleaded gasoline.
Avoid performing unnecessary spark tests.
Perform a spark test only when absolutely necessary. Perform this test as rapidly as possible with the injector connector disconnected.
While testing, never race the engine unless instructed.
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.