RX4000h 3MZ FE maintenance power window wireless remote Cửa sổ điện bảo trì RX4000h 3MZ FE không dây từ xa

3.ACTIONS TO BE TAKEN WHEN THE WARNING LIGHT IS LIT Warning Light Vehicle Condition 1 READY TO DRIVE Illuminates when the ignition switch is turned to the START position, this indicates

3MZ-FE ENGINE MECHANICAL > ENGINE > ON-VEHICLE INSPECTION

a. Remove the radiator cap

CAUTION:

Do not remove the radiator cap while the engine and radiator are still hot Thermal

expansion will cause hot engine coolant and steam to blow out from the radiator

b. Check if there are any excessive deposits of rust or scales around the radiator cap and

radiator filler hole The coolant should be free of oil

HINT:

If excessively dirty, clean the coolant passage and replace the coolant

c. Install the radiator cap

a. Warm up the engine and then wait for 5 minutes after turning the engine off, the oil level should be between the low level and full level marks of the dipstick

If low, check for leakage and add oil up to the full level mark

NOTICE:

Do not fill with engine oil above the full level mark

Standard specific gravity:

1.25 to 1.29 at 20°C (68°F)

a. Remove the air cleaner filter element from the air cleaner case

b. Visually check that there is no dirt, clog, and damage to the air cleaner filter element

NOTICE:

z Do not use a wire brush for cleaning

z Do not attempt to adjust the electrode gap of a used spark plug

a. Check the electrode

i. Using a megaohmmeter, measure the

insulation resistance

Correct insulation resistance:

10 MΩ or higher

If the resistance is less then the

specified value, proceed to step (b)

HINT:

If a megaohmmeter is not available,

perform the following simple

inspection instead

b. Alternative inspection method:

i. Quickly accelerate the engine to 4,000

rpm 5 times

ii. Remove the spark plug

iii. Visually check the spark plug

Result:

iv. Reinstall the spark plug

c. Check the spark plug for any damage to

its threads and insulator

If there is any damage, replace the spark

plug

INSPECT SPARK PLUG

Electrode condition Next step

Dry Go to next step

Wet Proceed to step (c)

d. Check the spark plug electrode gap.

Maximum electrode gap for used

spark plug:

1.3 mm (0.051 in.)

If the gap is greater than the maximum,

replace the spark plug

Correct electrode gap for new spark

plug:

1.0 to 1.1 mm (0.039 to 0.043 in.)

e. Clean the spark plugs

If the electrode has traces of wet carbon,

clean the electrode with a spark plug

cleaner and then dry it

If there are traces of oil, remove them

with gasoline before using the spark plug cleaner

a. Set the vehicle to inspection mode (Refer to INTRODUCTION > REPAIR INSTRUCTION > PRECAUTION(200503 - ))

Recommended spark plug:

DENSO made SK20R11

NGK made IFR6A11

INSPECT IGNITION TIMING

b. Warm up the engine.

c. When using the intelligent tester:

i. Connect the intelligent tester (with CAN VIM) to the DLC3

ii. Enter DATA LIST MODE on the intelligent tester

Ignition timing:

8 to 12° BTDC

NOTICE:

z Turn all the electrical systems off

z Inspect the engine idle speed with the cooling fan off

HINT:

Refer to the intelligent tester operator's manual if you need help to select DATA LIST

iii. Check that the ignition timing advances immediately when the engine speed is increased

d. When not using the intelligent tester:

i. Using SST, connect terminals 13 (TC)

and 4 (CG) of the DLC3

SST

09843-18040

NOTICE:

z Make sure of the terminal

numbers before connecting them Connection with a wrong terminal can damage the engine

z Turn off all electrical systems

before connecting the terminals

z Perform this inspection after the cooling fan motor is turned off

ii. Pull out the red-colored wire harness

as shown in the illustration

iii. Connect the tester terminal of the

timing light to the engine

v. Disconnect terminals 13 (TC) and 4 (CG) of the DLC3.

vi. Inspect ignition timing at idle

Ignition timing:

7 to 24° BTDC

vii. Confirm that the ignition timing advances when the engine rpm is increased

viii. Remove the timing light

a. Set the vehicle to inspection mode (Refer to INTRODUCTION > REPAIR INSTRUCTION > PRECAUTION(200503 - ))

b. Warm up the engine

c. Connect the intelligent tester (with CAN VIM) to the DLC3

d. Enter DATA LIST MODE on the intelligent tester

Idle speed:

850 to 950 rpm

NOTICE:

z When checking the idle speed, the transmission is in neutral

z Check the idle speed with the cooling fan off

z Switch off all accessories and air conditioning before connecting the intelligent tester

HINT:

Refer to the intelligent tester operator's manual for further details

a. Set the vehicle to inspection mode (Refer to INTRODUCTION > REPAIR INSTRUCTION > PRECAUTION(200503 - ))

b. Warm up and stop the engine

INSPECT ENGINE IDLE SPEED

INSPECT COMPRESSION

c. Remove the intake air surge tank (Refer to 3MZ-FE ENGINE CONTROL SYSTEM > KNOCK SENSOR > REMOVAL(200503 - )).

NOTICE:

If the throttle body connector is disconnected because the DTC is detected in inspection, always reconnect it

d. Disconnect the injector connectors

e. Remove the ignition coils

NOTICE:

If the ignition coil assembly connector is disconnected because the DTC is detected in

inspection, always reconnect it

f. Remove the spark plugs

g. Inspect cylinder compression pressure

i. Insert a compression gauge into the

spark plug hole

ii. Connect the intelligent tester (with

CAN VIM) to the DLC3

NOTICE:

Check the fully charged battery to

indicate HV battery voltage in ECU

z Check other cylinder's compression pressure in the same way

z This measurement must be done as quickly as possible

z After performing all the procedures, be sure to clear DTCs stored in the the memory Then, check that the normal system code is output

v. If the cylinder compression is low, pour a small amount of engine oil into the cylinder

through the spark plug hole and inspect again.

b. Start the engine

c. Run the engine at 2,500 rpm for approximately 180 seconds

d. Insert the CO/HC meter testing probe at

least 40 cm (1.3 ft) into the tailpipe

during idling

e. Check CO/HC concentration at idle

and/or 2,500 rpm

HINT:

When doing the 2 mode (with the

engine is in the idle and 2,500 rpm)

test, the measuring procedures are

prescribed by the applicable local

2 Incorrect valve clearance

3 Leaks in intake and exhaust valves

4 Leaks in cylinders

Low High

Rough idle (Fluctuating HC reading)

1 Vacuum leaks:

z PCV hoses

z Intake manifold

z Throttle body

z Brake booster line

2 Lean mixture causing misfire

High High Rough idle (Black smoke

from exhaust)

1 Restricted air filter

2 Plugged PCV valve

3 Faulty EFI systems:

z Faulty pressure regulator

z Defective water temperature sensor

z Defective mass air-flow meter

z Faulty ECM

z Faulty injectors

z Faulty throttle position sensor

INTRODUCTION > REPAIR INSTRUCTION > PRECAUTION

a. HINTS ON OPERATIONS

1.BASIC REPAIR HINT

1 Attire

z Always wear a clean uniform

z 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 Safety operation

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

z When working with the engine running, make sure

to provide ventilation for exhaust fumes in the workshop

z 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

z When jacking up the vehicle, be sure to support the specified location with a safety stand

b. JACKING UP AND SUPPORTING VEHICLE

i. Care must be taken when jacking up and supporting the vehicle Be sure to lift and

support the vehicle at the proper locations

c. PRECOATED PARTS

i. Precoated parts are bolts and nuts

that are coated with a seal lock

adhesive at the factory

ii. If a precoated part is retightened,

loosened or moved in any way, it

must be recoated with the specified

adhesive

iii. When reusing a precoated part, clean

off the old adhesive and dry the part

with compressed air Then apply new seal lock adhesive appropriate to that part

z When lifting up the vehicle, use appropriate safety equipment

4 Preparation of tools and measuring

z When the assembly is complicated, take notes For example, note the total number of electrical

connections, bolts, or hoses removed Add matchmarks to insure reassembly of components in the original positions Temporarily mark hoses and their fittings if needed

z Clean and wash the removed parts if necessary and assemble them after a thorough check

6 Removed parts

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

contaminating the new parts

z For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them with new ones

as instructed in this manual

z Retain the removed parts for customer inspection, if requested

iv. Some seal lock agents harden slowly You may have to wait for the seal lock adhesive to harden.

d. GASKETS

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

e. BOLTS, NUTS AND SCREWS

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

f. FUSES

i. When inspecting a fuse, check that

the wire of the fuse is not broken

ii. When replacing fuses, be sure that the

new fuse has the correct amperage

rating Do not exceed the rating or

use one with a lower rating

Shape (Example) Removal/Installation

Remove clips with clip remover or pliers

Remove fasteners with clip remover or screwdriver

Remove clips with wide scraper to preventpanel damage

Remove clips by pushing center pin througand prying out shell

h. REMOVAL AND INSTALLATION OF VACUUM HOSES

i. 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 damage the hose

ii. When disconnecting vacuum hoses,

use tags to identify where they should

be reconnected

iii. After completing any hose related

repairs, double check that the vacuum

hoses are properly connected The

label under the hood shows the proper

layout

iv. 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

i. TORQUE WHEN USING TORQUE WRENCH

WITH EXTENSION TOOL

i. Use the formula below to calculate

special torque values for situations

where SST or an extension tool is

combined with the torque wrench

Formula:

T' = L2/(L1 + L2) * T

NOTICE:

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

NOTICE:

The RX400h hybrid system contains a 288V high-voltage system with a strong alkali solution of 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

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

b. All voltage wire harness connectors are colored orange The HV battery and other voltage components have "High Voltage" caution labels Do not carelessly touch these wires and components

high-c. Before inspecting or servicing the

high-voltage system, be sure to follow 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 reinstalling it

while your are servicing the vehicle

NOTICE:

Do not put the vehicle into the

READY-on state after removing the service plug

(kgf*cm, ft.*lbf)}

L1 Length of SST or extension tool {cm

(in.)}

L2 Length of torque wrench {cm (in.)}

2.PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE

grip as the ECU may be damaged

d. After removing the service plug, wait 5

minutes before touching any of the

high-voltage connectors and terminals

HINT:

5 minutes are required to discharge the

high-voltage condenser inside the

inverter

e. Before wearing insulated gloves, make

sure that they are not cracked, ruptured,

torn, or damaged in any way Do not

wear wet insulated gloves

f. When servicing the vehicle, do not carry

metal objects like mechanical pencils or

scales that can be dropped accidentally

and cause a short circuit

g. Before touching a bare high-voltage

terminal, wear insulated gloves and use a

tester to make sure that the terminal

voltage is 0 V

h. After disconnecting or exposing a

high-voltage connector or terminal, insulate it

immediately using insulation tape

i. The screw of a high-voltage terminal

should be tightened firmly to the

specified torque Both insufficient and

excessive torque can cause failure

j. 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

k. 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.

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

a. If one of the warning lights (2) to (5) becomes lit, connect an intelligent tester to the DLC3 connector 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 the vehicle is first started

3.ACTIONS TO BE TAKEN WHEN THE WARNING LIGHT IS LIT

Warning Light Vehicle Condition

(1) READY (TO DRIVE)

Illuminates when the ignition switch is turned to the START position, this indicates that the vehicle is ready to be driven

(2) Master Warning Light

Blinks, illuminates, or sounds a buzzer that

is synchronized with the warning light of the multi-display

z Driving with doors opened

z Parking brake applied

z Washer fluid shortage

z VSC system malfunction

z Low Engine oil pressure

The following problems indicate that the auxiliary battery is depleted:

z No display appears on the instrument panel when the ignition switch is set to ON

z The hybrid system does not start

z The headlights are dim

z The sound from the horn is weak

CAUTION:

Never use a quick charger

z Engine coolant temperature malfunction

z Hybrid system malfunction

z 4WD system malfunction

z Moon roof is opened

z Shift lever is in the P position

(3) HV Battery Warning Light

z Illuminates when the hybrid vehicle battery is depleted

(This occurs when the vehicle remains parked for a prolonged length of time.)

z Illuminates when SOC (state of charge)

is low

(This occurs when the vehicle is being powered by the motor, due to a system malfunction After the malfunction is repaired, the hybrid vehicle battery can

be used.)

(4) Auxiliary Battery 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 MASTER WARNING.)

(5) Check Engine Warning Light Illuminates when there is a malfunction in the engine control system

(Illuminates with the ignition switch ON.)

4.ACTIONS TO BE TAKEN WHEN BATTERIES ARE DEPLETED

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

ii. Remove the key from the ignition switch

iii. Remove the 2 clips and engine room

cover side

iv. Using a booster cable, connect the 12

V battery of the rescue vehicle and

the auxiliary battery of the stalled

vehicle, as shown in the illustration

v. Start the engine of the rescue vehicle and run the engine at a speed slightly higher than usual

vi. Put the vehicle into the READY-on

state to start the hybrid system

Connecting

Sequence Connecting Location

1 Positive battery terminal of stalled

NOTICE:

Immediately disconnect the booster

cable in the reverse order of

connection after the hybrid system

and the engine have started Do not

leave the booster cable connected

because it is not designed for

recharging purposes

If the hybrid system fails to start and

the HV warning light turns ON, the HV

battery may be depleted

b. When the hybrid vehicle battery is

z The RX400h is equipped with the 4WD system by which the rear wheels are electronically controlled by the motor, VSC system, and TRC system Therefore, it is necessary to switch

to the 2WD operation mode and cancel all of these systems when only the front wheels are required to be rotated on a chassis dynamometer

a. Change to the inspection mode

b. Activating 2WD inspection mode (Not using the intelligent tester)

Perform the following steps from (1) through (4) in 60 seconds

i. Turn the ignition switch to the ON position

ii. Fully depress the accelerator pedal twice times with the transmission P position

iii. Fully depress the accelerator pedal twice times with the transmission N position

iv. Fully depress the accelerator pedal twice times with the transmission P position

v. Check that the HV system warning light flashed on the multi-information display

vi. Start the engine by turning the ignition switch while depressing the brake pedal

c. Activating 2WD inspection mode (Using the intelligent tester)

5.INSPECTION MODE

i. Connect the intelligent tester to the DLC3.

ii. Turn the ignition switch to the ON position

iii. Turn the intelligent tester on

iv. Select following menu items: DIAGNOSIS / OBD / MOBD / HV ECU / ACTIVE TEST /

INSPECTION MOD1 / ON

v. Check that the HV system warning light flashers on the multi-information display and the master warning light is illuminated in the combination meter

vi. Start the engine by turning the ignition switch while depressing the brake pedal

d. Activating 4WD inspection mode (Not using the intelligent tester)

Perform the following steps from (1) through (4) in 60 seconds

i. Turn the ignition switch to the ON position

ii. Fully depress the accelerator pedal four with the transmission P position

iii. Fully depress the accelerator pedal four with the transmission N position

iv. Fully depress the accelerator pedal four with the transmission P position

v. Check that the HV system warning light flashed on the multi-information display

vi. Start the engine by turning the ignition switch while depressing the brake pedal

e. Activating 4WD inspection mode (Using the intelligent tester)

i. Connect the intelligent tester to the DLC3

ii. Turn the ignition switch to the ON position

iii. Turn the intelligent tester on

iv. Select following menu items: DIAGNOSIS / OBD / MOBD / HV ECU / ACTIVE TEST /

INSPECTION MOD3 / ON

v. Check that the HV system warning light flashers on the multi-information display and the master warning light is illuminated in the combination meter

vi. Start the engine by turning the ignition switch while depressing the brake pedal

6.SPECIAL NOTES FOR VEHICLE INSPECTION

CAUTION:

If the vehicle is run in the 2WD inspection mode, for such as a speedometer test, DTC ●●●●● may be output Therefore, if the warning light comes on, after canceling the 2WD inspection mode, check for DTCs using the intelligent tester and clear the DTCs

a. Vehicle conditions

i. Before activating inspection mode, turn the air conditioning off, start the engine with the shift lever in the P position, and check the engine stops within several seconds after

starting (engine warm up check)

ii. Activate inspection mode and inspect the vehicle

Shift position for each test:

iii. Reset inspection mode immediately after completion of inspection

z Be sure to perform the test in the 2WD inspection mode

z Do not use the speedometer tester to perform rapid starting or quick

acceleration/deceleration without first setting the proper load on the vehicle Failing to set the load may damage the transaxle

i. Depress the accelerator pedal slowly and gradually accelerate the vehicle Make a

measurement

ii. After the measurement, use the brake to gradually decelerate the vehicle

c. Special notes for using the chassis dynamometer

i. Always set an appropriate load before starting the test

3 Speedometer test 2WD inspection mode D

4 Exhaust gas test (idling) 4WD inspection mode P

5 Headlight test 4WD inspection mode or normal P

Suddenly acceleration or deceleration of the vehicle on a chassis dynamometer under minimal load may damage the transaxle

d. Activating 2WD inspection mode (Not using the intelligent tester)

Perform the following steps from (1) through (4) in 60 seconds

i. Turn the ignition switch to the ON position

ii. Fully depress the accelerator pedal twice times with the transmission P position

iii. Fully depress the accelerator pedal twice times with the transmission N position

iv. Fully depress the accelerator pedal twice times with the transmission P position

v. Check that the HV system warning light flashed on the multi-information display

vi. Start the engine by turning the ignition switch while depressing the brake pedal

e. Activating 2WD inspection mode (Using the intelligent tester)

i. Connect the intelligent tester to the DLC3

ii. Turn the ignition switch to the ON position

iii. Turn the intelligent tester on

iv. Select following menu items: DIAGNOSIS / OBD / MOBD / HV ECU / ACTIVE TEST /

INSPECTION MOD1 / ON

v. Check that the HV system warning light flashers on the multi-information display and the master warning light is illuminated in the combination meter

vi. Start the engine by turning the ignition switch while depressing the brake pedal

f. Activating 4WD inspection mode (Not using the intelligent tester)

Perform the following steps from (1) through (4) in 60 seconds

i. Turn the ignition switch to the ON position

ii. Fully depress the accelerator pedal four with the transmission P position

iii. Fully depress the accelerator pedal four with the transmission N position

iv. Fully depress the accelerator pedal four with the transmission P position

v. Check that the HV system warning light flashed on the multi-information display

vi. Start the engine by turning the ignition switch while depressing the brake pedal

g. Activating 4WD inspection mode (Using the intelligent tester)

i. Connect the intelligent tester to the DLC3.

ii. Turn the ignition switch to the ON position

iii. Turn the intelligent tester on

iv. Select following menu items: DIAGNOSIS / OBD / MOBD / HV ECU / ACTIVE TEST /

INSPECTION MOD3 / ON

v. Check that the HV system warning light flashers on the multi-information display and the master warning light is illuminated in the combination meter

vi. Start the engine by turning the ignition switch while depressing the brake pedal

h. Deactivating inspection mode

i. Turn the ignition switch off The HV main system turns off simultaneously

CAUTION:

z The idling speed in inspection mode is approximately 1,000 rpm The engine speed increases to 1,500 rpm if the accelerator pedal is depressed by less than 60 % If the accelerator pedal is depressed by more than 60%, the engine speed increases to 2,500 rpm

z If a DTC is set during inspection mode, the master warning light and the warning massage illuminate on the multi-information display

z When the master warning light illuminates during the inspection mode, deactivate the inspection mode, and check DTC(s)

z Driving the vehicle without deactivating the inspection mode may damage the

transaxle

NOTICE:

The RX400h hybrid system contains a 288V high-voltage system with a strong alkali solution of 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

a. Items to be prepared or operation at the accident site

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

z Saturated boric acid solution 20 L (obtain 800 g of boric acid powder, put it into a

container, and dissolve it in water)

z Red litmus paper

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

z A shop rag or piece of cloth (for wiping off the electrolyte)

z Insulation tape (for insulating cable)

z Electrical tester

b. Actions to be taken at the accident site

7.ACTIONS TO BE TAKEN FOR VEHICLE DAMAGED BY IMPACT

NOTICE:

Do not touch a bare cable that may have high-voltage If the cable must be touched or if accidental contract is unavoidable, wear insulated gloves and insulate the cable using

insulation tape

z 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

z 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

z Work on the vehicle only after the vehicle has been pulled out of the water

i. Check the vicinity of the hybrid vehicle battery for any leakage of the electrolyte

NOTICE:

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 leak Check that the paper does not turn blue Wipe the neutralized liquid with a shop rag or piece of cloth

ii. If damage to any of the voltage components and cable is suspected, cut the voltage circuit using the procedure on the following pages

high-iii. Turn the ignition switch off.

HINT:

If the ignition switch cannot be

turned off, remove the IGCT No.1

fuse from the HV relay block or

disconnect the cable from the

negative terminal of the auxiliary

battery

iv. Wear insulated gloves, and then

remove the service plug

NOTICE:

Be sure to install the service plug before turning on the ignition switch Starting the hybrid system with the service plug removed may damage the ECU

c. Moving the damaged vehicle

If any of the following conditions are met, tow the vehicle away using a tow truck

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

z The driving, traction, or fuel system is damaged

z The master warning light is on

z The READY light does not come on

when the vehicle is in the READY-on

state

CAUTION:

z 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

NOTICE:

Perform the procedure below if the

READY light turns off , or there are

abnormal noises, unusual smells, or strong vibrations while driving:

i. Park the vehicle in a safe place

ii. Shift the shift lever to the "P" position, and apply the parking brake

iii. Turn the ignition switch off, and disconnect the power cable from the negative (-) terminal

of the auxiliary battery

iv. Remove the service plug while wearing insulated gloves

d. Actions required after moving the damaged vehicle

i. 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 leak Check that the paper does not turn blue Wipe the neutralized liquid with a shop rag or piece of cloth

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

z Protective clothing (Insulated gloves, rubber gloves, goggles, and safety shoes)

z Saturated boric acid solution 20 L (obtain 800 g of boric acid powder, put it into a

container, and dissolve it in water)

z Red litmus paper

z Shop rags (for wiping off the electrolyte)

z Vinyl tape (for insulating cable)

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

ii. Check the HV battery and immediate area for any electrolyte leakage

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 leak Check that the paper does not turn blue Wipe the

neutralized liquid with a shop rag or piece of cloth

NOTICE:

z 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

z 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

iii. Do not touch a bare cable that could be a high voltage cable If the cable must be touched

or if accidental contact is unavailable, follow the following 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 insulation tape

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

high-NOTICE:

Do not touch a bare cable that may have high-voltage If the cable must be touched or if accidental contract is unavoidable, wear insulated gloves and insulate the cable using insulation tape

v. Turn the ignition switch off

HINT:

If the ignition switch cannot be turned off, remove the IGCT No.1 fuse from the HV relay block or disconnect the cable from the negative terminal of the auxiliary battery

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

g. Precautions to be taken when disposing of the vehicle

z Accidents such as electric shocks could result if the vehicle and its hybrid vehicle

battery are disposed of improperly or abandoned Therefore, make sure to return any hybrid battery to the prescribed recovery route through a LEXUS dealer

i. Precautions to be observed when towing

i. Tow the damaged vehicle with its front and rear wheels lifted off the ground

CAUTION:

Towing the damaged vehicle with its front wheels on the ground may cause the motor to generate electricity This electricity could, depending on the nature of the damage, leak and cause a fire

j. Towing with the 4 wheels on the ground

CAUTION:

z If the damaged vehicle needs to be towed using a rope, do not exceed 30 km/h (19 mph) and tow a limit distance and then have the vehicle towed by a truck

z Turn the ignition switch to the ON position and shift the selector lever to the N position

z If any abnormality is present in the damaged vehicle during towing, stop towing

immediately

The LEXUS RX400h is equipped with a Supplemental Restraint System (SRS)

CAUTION:

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 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

a. GENERAL NOTICE

i. 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 the DTCs before disconnecting the battery

ii. Work must be started at least 90 seconds after the ignition 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 ignition 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, clock and audio system memory is erased 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

(Refer to SUPPLEMENTAL RESTRAINT SYSTEM > STEERING PAD > DISPOSAL(200503 - ) for steering pad)

(Refer to SUPPLEMENTAL RESTRAINT SYSTEM > FRONT PASSENGER AIRBAG ASSEMBLY > DISPOSAL(200503 - ) for front passenger airbag assembly)

(Refer to SUPPLEMENTAL RESTRAINT SYSTEM > DRIVER SIDE KNEE AIRBAG ASSEMBLY > DISPOSAL(200503 - ) for front seat side airbag assembly)

(Refer to SUPPLEMENTAL RESTRAINT SYSTEM > FRONT SEAT SIDE AIRBAG ASSEMBLY > DISPOSAL(200503 - ) for driver side knee airbag assembly)

(Refer to SUPPLEMENTAL RESTRAINT SYSTEM > CURTAIN SHIELD AIRBAG ASSEMBLY > DISPOSAL(200503 - ) for curtain shield airbag assembly)

(Refer to SEAT BELT > FRONT SEAT OUTER BELT ASSEMBLY > DISPOSAL(200503 - ) for front seat outer belt assembly)

iv. Never use SRS parts from another vehicle When replacing parts, use new parts

v. Before repairs, remove the airbag sensor assemblies if impacts are likely to be applied to the sensor during repairs

vi. Never disassemble and attempt to repair all airbag sensor assemblies and all airbag

assemblies

1 Steering pad

2 Front passenger airbag assembly

3 Driver side knee airbag assembly

4 Front seat side airbag assembly

5 Curtain shield airbag assembly

6 Front seat outer belt assembly

vii. 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

viii. Do not directly expose the airbag sensor assembly or airbag assembly to hot air or flames

ix. Use a voltmeter / ohmmeter with high impedance (minimum=10 kΩ) for troubleshooting electrical circuits

x. Information labels are attached to the SRS components Follow the instructions on the labels

xi. After work on the SRS is completed, check the SRS warning light

b. SPIRAL CABLE

i. 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 (Refer to

SUPPLEMENTAL RESTRAINT SYSTEM

> SPIRAL CABLE > INSPECTION

(200503 - ))

c. STEERING PAD

i. Always place a removed or new steering pad surface upward as shown in the illustration Placing the horn button with the pad surface facing down could cause a serious accident if the airbag inflates Also, do not place anything on top of the horn button

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

iii. Grease or detergents of any kind should not be applied to the horn button

iv. Store the horn button 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

v. When using electric welding anywhere on the vehicle, disconnect the airbag ECU

connectors (4 pins) These connectors contain shorting springs This feature reduces the possibility of the airbag deploying due to current entering the squib wiring

vi. When disposing of the vehicle or the horn button assembly by itself, the airbag should be deployed using SST before disposal (Refer to SUPPLEMENTAL RESTRAINT SYSTEM > STEERING PAD > DISPOSAL(200503 - )) Activate the airbag in a safe place away from electrical noise

d. FRONT PASSENGER AIRBAG ASSEMBLY

i. 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 inflation direction facing down could cause a serious accident if the airbag inflates

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

iii. Grease or detergents of any kind should not be applied to the front passenger airbag assembly

iv. 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

v. When using electric welding anywhere on the vehicle, disconnect the airbag ECU

connectors (4 pins) These connectors contain shorting springs This feature reduces the possibility of the airbag deploying due to current entering the squib wiring

vi. When disposing of the vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal (Refer to SUPPLEMENTAL RESTRAINT SYSTEM > FRONT PASSENGER AIRBAG ASSEMBLY > DISPOSAL(200503 - )) Activate in a safe place, away from electrical noise

e. DRIVER SIDE KNEE AIRBAG ASSEMBLY AND FRONT PASSENGER SIDE KNEE AIRBAG