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.
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 - Use wheel chocks to secure the vehicle.
- When working with the engine running, make sure to provide ventilation for exhaust fumes in the workshop.
- When removing or installing heavy parts, such as the engine, transmission, differential, etc., before starting work make sure there are no problems with the equipment that will be used.
- When working with 2 or more persons, be sure to check safety for one another.
- If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others.
4 Preparation of tools and measuring gauge Before starting operation, prepare a tool stand, SST, gauge, oil and parts for replacement. 5 Removal and installation, disassembly and assembly operations - Diagnose with a thorough understanding of proper procedures and of the reported problem.
- Before removing the parts, check the general condition of the assembly and for deformation and damage.
- When the assembly is complicated, take notes. For example, note the total number of electrical connections, bolts, or hoses removed. Add matchmarks to ensure reassembly of components in the original positions. Temporarily mark hoses and their fittings if needed.
- Clean and wash the removed parts if necessary and assemble them after a thorough check.
6 Removed parts - Place the removed parts in a separate box to avoid mixing them up with the new parts or contaminating the new parts.
- For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them with new ones as instructed in this information.
- 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.
- PRECOATED BOLTS
- Precoated bolts are bolts that have the thread area coated with seal lock adhesive.
- If a precoated bolt is retightened, loosened or moved, use the specified adhesive to coat it.NOTE:
Perform the torque check with the bolt tightened to the lowest permitted torque value.
- When precoated parts are reused, remove the old adhesive, clean them with non-residue solvent, and dry them with compressed air. Then apply new seal lock adhesive appropriate to those parts, and install them to the specified torque.
- The adhesive may take a specified amount of time until it hardens.
- GASKETS
- Gaskets are non-reusable. Always replace them with new ones.
- 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
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- 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 FUSIBLE LINK ASSEMBLY FL
- CLIPS
- When prying a clip to remove it, always tape the tip of the tool with protective tape to protect the vehicle from damage.
- 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) Illustration 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.
- CLAWS
- When prying a claw to detach it, always tape the tip of the tool with protective tape to protect the vehicle from damage.
- 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) Illustration 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.
- HINGE, GUIDE, CLAMP, PIN 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) Illustration Procedures Disengage the pins by pulling. Disengage the pins by pulling. Remove the clamps with pliers. Disengage the pins by pulling.
- The removal and installation methods of typical hinges, guides, clamps and pins used for vehicle body parts are shown in the table below.
- NOTICE FOR ENGINE HOOD/DOOR ADJUSTMENT
- If centering bolts are used for the hinges of the engine hood, door, luggage compartment door, etc., replace the centering bolts with standard bolts before performing the engine hood/door adjustment.
- 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.
- 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
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with a torque wrench.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 information, 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 the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.NOTE:
After removing the service plug grip, turning the power switch on (READY) may cause a malfunction. Do not turn the power switch on (READY) unless instructed by the repair information.
- After disconnecting the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals.
HINT:
Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.
- 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 wearing insulated gloves, make sure that they are not cracked, ruptured, torn, or damaged in any way. Do not wear wet insulated gloves.
- 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 LS600h L automatically turns the engine ON and OFF when the READY light on the instrument panel is ON. To avoid injury, Please make sure that both the indicator on the power switch and the READY lamp on the meter are off
- ACTIONS TO BE TAKEN WHEN BATTERIES ARE DEPLETED
HINT:
The vehicle uses a 12 V auxiliary and a 288 V hybrid vehicle battery. Therefore, there are two recharging methods when the batteries are depleted.
- Perform this procedure when the auxiliary battery is fully depleted.
HINT:
The following problems indicate that the auxiliary battery is depleted:
- No display appears on the instrument panel when the power switch is turned on (IG).
- The hybrid system does not start.
- The headlights are dim.
- The sound from the horn is weak.
NOTE:Never use a quick charger.
- Move the shift lever to the P position and engage the parking brake.
- Turn the power switch off and remove the key from the interior detection area.
- Using booster cables, connect the 12 V battery of the rescue vehicle and the auxiliary battery of the stalled vehicle as shown in the illustration.NOTE:
Do not allow the booster cable to contact the seat vibration module assembly. The positive (+) terminal side of the auxiliary battery is close to the seat vibration module assembly. When charging the battery, it is extremely dangerous if the booster cable contacts the seat vibration module assembly, as sparks occur and the seat vibration module assembly may be damaged.
- Perform this procedure when the auxiliary battery is fully depleted.
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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.
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