Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2011 Lexus GS 450hFACTORY OEM SERVICE PROCEDURE
Repair Instruction: Precaution: Precaution
- BASIC REPAIR HINT
- HINTS ON OPERATIONS
1 Attire - Always wear a clean uniform.
- Hat and safety shoes must be worn.
2 Vehicle protection Prepare a grille cover, fender cover, seat cover and floor mat before starting the operation. 3 Safe operation - When working with 2 or more persons, be sure to check safety for 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 location with a safety stand.
- When lifting up the vehicle, use appropriate safety equipment.
4 Preparation of tools and measuring gauge Before starting operation, prepare a tool stand, SST, gauge, oil and parts for replacement. 5 Removal and installation, disassembly and assembly operations - Diagnose with a thorough understanding of proper procedures and of the reported problem.
- Before removing the parts, check the general condition of the assembly and for deformation and damage.
- When the assembly is complicated, take notes. For example, note the total number of electrical connections, bolts, or hoses removed. Add matchmarks to ensure reassembly of components in the original positions. Temporarily mark hoses and their fittings if needed.
- Clean and wash the removed parts if necessary and assemble them after a thorough check.
6 Removed parts - Place the removed parts in a separate box to avoid mixing them up with the new parts or contaminating the new parts.
- For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them with new ones as instructed in this article.
- Retain the removed parts for customer inspection, if requested.
7* Checks to perform after work is finished - Make sure that removed and installed parts (oil filler cap, level dipstick, floor mat, etc.) are properly installed/tightened.
- Make sure that none of the cloths or tools that were used have been left in the engine compartment or within the vehicle.
- Check that there are no oil leaks.
WARNING: *: Be sure to perform these checks properly, Not performing these checks properly after finishing work can lead to serious accident or injury. - 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
- Precoated parts are bolts and nuts that are coated with a 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 appropriate 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 torques. Always use a torque wrench.
- FUSES
- When inspecting a fuse, check that the wire of the fuse is not broken.
- If the wire of a fuse is broken, confirm that there are no shorts in its circuit.
- When a fuse is replaced, a fuse with the same amperage rating must be used.
Graphic 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 clips with new clips.
Shape (Example) Graphic Procedures - Remove clips with a clip remover or pliers.
- Remove clips with a clip remover or screwdriver.
- Remove clips with a wide scraper to prevent panel damage.
- Remove clips by pushing the center pin through and prying out the shell.
- Remove clips by unscrewing the center pin and prying out the shell.
- Remove clips by prying out the pin and then prying out the shell.
- The removal and installation methods of typical clips used for vehicle body parts are shown in the table below.
- CLAWS
- The removal and installation methods of typical claws used for vehicle body parts are shown in the table below.
HINT:
If claws of caps or covers are damaged during a procedure, always replace the caps or covers with new ones.
Shape (Example) Graphic Procedures - Using a screwdriver, detach the claws and remove the caps or covers.
- Using a screwdriver, detach the claws and remove the caps or covers.
- Using a screwdriver, detach the claws and remove the caps or covers.
- The removal and installation methods of typical claws used for vehicle body parts are shown in the table below.
- REMOVAL AND INSTALLATION OF VACUUM HOSES
- To disconnect a vacuum hose, pull and twist from the end of the hose. Do not pull from the middle of the hose as this may cause damage.
- 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, it may leak air. 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 the wrench is used to tighten to a torque specification in this article, the actual torque will be excessive and parts will be damaged.
- Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with a torque wrench.
- HINTS ON OPERATIONS
- PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE
- Engineers must undergo special training to be able to perform high-voltage system inspection and servicing.
- All high-voltage wire harnesses are colored orange. The HV battery and other high-voltage components have "High Voltage" caution labels. Do not carelessly touch these wires and components.
- 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 you are servicing the vehicle.
- After removing the service plug, wait 10 minutes before touching any of the high-voltage connectors and terminals.
HINT:
10 minutes are required to discharge the high-voltage condenser inside the inverter.
- Be sure to install the service plug before starting the hybrid system. Starting the hybrid system with the service plug removed may damage the vehicle.
- Before using insulated gloves, be sure to check them for cracks, tears and other types of damage by performing the following procedure.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- 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 scales that can be dropped accidentally and cause a short circuit.
- Before touching a bare high-voltage terminal, wear insulated gloves and use an electrical tester to ensure that the terminal is not charged with electricity (approximately 0 V).
- After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulation tape.
- The screw of a high-voltage terminal should be tightened firmly to the specified torque. Both insufficient and excessive torque can cause failure.
- Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION." sign to notify other engineers that a high-voltage system is being inspected and/or repaired.
- Do not place the battery upside down while removing and installing it.
- 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.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- PRECAUTIONS TO BE OBSERVED WHEN INSPECTING OR SERVICING ENGINE COMPARTMENT
The LEXUS GS450h automatically turns the engine ON and OFF when the READY light on the instrument panel is ON. To avoid injury, remove the key from the vehicle before inspecting or servicing the engine compartment.
- ACTIONS TO BE TAKEN WHEN BATTERIES ARE DEPLETED
- Perform this procedure when the auxiliary battery is fully depleted.
HINT:
The following problems indicate that the auxiliary battery is depleted:
- No display appears on the instrument panel when the power switch is ON (IG).
- The hybrid system does not start.
- The headlights are dim.
- The sound from the horn is weak.
NOTE: Never use a quick charger.- Move the shift lever to the P position and engage the parking brake.
- Remove the key from the vehicle.
- Using a booster cable, connect the rescue vehicle's 12 V battery positive (+) lead to the stalled vehicle's relay block positive (+) terminal and the negative (-) lead to the suspension support's nut on the right side.
- Start the engine of the rescue vehicle and run the engine at a speed slightly higher than the idling speed for 5 minutes to charge the auxiliary battery of the stalled vehicle.
- Depress the brake pedal and push the power switch to start the hybrid system.
If the hybrid system fails to start, the master warning light flashes, and the multi-information display is as shown in the graphic, the HV battery may be depleted.
- Disconnect the booster cable in the reverse order of the connection procedure.NOTE: If the auxiliary battery needs to be replaced, replace it only with a 12 V battery specially designed for use with the LEXUS GS450h.
- When the HV battery is depleted, replace the HV battery.
HINT:
If the HV battery is depleted, the master warning light flashes, and the multi-information display is as shown, and DTC P3000-388, 389 or 603 code is output.
- Perform this procedure when the auxiliary battery is fully depleted.
- ACTIONS TO BE TAKEN FOR VEHICLE DAMAGED BY IMPACT
- Items to be prepared for operation at the site of the accident
- Protective clothing (insulated gloves, rubber gloves, goggles, and safety shoes)
- Saturated boric acid solution 20 L (obtain 800 g of boric acid powder, put it into a container, and dissolve it in water)
- Red litmus paper
- ABC fire extinguisher (effective against both oil flames and electrical flames)
- Shop rags (for wiping off the electrolyte)
- Vinyl tape (for insulating cables)
- Electrical tester
- Actions to be taken at the accident site
- Wear insulated or rubber gloves, goggles and safety shoes.
- Do not touch a bare cable that could be a high voltage cable. If the cable must be touched or if accidental contact is unavoidable, follow these instructions: 1) wear insulated or rubber gloves and goggles, 2) measure the voltage between the cable and the body ground using an electrical tester, and 3) insulate the cable using vinyl tape.
- 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 immediate area for any electrolyte leakage. Do not touch any leaked liquid because it could be a highly alkaline electrolyte. Wear rubber gloves and goggles, and then apply red litmus paper to the leak. If the paper turns blue, the liquid must be neutralized before wiping. Neutralize the liquid using the following procedures: 1) apply saturated boric acid solution to the liquid, and 2) reapply red litmus paper and make sure it does not turn blue. Repeat steps 1 and 2 above until the paper does not turn blue. Then, wipe the neutralized liquid with a shop rag.
- If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the procedure below.
- Move the shift lever to the P position and engage the parking brake.
- Remove the key from the vehicle. Then disconnect the cable from the negative (-) terminal of the auxiliary battery.
- Remove the service plug while wearing insulated gloves.
WARNING: Do not turn the power switch ON (READY) while removing the service plug.
- Items to be prepared for operation at the site of the accident
Factory Service Tools
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.