Introduction: Overview Lexus HS I

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1. GENERAL DESCRIPTION This information is written in accordance with SAE J2008. Repair operations can be separated mainly into the following 3 processes: Diagnosis Removing / Installing, Replacing, Disassembling / Reassembling, Checking and Adjusting Final Inspection The following procedure is omitted from this article. However, this procedure must be performed. Use a jack or lift to perform operations. Clean all removed parts. Perform a visual check before and after performing any work.
2. INDEX An alphabetical INDEX is provided at the end of the article as a reference to help find the item to be repaired.
3. PREPARATION Use of Special Service Tools (SST) and Special Service Materials (SSM) may be required, depending on the repair procedure. Be sure to use SST and SSM when they are required and follow the work procedure properly. A list of SST and SSM is in the "Preparation" article of this article.
4. REPAIR PROCEDURES A component illustration is placed under the title where necessary. Non-reusable parts, grease application areas, precoated parts and torque specifications are noted in the component illustrations. The following illustration is an example. Torque specifications, grease application areas and non-reusable parts are emphasized in the procedures. HINT: There are cases where such information can only be explained by using an illustration. In these cases, torque, oil and other information are described in the illustration. Only items with key points are described in the text. What to do and other details are explained using illustrations next to the text. Both the text and illustrations are accompanied by standard values and notices. Illustration What to do and where to do it Task heading What work will be performed Explanation text How to perform the task Information such as specifications and warnings, which are written in boldface text Illustrations of similar vehicle models are sometimes used. In these cases, minor details may be different from the actual vehicle. Procedures are presented in a step-by-step format.
5. SERVICE SPECIFICATIONS Specifications are presented in boldface text throughout the information. The specifications are also found in the "Service Specifications" article for reference.
6. TERM DEFINITIONS CAUTION Possibility of injury to you or other people. NOTICE Possibility of damage to components being repaired. HINT Provides additional information to help you perform repairs.
7. INTERNATIONAL SYSTEM OF UNITS The units used in this article comply with the International System of Units (SI UNIT) standard. Other units from the metric system and the English systems are also provided. Example: Torque: 30 N*m (310 kgf*cm, 22 ft.*lbf)

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1. VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the vehicle body and on the certification label as shown in the illustration. A Vehicle Identification Number B Certification Label
2. ENGINE SERIAL NUMBER AND TRANSAXLE SERIAL NUMBER The engine serial number is stamped on the cylinder block of the engine as shown in the illustration. A 2AZ-FXE Engine Serial Number The transaxle code is stamped on the case as shown in the illustration. A P311 Transaxle Code

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1. BASIC REPAIR HINT HINTS ON OPERATIONS 1 Attire Always wear a clean uniform. A hat and safety shoes must be worn. 2 Vehicle protection Prepare a grille cover, fender cover, seat cover and floor mat before starting work. 3 Safety procedures When working with 2 or more persons, be sure to check the safety of one another. When working with the engine running, make sure to provide ventilation for exhaust fumes in the workshop. 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. When jacking up the vehicle, be sure to support the specified locations with safety stands. When lifting up the vehicle, use appropriate safety equipment. 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 Diagnose with a thorough understanding of proper procedures and of the reported problem. Before removing any parts, check the general condition of the assembly and for deformation and damage. If the procedure 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 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 information. Retain the removed parts for customer inspection, if requested. 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. PRECOATED PARTS TEXT IN ILLUSTRATION *1 Seal Lock Adhesive 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. FUSES TEXT IN ILLUSTRATION *1 INCORRECT *2 CORRECT 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. HINT: 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. Remove the clips with a clip remover or screwdriver. Remove the clips with a wide scraper to prevent panel damage. Remove the clips by pushing the center pin through and prying out the shell. Remove the clips by unscrewing the center pin and prying out the shell. 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. HINT: 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. HINT: 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 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. TEXT IN ILLUSTRATION *1 INCORRECT *2 CORRECT 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 information, the actual torque will be excessive and parts will be damaged.
2. PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE WARNING: 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 information 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. NOTE: After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction. After removing the service plug, wait 10 minutes before touching any of the high-voltage connectors and terminals. HINT: 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 for 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" 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.
3. 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.
4. ACTIONS TO BE TAKEN WHEN A WARNING LIGHT IS LIT TEXT IN ILLUSTRATION *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 Techstream to the DLC3 to check the DTCs (Diagnostic Trouble Codes). Then, refer to the applicable troubleshooting steps in this article 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.)
5. ACTIONS TO BE TAKEN WHEN BATTERIES ARE DISCHARGED HINT: The vehicle uses a 12 V auxiliary and a 244.8 V hybrid vehicle battery. Therefore, there are two recharging methods when the batteries are discharged. Perform this procedure when the auxiliary battery is fully discharged. HINT: The following problems indicate that the auxiliary battery is discharged: 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. Park (P) cannot be disengaged. NOTE: Never use a quick charger. Engage the parking brake. Turn the power switch off and remove the key from the interior detection area. Remove the No. 1 relay block cover. 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. HINT: 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 Position shown in the illustration on stalled vehicle 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 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. TEXT IN ILLUSTRATION *1 Master Warning Light *2 Multi-information Display When the hybrid vehicle battery is discharged: Using the THS charger, charge the hybrid vehicle battery. HINT: Perform this operation when the hybrid vehicle battery is discharged or low, or if Traction Battery Preservation Mode is displayed and DTC P3000-388 or 389 is stored in the hybrid vehicle control ECU.
6. ACTIONS TO BE TAKEN FOR VEHICLES DAMAGED BY IMPACT WARNING: The vehicle has a hybrid system that operates at voltages of 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 article 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 liter (21.1 US qts, 17.6 Imp.qts) (obtain 800 g (1.7 lb) 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 WARNING: 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. WARNING: 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. WARNING: Be sure to wear insulated gloves, goggles, and safety shoes. TEXT IN ILLUSTRATION *1 Inverter with Converter Assembly *2 Engine Room Junction Block Assembly *3 Auxiliary Battery *4 HV Battery Assembly *5 Frame Wire *6 Hybrid Vehicle Transaxle Assembly *7 Water Pump with Motor Assembly *8 Compressor with Motor Assembly Turn the power switch off. TEXT IN ILLUSTRATION *1 IGCT NO. 2 Fuse *2 Engine Room Junction Block Assembly HINT: If the power switch cannot be turned off, remove the IGCT NO. 2 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 information because this may cause a malfunction. Moving the damaged vehicle If any of the following conditions is 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). WARNING: 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. Push the P position switch, and apply the parking brake. Turn the power switch off, and disconnect the 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 liter (21.1 US qts, 17.6 Imp.qts) (obtain 800 g (1.7 lb) 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 WARNING: 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. WARNING: 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. WARNING: 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. Turn the power switch off. TEXT IN ILLUSTRATION *1 IGCT NO. 2 Fuse *2 Engine Room Junction Block Assembly HINT: If the power switch cannot be turned off, remove the IGCT NO. 2 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 information 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. WARNING: 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 an authorized dealer. Precautions to be observed when towing Tow the damaged vehicle with its front and rear wheels lifted off the ground. WARNING: Towing the damaged vehicle with its front 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 WARNING: 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. HINT: Neutral (N) cannot be selected if the auxiliary battery is disconnected.
7. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER This vehicle is equipped with a Supplemental Restraint System (SRS). WARNING: 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 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. WARNING: 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 kohms) 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. SPIRAL CABLE TEXT IN ILLUSTRATION *1 Alignment Mark 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. Refer to «INSTALLATION»(ref-398090-S09011507602011051600000) . 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. TEXT IN ILLUSTRATION *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. Refer to «DISPOSAL»(ref-398090-S18065154342011051600000) . 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. TEXT IN ILLUSTRATION *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. Refer to «DISPOSAL»(ref-398090-S42534735972011051600000) . 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. TEXT IN ILLUSTRATION *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. Refer to «DISPOSAL»(ref-398090-S31389231962011051600000) for driver side. Refer to «DISPOSAL»(ref-398090-S32648478672011051600000) 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. Refer to «DISPOSAL»(ref-398090-S06430241642011051600000) for front side. Refer to «DISPOSAL»(ref-398090-S02823632542011051600000) 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. TEXT IN ILLUSTRATION *1 CORRECT *2 INCORRECT *3 Clear Plastic Bag - - WARNING: 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. Refer to «DISPOSAL»(ref-398090-S04809057972011051600000) . Deploy the airbag in a safe place away from electrical noise. SEAT OUTER BELT ASSEMBLY (SEAT BELT PRETENSIONER) Never measure the resistance of the front seat outer belt assembly. This may cause the pretensioner of the front seat outer belt assembly to activate, which could cause serious injury. Never disassemble the front seat outer belt assembly. Never install the front seat outer belt assembly on another vehicle. Store the front 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 front seat outer belt assembly unit by itself, the front seat outer belt assembly should be activated before disposal. Refer to «DISPOSAL»(ref-398091-S31870439722011051600000) for front side. Refer to «DISPOSAL»(ref-398091-S34187051562011051600000) for rear side). Activate the front seat outer belt assembly in a safe place away from electrical noise. As the front 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 front seat outer belt assembly. Grease, detergents, oil or water should not be applied to the front 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.
8. ELECTRONIC CONTROL TEXT IN ILLUSTRATION *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 at least 60 seconds before disconnecting the cable from the negative (-) battery terminal. When the auxiliary battery is replaced or the cable is disconnected from its negative (-) battery terminal, the ISC learning value will be initialized and symptoms as a noise from the hybrid vehicle transaxle assembly may occur until ISC learning is performed. Therefore, perform ISC learning when the auxiliary battery is replaced or the cable is disconnected from the negative (-) terminal of the auxiliary battery. Refer to «Loud Rattle from Hybrid Vehicle Transmission»(ref-398092-S33434230122011051600000) . 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. HANDLING OF ELECTRONIC PARTS TEXT IN ILLUSTRATION *1 INCORRECT 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.
9. 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.
10. 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.
11. HANDLING OF HOSE CLAMPS TEXT IN ILLUSTRATION *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.
12. 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 information 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.
13. HEADLIGHT INSPECTION OR MAINTENANCE When the headlights are illuminated, do not cover the headlights for 3 minutes or more. TEXT IN ILLUSTRATION *1 Illumination for 3 minutes or more prohibited if covered 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.
14. FOR VEHICLES EQUIPPED WITH TRACTION CONTROL (TRAC) 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 TRAC and VSC systems. Refer to «INSPECTION MODE PROCEDURE»(ref-398089-S21258796492011051600000) . NOTE: If the vehicle is tested in normal mode on the tester, TRAC and VSC operation may cause the vehicle to jump off of the tester. Secure the vehicle with chains for safety. 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.
15. ELECTRONIC SHIFT LEVER SYSTEM BASIC OPERATION This vehicle is equipped with an electronic shift lever system. This system electrically communicates the driver's intended shift state to the ECUs responsible for system control. The system also uses an electrically operated transaxle parking lock mechanism. HINT: The parking lock mechanism of the transaxle cannot be operated if the auxiliary battery is discharged or has been disconnected. There is no mechanical connection between the P position switch (transmission shift main switch), shift lever and the transaxle. This system allows the driver to select the reverse (R), neutral (N), drive (D) and brake (B)* shift states using the shift lever or select park (P) by pushing the P position switch (transmission shift main switch). Shift states are ECU controlled based on the actions of the driver and various conditions. Shift states can be verified using the shift position indicator in the combination meter or by using the Techstream. *: For enhanced engine braking.
16. WHEN INSPECTING VEHICLES NOTE: When the vehicle is run in inspection mode for an operation such as a speedometer test, a DTC may be set. Therefore, if the warning light comes on, after canceling inspection mode, check for DTCs using the Techstream and clear the DTCs. VEHICLE CONDITIONS Before activating inspection mode, turn the air conditioning off, start the hybrid system with park (P) selected, and check that the engine stops within several seconds after starting (engine warm up check). Activate the appropriate inspection mode and inspect the vehicle. Refer to «INSPECTION MODE PROCEDURE»(ref-398089-S21258796492011051600000) . HINT: Different types of inspection mode are available. One is Maintenance Mode, and the other is Certification Mode. The following table indicates the mode appropriate for each test item. The shift state for each test is as follows: Test Item Mode Shift State 1. Vehicle straight travelling test (side slip inspection) Maintenance mode or normal mode D 2. Braking force test Maintenance mode N 3. Speedometer test Maintenance mode D 4. Exhaust gas test (idling) Maintenance mode P 5. Headlight test Maintenance mode or normal mode P Cancel inspection mode immediately after completion of inspection. NOTE: Driving the vehicle without canceling inspection mode may damage the transaxle. WHEN USING A BRAKE TESTER WARNING: Be sure to perform the test in maintenance mode. 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 WARNING: Be sure to perform the test in maintenance mode. NOTE: Do not perform rapid starting or quick acceleration on a speedometer tester. If rapid starting or quick acceleration is performed on a speedometer tester, damage may occur to 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 the 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. HINT: *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 maintenance mode. Start the engine and then increase the vehicle speed gradually with drive (D) selected. 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.
17. WHEN TOWING 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 (flatbed 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 Turn the power switch on (IG). Depress the brake pedal and move the shift lever to N. Release the parking brake. 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. If the hybrid system is off, the power assist for the brakes and steering will not function, making steering and braking more difficult. Do not turn off the power switch. Turning off the power switch may result in engagement of the parking lock, resulting in a hazardous situation or accident. HINT: Neutral (N) cannot be selected if the auxiliary battery is discharged or if it has been disconnected. 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.
18. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER WARNING: 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 a spark test as rapidly as possible with the injector connectors 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.

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Scheme 56

1. NOTICE ABOUT VEHICLE CONDITION WHEN RAISING VEHICLE The vehicle must be unloaded before jacking up or raising the vehicle. Never jack up or raise a heavily loaded vehicle. When removing any heavy components like the engine or transaxle, the vehicle center of gravity will shift. To stabilize the vehicle, place a balance weight in a location that will prevent the vehicle from rolling or shifting, or place a transmission jack under the appropriate jack position at the opposite end of the vehicle.
2. NOTICE FOR USING 4 POST LIFT Follow the safety procedures outlined in the lift's instruction manual. Do not damage the tires or wheels while driving onto the lift. Use wheel chocks to secure the vehicle.
3. NOTICE FOR USING JACK AND SAFETY STANDS Work on a level surface. Use wheel chocks at all times. Use safety stands with rubber attachments as shown in the illustration. TEXT IN ILLUSTRATION *1 Rubber Attachment Set the jack and safety stands exactly under the specified locations on the vehicle. Do not work on or leave the vehicle supported only by a jack. Be sure to support the vehicle with safety stands. When jacking up the vehicle, first release the parking brake and move the shift lever to N. When jacking up the entire vehicle: When jacking up the front wheels first, make sure wheel chocks are behind the rear wheels. When jacking up the rear wheels first, make sure wheel chocks are in front of the front wheels. When jacking up only the front or rear wheels of the vehicle: Before jacking up the front wheels, place wheel chocks on both sides of the rear wheels. Before jacking up the rear wheels, place wheel chocks on both sides of the front wheels. When lowering a vehicle that only has its front or rear wheels jacked up. Before lowering the front wheels, make sure wheel chocks are in front of the rear wheels. Before lowering the rear wheels, make sure wheel chocks are behind the front wheels.
4. NOTICE FOR USING A SWING ARM TYPE LIFT Follow the safety procedures outlined in the lift's instruction manual. Use swing arms equipped with rubber attachments as shown in the illustration. Position the vehicle so that its center of gravity is centered on the lift (length of "L" in the illustration should be as short as possible). Ensure that the rubber cushions or swing arms do not contact the body cladding or lower moldings. Be sure to lock the swing arms before raising the vehicle (if equipped with arm locks). Use the lift to raise the vehicle until the tires are off the ground, then stop the lift and shake the front and rear of the vehicle to make sure that it is stable.
5. NOTICE FOR USING PLATE TYPE LIFT Follow the safety procedures outlined in the lift's instruction manual. Use plate lift attachments (rubber lifting blocks) on top of the plates. Be sure to set the vehicle to the specified position described in the following chart and shown in the following illustration. Right and left set position Center the vehicle on the lift. Front and rear set position Align the plate cushion ends with the lower ends of the attachments (A). Be sure to set the attachment to position (B) as shown in the illustration. Ensure that the plate lift or rubber lifting blocks do not contact the body cladding or lower moldings. Use the lift to raise the vehicle until the tires are off the ground, then stop the lift and shake the front and rear of the vehicle to make sure that it is stable.

GENERAL INFORMATION

1. A large number of ECU controlled systems are used in this vehicle. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnosis and necessary repairs.

1. (For using the Techstream*) HINT: *: The Techstream is the name for the diagnostic tester in North America. Before using the Techstream, read the operator's manual thoroughly. If the Techstream cannot communicate with the ECU controlled systems when connected to the DLC3 with the power switch on (IG) and the Techstream turned on, there is a problem on the vehicle side or the Techstream side. If communication is possible when the Techstream is connected to another vehicle, inspect the diagnosis data link line (bus (+) line), CANH and CANL lines, and the power circuits for the vehicle ECUs. If communication is still not possible when the Techstream is connected to another vehicle, the problem is probably in the Techstream itself. Perform the Self Test procedure outlined in the Techstream operator's manual.

Scheme 57

1. TROUBLESHOOTING PROCEDURES The troubleshooting procedures consist of diagnosis procedures for when a DTC is stored and diagnosis procedures for when no DTC is stored. The basic idea is explained in the following table. Procedure Type Details Troubleshooting Method DTC Based Diagnosis The diagnosis procedure is based on the DTC that is stored. The malfunctioning part is identified based on the DTC detection conditions using a process of elimination. The possible trouble areas are eliminated one-by-one by use of the Techstream and inspection of related parts. Symptom Based Diagnosis (No DTCs stored) The diagnosis procedure is based on problem symptoms. The malfunctioning part is identified based on the problem symptoms using a process of elimination. The possible trouble areas are eliminated one-by-one by use of the Techstream and inspection of related parts. Vehicle systems are complex and use many ECUs that are difficult to inspect independently. Therefore, a process of elimination is used, where components that can be inspected individually are inspected, and if no problems are found in these components, the related ECU is identified as the problem and replaced. It is extremely important to ask the customer about the environment and the conditions present when the problem occurred (Customer Problem Analysis). This makes it possible to simulate the conditions and confirm the symptom. If the symptom cannot be confirmed or the DTC does not recur, the malfunctioning part may not be identified using the troubleshooting procedure, and the ECU for the related system may be replaced even though it is not defective. If this happens, the original problem will not be solved. In order to prevent endless expansion of troubleshooting procedures, the troubleshooting procedures are written with the assumption that multiple malfunctions do not occur simultaneously for a single problem symptom. To identify the malfunctioning part, troubleshooting procedures narrow down the target by separating components, ECUs and wire harnesses during the inspection. If the wire harness is identified as the cause of the problem, it is necessary to inspect not only the connections to components and ECUs but also all of the wire harness connectors between the component and the ECU.
2. DESCRIPTION Each system data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the Techstream to check for malfunctions and perform repairs.
3. CHECK DLC3 The vehicle ECUs use ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. Symbol Terminal No. Name Reference Terminal Result Condition SIL 7 Bus "+" line 5 - Signal ground Pulse generation During transmission CG 4 Chassis ground Body ground 1 ohms or less Always SG 5 Signal ground Body ground 1 ohms or less Always BAT 16 Battery positive Body ground 11 to 14 V Always CANH 6 CAN "High" line 14 - CANL 54 to 69 ohms Power switch off* Battery positive 6 kohms or higher Power switch off* 4 - CG 200 ohms or higher Power switch off* CANL 14 CAN "Low" line Battery positive 6 kohms or higher Power switch off* 4 - CG 200 ohms or higher Power switch off* NOTE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the power switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector.

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1. BASIC INSPECTION WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS Unless otherwise stated, all resistance measurements are standard values measured at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. HANDLING CONNECTORS TEXT IN ILLUSTRATION *1 INCORRECT *2 CORRECT When disconnecting a connector, first squeeze the mating connector housing halves tightly together to release the lock, and then press the lock claw and separate the connector. When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. Before connecting a connector, check that there are no deformations, damage, looseness or missing terminals. When connecting a connector, press firmly until it locks with a "click" sound. If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTE: As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. Do not damage the terminals by moving the inserted tester needle. CHECKING CONNECTORS TEXT IN ILLUSTRATION *1 Core Wire *2 Looseness of Crimping *3 Terminal Deformation *4 Pull Lightly Checking when a connector is connected: Squeeze the connectors together to confirm that they are fully connected and locked. Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Visually check for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated or deformed terminals. Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension when inserting and after full engagement. NOTE: When testing a gold-plated female terminal, always use a gold-plated male terminal. CONNECTOR TERMINAL REPAIR METHOD TEXT IN ILLUSTRATION *1 CORRECT *2 INCORRECT If there is any foreign matter on the terminal, clean the contact point with compressed air or a cloth. Never rub the contact point using sandpaper as the plating may come off. If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. Damaged, deformed or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. WIRE HARNESS HANDLING TEXT IN ILLUSTRATION *1 INCORRECT If removing a wire harness, check the wiring and clamps before proceeding so that it can be restored in the same way. Never twist, pull or slacken the wire harness more than necessary. The wire harness should never come into contact with any high temperature part, rotating, moving, vibrating or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. When installing parts, never pinch the wire harness. Never cut or break the cover of the wire harness. If it is cut or broken, repair it with insulating tape or replace the wire harness.
2. CHECK FOR OPEN CIRCUIT For an open circuit in the wire harness in (Scheme 1), measure the resistance and voltage as follows: Check the resistance. Disconnect connectors A and C and measure the resistance between the terminals of the connectors. Standard Resistance (Scheme 2) Tester Connection Specified Condition Connector A terminal 1 - Connector C terminal 1 10 kohms or higher Connector A terminal 2 - Connector C terminal 2 Below 1 ohms HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the values specified above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. Disconnect connector B and measure the resistance between the terminals of the connectors. Standard Resistance (Scheme 3) Tester Connection Specified Condition Connector A terminal 1 - Connector B1 terminal 1 Below 1 ohms Connector B2 terminal 2 - Connector C terminal 2 10 kohms or higher If the results match the values specified above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. Check the voltage. In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between body ground and the following terminals (in this order): 1) terminal 1 of connector A, 2) terminal 1 of connector B, and 3) terminal 1 of connector C. Standard Voltage (Scheme 4) Tester Connection Specified Condition Connector A terminal 1 - Body ground 5 V Connector B terminal 1 - Body ground 5 V Connector C terminal 1 - Body ground Below 1 V If the results match the values specified above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT If a wire in the harness is shorted to ground (Scheme 5), locate the shorted section by measuring the resistance as follows: Check the resistance to body ground. Disconnect connectors A and C and measure the resistance. Standard Resistance (Scheme 6) Tester Connection Specified Condition Connector A terminal 1 - Body ground Below 1 ohms Connector A terminal 2 - Body ground 10 kohms or higher HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the values specified above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Disconnect connector B and measure the resistance. Standard Resistance (Scheme 7) Tester Connection Specified Condition Connector A terminal 1 - Body ground 10 kohms or higher Connector B2 terminal 2 - Body ground Below 1 ohms If the results match the values specified above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C.
4. CHECK AND REPLACE ECU NOTE: The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. When no measuring condition is specified, perform the inspection with the engine stopped and the power switch on (IG). Check that the connectors are fully seated. Check for loose, corroded or broken wires. First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. Measure the resistance between the ECU ground terminal and body ground. TEXT IN ILLUSTRATION *1 Ground Standard resistance Below 1 ohms Disconnect the ECU connector. Check the ground terminals on the ECU side and wire harness side for bent terminals, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals. TEXT IN ILLUSTRATION *1 Component without harness connected (ECU) *2 Ground *3 Front view of wire harness connector (to ECU) *4 Ground

Scheme 72

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1. OPERATION FLOW HINT: Perform troubleshooting in accordance with the procedure below. The following is an outline of basic troubleshooting procedure. Confirm the troubleshooting procedure for the circuit you are working on before beginning troubleshooting. VEHICLE BROUGHT TO WORKSHOP NEXT: Go to next step CUSTOMER PROBLEM ANALYSIS Ask the customer about the conditions and environment when the problem occurred. NEXT: Go to next step INSPECT BATTERY VOLTAGE Standard voltage 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding to the next step. NEXT: Go to next step SYMPTOM CONFIRMATION AND DTC (AND FREEZE FRAME DATA) CHECK Visually check the wire harnesses, connectors and fuses for open and short circuits. Warm up the engine to the normal operating temperature. Confirm the problem symptoms and conditions, and check for DTCs. Result Result Proceed to DTC is output A DTC is not output B B --> GO TO f A: Go to next step DTC CHART Find the output DTC in the DTC chart. Look at the Trouble Area column for a list of potentially malfunctioning circuits and/or parts. NEXT --> GO TO g PROBLEM SYMPTOMS CHART Find the problem symptoms in the problem symptoms table. Look at the Suspected Area column for a list of potentially malfunctioning circuits and/or parts. NEXT: Go to next step CIRCUIT INSPECTION OR PARTS INSPECTION Identify the malfunctioning circuit or part. NEXT: Go to next step ADJUST, REPAIR OR REPLACE Adjust, repair or replace the malfunctioning circuit or parts. NEXT: Go to next step CONFIRMATION TEST After the adjustment, repairs or replacement of components, confirm that the malfunction no longer exists. If the malfunction does not recur, perform a confirmation test under the same conditions and in the same environment as when the malfunction first occurred. NEXT --> END
2. CUSTOMER PROBLEM ANALYSIS HINT: When troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. The following 5 items are important points for problem analysis: What Vehicle model, system name When Date, time, occurrence frequency Where Road conditions Under what conditions? Driving conditions, weather conditions How did it happen? Problem symptoms
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT: The diagnostic system in this vehicle has various functions. The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. By using these functions, the problem areas can be narrowed down and troubleshooting can be more effective. Diagnostic functions are incorporated in the following systems of this vehicle. System Symptom Confirmation and Diagnostic Trouble Code DTC Check (Normal Mode) DTC Check (Check Mode) Sensor Check/Test Mode (Input Signal Check) Data List Active Test SFI System (2AZ-FXE) o o - o o Hybrid Control System o - - o o Hybrid Battery System o - - o o Cruise Control System o - - o - Dynamic Radar Cruise Control System o - - o o Lane-Keeping Assist System o - - o o Electronic Shift Lever System o - - o - Tire Pressure Warning System o - - o o Electronically Controlled Brake System o - o o o Power Steering System o - - o - Power Tilt and Power Telescopic Steering Column System o - - o o Audio and Visual System (w/ Navigation System) o - - - - Audio and Visual System (w/o Navigation System) o - - - - Navigation System o - - - o Intuitive Parking Assist System o - - o o Wide View Front Monitor System o - - - - Rear View Monitor System (w/ Wide View Front Monitor System) o - - o - Rear View Monitor System (w/o Wide View Front Monitor System) - - - - - Garage Door Opener System (w/ Automatic High Beam System) - - - - - Garage Door Opener System (w/o Automatic High Beam System) - - - - - Safety connect System o - - o - Lexus Enform System - - - - - LIN Communication System o - - o - CAN Communication System o - - - - Power Door Lock Control System o - - o o Wireless Door Lock Control System o - - o o Smart Access System with Push-botton Start (for Entry Function) o - - o o Smart Access System with Push-botton Start (for Start Function) o - - o o Engine Immobilizer System o - - o o Theft Deterrent System - - - o o Lighting System (Interior) - - - o o Meter / Gauge System o - - o o Clock System - - - - - Airbag System o o - o - Occupant Classification System o - - o - Pre-Collision System o - - o o Front Power Seat Control System (w/ Memory) o - - o o Front Power Seat Control System (w/o Memory) - - - - - Seat Heater System - - - - - Climate Control Seat System - - - - - Seat Belt Tension Reducer System - - - - - Seat Belt Warning System - - - o o Air Conditioning System o - - o o Rear Sunshade System - - - o o Windshield Deicer System - - - - o Power Window Control System o - - o o Window Defogger System - - - - o Sliding Roof System o - - o o Luggage Compartment Door Opener System - - - o o Fuel Lid Opener System - - - o o Power Mirror Control System (w/ Memory) - - - o o Power Mirror Control System (w/o Memory) - - - - - Wiper and Washer System - - - - o Lighting System (Exterior) o - - o o Horn System - - - - - In the DTC check, it is very important to determine whether the problem indicated by the DTC either: 1) still occurs, or 2) occurred in the past but has returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the flowchart below. Never skip the DTC check. Failing to check for DTCs, depending on the case, may result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedure listed in the flowchart in the correct order. The following flowchart shows how to proceed with troubleshooting using the DTC check. Directions from the flowchart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. DTC CHECK NEXT: Go to next step MAKE A NOTE OF DTC DISPLAYED AND THEN CLEAR MEMORY NEXT: Go to next step SYMPTOM CONFIRMATION Result Result Proceed to No symptoms exist A Symptoms exist B B --> GO TO e A: Go to next step SIMULATION TEST USING SYMPTOM SIMULATION METHODS NEXT: Go to next step DTC CHECK Result Result Proceed to DTC is not output A DTC is output B B --> TROUBLESHOOT FOR PROBLEM INDICATED BY DTC A: Go to next step SYMPTOM CONFIRMATION Result Result Proceed to No symptoms exist A Symptoms exist B If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B --> END A --> TROUBLESHOOT FOR EACH PROBLEM SYMPTOM The problem still occurs in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The following symptom simulation tests are effective substitutes for the conditions and can be applied to a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to Problem Symptoms Table for each system to narrow down the possible causes. To reproduce DTCs, it is necessary to satisfy the respective DTC detection conditions. VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. TEXT IN ILLUSTRATION *1 Vibrate Slightly *2 Shake Slightly PARTS OR SENSORS Apply slight vibration with a finger to the part or sensor suspected to be the cause of the problem, and check whether the malfunction occurs. NOTE: Applying strong vibration to relays may open the relays. CONNECTORS Slightly shake the connector vertically and horizontally. WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT: The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. HEAT METHOD: When a malfunction seems to occur when the area in question is heated. Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTE: Do not heat components to more than 60°C (140°F). Exceeding this temperature may damage the components. Do not apply heat directly to parts in an ECU. WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. Sprinkle water onto the vehicle and check if the malfunction occurs. NOTE: Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. Never apply water directly onto the electronic components. HINT: If the vehicle has or had a water leak problem, the leak may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when the electrical load is high. Turn on the heater blower, headlights, rear window defogger and all other electrical loads. Check if the malfunction recurs.
5. DIAGNOSTIC TROUBLE CODE CHART Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate article's Diagnostic Trouble Code Chart. Use the chart to determine the trouble area and the proper inspection procedure. A description of each of the chart's columns is shown in the table below. Item Description DTC No. Indicates the diagnostic trouble code. Detection Item Indicates the system or details of the problem. Trouble Area Indicates the suspected areas of the problem. See Indicates where the inspection procedure for each circuit is to be found, or gives instruction for checking and repairs.
6. PROBLEM SYMPTOMS TABLE When no DTC is output but the problem still occurs, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptom are shown in the table. The suspected areas are listed in order of probability. A description of each of the table columns is shown in the following table. HINT: In some cases, the problem is not detected by the diagnostic system even though a problem symptom occurs. It is possible that the problem occurs outside the detection range of the diagnostic system, or that the problem occurs in a completely different system. Item Description Symptom - Suspected Area Indicates the circuit or part which needs to be checked. See Indicates where the inspection procedure is located.
7. INSPECTION A description of the main points for inspection of suspected areas is shown in the following table. Item Description Description The major role and operation of the circuit or system and its component parts are explained. DTC No., DTC Detection Condition and Trouble Area Indicates the diagnostic trouble codes, DTC detection conditions and suspected areas for a problem. Wiring Diagram This is a wiring diagram for the circuit or system. This diagram can be used together with the Electrical Wiring Diagram to thoroughly understand the circuit. Wire colors are indicated by alphabetical codes. B = Black, L = Blue, R = Red, BR = Brown, LG = Light Green, V = Violet, G = Green, O = Orange, W = White, GR = Gray, P = Pink, Y = Yellow, SB = Sky Blue The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Inspection Procedure This shows the procedure not only to determine whether the circuit is normal or abnormal, but also to determine whether the problem is located in the sensors, actuators, wire harness or ECU. Illustration of the ECU connector during the check The illustration shows whether the connector being checked is connected or disconnected. The connections for an electrical tester are indicated by (+) or (-) after the terminal name. For inspections between a connector and body ground, information about the ground is not shown in the illustration.

ABBREVIATIONS USED

See also:
• REGISTRATION
• REGISTRATION