Part 1

INTRODUCTION: REPAIR INSTRUCTION:

PRECAUTION

1. BASIC REPAIR HINT
(a) HINTS ON OPERATIONS









(b) JACKING UP AND SUPPORTING VEHICLE
(1) Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations.






(c) PRECOATED PARTS
(1) Precoated parts are bolts and nuts that are coated with a seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened or moved in any way, it must be recoated with the specified adhesive.
(3) 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.
(4) Some seal lock agents harden slowly. You may have to wait for the seal lock adhesive to harden.

(d) GASKETS
(1) When necessary, use a sealer on gaskets to prevent leaks.
(e) BOLTS, NUTS AND SCREWS
(1) Carefully follow all the specifications for tightening torques. Always use a torque wrench.
(f) FUSES





(1) When inspecting a fuse, check that the wire of the fuse is not broken.
(2) When replacing fuses, be sure that the new fuse has the correct amperage rating. Do not exceed the rating or use one with a lower rating.






(g) CLIPS
(1) 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 work, always replace the damaged clip with a new one.









(h) REMOVAL AND INSTALLATION OF VACUUM HOSES





(1) To disconnect a vacuum hose, pull and twist from the end of the hose. Do not pull from the middle of the hose as this may damage the hose.





(2) When disconnecting vacuum hoses, use tags to identify where they should be reconnected.
(3) After completing any hose related repairs, double check that the vacuum hoses are properly connected. The label under the hood shows the proper layout.
(4) When using a vacuum gauge, never force the hose onto a connector that is too large. If a hose has been stretched, air may leak. Use a step-down adapter if necessary.
(i) TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL









(1) Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with the torque wrench.
Formula:
T' = L2/(L1 + L2) * T





NOTE: If an extension tool or SST is combined with a torque wrench and the wrench is used to tighten to a torque specification, the actual torque will be excessive and parts will be damaged.

2. PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE
NOTE: The RX400h hybrid system contains a 288V high-voltage system with a strong alkali solution of potassium hydroxide. Be sure to follow the instructions to handle the system correctly. Failure to do so may result in serious injury or electrocution.

(a) Engineer must undergo special training to be able to perform high-voltage system inspection and servicing.
(b) All high-voltage wire harness connectors are colored orange. The HV battery and other high-voltage components have "High Voltage" caution labels. Do not carelessly touch these wires and components.






(c) Before inspecting or servicing the high-voltage system, be sure to follow safety measures, such as wearing insulated gloves and removing the service plug to prevent electrocution. Carry the removed service plug in your pocket to prevent other technicians from reinstalling it while your are servicing the vehicle.
NOTE: Do not put the vehicle into the READY-on state after removing the service plug grip as the ECU may be damaged.

(d) After removing the service plug, wait 5 minutes before touching any of the high-voltage connectors and terminals.
HINT: 5 minutes are required to discharge the high-voltage condenser inside the inverter.





(e) Before wearing insulated gloves, make sure that they are not cracked, ruptured, torn, or damaged in any way. Do not wear wet insulated gloves.

(f) When servicing the vehicle, do not carry metal objects like mechanical pencils or scales that can be dropped accidentally and cause a short circuit.
(g) Before touching a bare high-voltage terminal, wear insulated gloves and use a tester to make sure that the terminal voltage is 0 V.






(h) After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulation tape.

(i) The screw of a high-voltage terminal should be tightened firmly to the specified torque. Both insufficient and excessive torque can cause failure.
(j) Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION" sign to notify other engineers that a high-voltage system is being inspected and/or repaired.





(k) After servicing the high-voltage system and before reinstalling the service plug, check again that you have not left a part or tool inside, that the high-voltage terminal screws are firmly tightened, and that the connectors are correctly connected.
(l) Do not place the battery upside down while removing and installing it.
3. ACTIONS TO BE TAKEN WHEN THE WARNING LIGHT IS LIT





(a) If one of the warning lights (2) to (5) becomes lit, connect Techstream to the DLC3 connector to check the DTCs (Diagnostic Trouble Codes). Then, refer to the applicable troubleshooting steps to inspect and repair the affected area. The foregoing actions are also required if the READY light does not illuminate when the vehicle is first started.






4. ACTIONS TO BE TAKEN WHEN BATTERIES ARE DEPLETED
HINT: The LEXUS RX400h uses a 12 V auxiliary and a 288 V hybrid vehicle battery. Therefore, there are two recharging methods when the batteries are depleted.

(a) 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 ignition switch is set to ON.
- The hybrid system does not start.
- The headlights are dim.
- The sound from the horn is weak.
CAUTION: Never use a quick charger.
(1) Move the shift lever to the P position and engage the parking brake.
(2) Remove the key from the ignition switch





(3) Remove the 2 clips and engine room cover side.





(4) Using a booster cable, connect the 12 V battery of the rescue vehicle and the auxiliary battery of the stalled vehicle, as shown in the illustration.





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





(6) Put the vehicle into the READY-on state to start the hybrid system.
NOTE: Immediately disconnect the booster cable in the reverse order of connection after the hybrid system and the engine have started. Do not leave the booster cable connected because it is not designed for recharging purposes.

If the hybrid system fails to start and the HV warning light turns ON, the HV battery may be depleted.

(b) When the hybrid vehicle battery is depleted:
Replace the hybrid vehicle battery.
HINT: When the hybrid vehicle battery is depleted, the HYBRID VEHICLE BATTERY WARNING illuminates, and DTC P3000-389 is stored in the hybrid ECU.

5. INSPECTION MODE
HINT:
- If the engine is warmed up and the battery is charged, the engine of RX400h will stop after the vehicle stops. Therefore, if the engine is required to run continuously even after the vehicle stops, such as for an ignition timing check, switch to the 4WD inspection mode.
- The RX400h is equipped with the 4WD system by which the rear wheels are electronically controlled by the motor, VSC system, and TRC system. Therefore, it is necessary to switch to the 2WD operation mode and cancel all of these systems when only the front wheels are required to be rotated on a chassis dynamometer.

(a) Change to the inspection mode.
(b) Activating 2WD inspection mode (Not using Techstream)
Perform the following steps from (1) through (4) in 60 seconds.
(1) Turn the ignition switch to the ON position.
(2) Fully depress the accelerator pedal twice times with the transmission P position.
(3) Fully depress the accelerator pedal twice times with the transmission N position.
(4) Fully depress the accelerator pedal twice times with the transmission P position.
(5) Check that the HV system warning light flashed on the multi-information display.
(6) Start the engine by turning the ignition switch while depressing the brake pedal.
(c) Activating 2WD inspection mode (Using Techstream)
(1) Connect Techstream to the DLC3.
(2) Turn the ignition switch to the ON position.
(3) Turn Techstream on.
(4) Select following menu items: Powertrain / Hybrid Control / Active Test / Inspection Mode -2WD Inspection.
(5) Check that the HV system warning light flashers on the multi-information display and the master warning light is illuminated in the combination meter.
(6) Start the engine by turning the ignition switch while depressing the brake pedal.
(d) Activating 4WD inspection mode (Not using Techstream)
Perform the following steps from (1) through (4) in 60 seconds.
(1) Turn Techstream to the ON position.
(2) Fully depress the accelerator pedal four with the transmission P position.
(3) Fully depress the accelerator pedal four with the transmission N position.
(4) Fully depress the accelerator pedal four with the transmission P position.
(5) Check that the HV system warning light flashed on the multi-information display.
(6) Start the engine by turning the ignition switch while depressing the brake pedal.
(e) Activating 4WD inspection mode (Using Techstream)
(1) Connect Techstream to the DLC3.
(2) Turn the ignition switch to the ON position.
(3) Turn Techstream on.
(4) Select following menu items: Powertrain / Hybrid Control / Active Test / Inspection Mode -4WD Inspection.
(5) Check that the HV system warning light flashers on the multi-information display and the master warning light is illuminated in the combination meter.
(6) Start the engine by turning the ignition switch while depressing the brake pedal.
6. SPECIAL NOTES FOR VEHICLE INSPECTION
CAUTION: If the vehicle is run in the 2WD inspection mode, for such as a speedometer test, a DTC may be output. Therefore, if the warning light comes on, after canceling the 2WD inspection mode, check for DTCs using Techstream and clear the DTCs.

(a) Vehicle conditions
(1) Before activating inspection mode, turn the air conditioning off, start the engine with the shift lever in the P position, and check the engine stops within several seconds after starting (engine warm up check).
(2) Activate inspection mode and inspect the vehicle.
Shift position for each test:





(3) Reset inspection mode immediately after completion of inspection.
CAUTION: After canceling the inspection mode, turn the ignition switch ON again and check that the warning light is OFF.

(b) Special notes for speedometer test
CAUTION:
- Be sure to perform the test in the 2WD inspection mode.
- Do not use the speedometer tester to perform rapid starting or quick acceleration/deceleration without first setting the proper load on the vehicle. Failing to set the load may damage the transaxle.
(1) Depress the accelerator pedal slowly and gradually accelerate the vehicle. Make a measurement.
(2) After the measurement, use the brake to gradually decelerate the vehicle.
(c) Special notes for using the chassis dynamometer
(1) Always set an appropriate load before starting the test.
NOTE: Suddenly acceleration or deceleration of the vehicle on a chassis dynamometer under minimal load may damage the transaxle.

(d) Activating 2WD inspection mode (Not using Techstream)
Perform the following steps from (1) through (4) in 60 seconds.
(1) Turn the ignition switch to the ON position.
(2) Fully depress the accelerator pedal twice times with the transmission P position.
(3) Fully depress the accelerator pedal twice times with the transmission N position.
(4) Fully depress the accelerator pedal twice times with the transmission P position.
(5) Check that the HV system warning light flashed on the multi-information display.
(6) Start the engine by turning the ignition switch while depressing the brake pedal.
(e) Activating 2WD inspection mode (Using Techstream)
(1) Connect Techstream to the DLC3.
(2) Turn the ignition switch to the ON position.
(3) Turn Techstream on.
(4) Select following menu items: Powertrain / Hybrid Control / Active Test / Inspection Mode -2WD Inspection.
(5) Check that the HV system warning light flashers on the multi-information display and the master warning light is illuminated in the combination meter.
(6) Start the engine by turning the ignition switch while depressing the brake pedal.
(f) Activating 4WD inspection mode (Not using Techstream)
Perform the following steps from (1) through (4) in 60 seconds.
(1) Turn the ignition switch to the ON position.
(2) Fully depress the accelerator pedal four with the transmission P position.
(3) Fully depress the accelerator pedal four with the transmission N position.
(4) Fully depress the accelerator pedal four with the transmission P position.
(5) Check that the HV system warning light flashed on the multi-information display.
(6) Start the engine by turning the ignition switch while depressing the brake pedal.
(g) Activating 4WD inspection mode (Using Techstream)
(1) Connect Techstream to the DLC3.
(2) Turn the ignition switch to the ON position.
(3) Turn Techstream on.
(4) Select following menu items: Powertrain / Hybrid Control / Active Test / Inspection Mode -4WD Inspection.
(5) Check that the HV system warning light flashers on the multi-information display and the master warning light is illuminated in the combination meter.
(6) Start the engine by turning the ignition switch while depressing the brake pedal.
(h) Deactivating inspection mode
(1) Turn the ignition switch off. The HV main system turns off simultaneously.
CAUTION:
- The idling speed in inspection mode is approximately 1,000 rpm. The engine speed increases to 1,500 rpm if the accelerator pedal is depressed by less than 60 %. If the accelerator pedal is depressed by more than 60%, the engine speed increases to 2,500 rpm.
- If a DTC is set during inspection mode, the master warning light and the warning massage illuminate on the multi-information display.
- When the master warning light illuminates during the inspection mode, deactivate the inspection mode, and check DTC(s).
- Driving the vehicle without deactivating the inspection mode may damage the transaxle.

7. ACTIONS TO BE TAKEN FOR VEHICLE DAMAGED BY IMPACT
NOTE: The RX400h hybrid system contains a 288V high-voltage system with a strong alkali solution of potassium hydroxide. Be sure to follow the instructions to handle the system correctly. Failure to do so may result in serious injury or electrocution.

(a) Items to be prepared for operation at the accident site
- Protective clothing (insulated gloves, rubber gloves, goggles, and safety shoes)
- Saturated boric acid solution 20 L (obtain 800 g of boric acid powder, put it into a container, and dissolve it in water)
- Red litmus paper
- ABC fire extinguisher (effective against both oil flames and electrical flames)
- A shop rag or piece of cloth (for wiping off the electrolyte)
- Insulation tape (for insulating cable)
- Electrical tester

(b) Actions to be taken at the accident site
NOTE: Do not touch a bare cable that may have high-voltage. If the cable must be touched or if accidental contract is unavoidable, wear insulated gloves and insulate the cable using insulation tape.
- 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.
(1) Check the vicinity of the hybrid vehicle battery for any leakage of the electrolyte.
NOTE: Do not touch any leaked liquid because it could be highly alkaline electrolyte. Wear rubber gloves and goggles, neutralize the liquid with saturated boric acid solution, and then apply red litmus paper to the leak. Check that the paper does not turn blue. Wipe the neutralized liquid with a shop rag or piece of cloth.
(2) If damage to any of the high-voltage components and cable is suspected, cut the high-voltage circuit using the procedure on the following pages.









(3) Turn the ignition switch off.
HINT: If the ignition switch cannot be turned off, remove the IGCT No.1 fuse from the HV relay block or disconnect the cable from the negative terminal of the auxiliary battery.
(4) Wear insulated gloves, and then remove the service plug.
NOTE: Be sure to install the service plug before turning on the ignition switch. Starting the hybrid system with the service plug removed may damage the ECU.

(c) Moving the damaged vehicle
If any of the following conditions are met, tow the vehicle away using a tow truck.
- One or more of the high-voltage components and cables are damaged.
- The driving, traction, or fuel system is damaged.
- The master warning light is on.
- The READY light does not come on when the vehicle is in the READY-on state.





CAUTION:
- Before towing the vehicle away using a tow truck, disconnect the cable from the negative (-) terminal of the auxiliary battery and remove the service plug.
NOTE: Perform the procedure below if the READY light turns off , or there are abnormal noises, unusual smells, or strong vibrations while driving:
(1) Park the vehicle in a safe place.
(2) Shift the shift lever to the "P" position, and apply the parking brake.
(3) Turn the ignition switch off, and disconnect the power cable from the negative (-) terminal of the auxiliary battery.
(4) Remove the service plug while wearing insulated gloves.
(d) Actions required after moving the damaged vehicle
(1) Procedure
If you see any liquid on the road surface, it could be highly alkaline electrolyte leakage.
Wear rubber gloves and goggles, neutralize the liquid with saturated boric acid solution, and then apply red litmus paper to the leak. Check that the paper does not turn blue. Wipe the neutralized liquid with a shop rag or piece of cloth.
(e) Items to be prepared (when repairing damaged vehicles)
- 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
- Shop rags (for wiping off the electrolyte)
- Vinyl tape (for insulating cable)
- Electrical tester

(f) Precautions to be observed when servicing the damaged vehicle
NOTE: Always follow instructions to ensure safety.
(1) Wear insulated or rubber gloves, goggles, and safety shoes.
(2) Check the HV battery and immediate area for any electrolyte leakage.
Do not touch any leaked liquid because it could be highly alkaline electrolyte. Wear rubber gloves and goggles, neutralize the liquid with saturated boric acid solution, and then apply red litmus paper to the leak. Check that the paper does not turn blue. Wipe the neutralized liquid with a shop rag or piece of cloth.
NOTICE:
- 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.
(3) Do not touch a bare cable that could be a high voltage cable. If the cable must be touched or if accidental contact is unavailable, follow the following instructions: 1) wear insulated or rubber gloves and goggles, 2) measure the voltage between the cable and the body ground using an electrical tester, and 3) insulate the cable using insulation tape.
(4) If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the procedure below.
NOTE: Do not touch a bare cable that may have high-voltage. If the cable must be touched or if accidental contract is unavoidable, wear insulated gloves and insulate the cable using insulation tape.
(5) Turn the ignition switch off.
HINT: If the ignition switch cannot be turned off, remove the IGCT No.1 fuse from the HV relay block or disconnect the cable from the negative terminal of the auxiliary battery.
(6) Wear insulated gloves, and then remove the service plug.
(g) Precautions to be taken when disposing of the vehicle
(1) Disposing of HV battery
When scrapping the vehicle, remove the HV battery from the vehicle and return it to the location specified by the manufacturer. Any damaged HV battery should also be returned to the specified location.
CAUTION:
- After removing the battery, keep it away from water. Water may heat the battery, which results in fire.
- Accidents such as electric shocks could result if the vehicle and its hybrid vehicle battery are disposed of improperly or abandoned. Therefore, make sure to return any hybrid battery to the prescribed recovery route through a LEXUS dealer.

(i) Precautions to be observed when towing
(1) Tow the damaged vehicle with its front and rear wheels lifted off the ground.
CAUTION: Towing the damaged vehicle with its front wheels on the ground may cause the motor to generate electricity. This electricity could, depending on the nature of the damage, leak and cause a fire.

(j) Towing with the 4 wheels on the ground
CAUTION:
- If the damaged vehicle needs to be towed using a rope, do not exceed 30 km/h (19 mph) and tow a limit distance and then have the vehicle towed by a truck.
- Turn the ignition switch to the ON position and shift the selector lever to the N position.
- If any abnormality is present in the damaged vehicle during towing, stop towing immediately.


8. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER
The LEXUS RX400h is equipped with a Supplemental Restraint System (SRS).
CAUTION: Failure to carry out the service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing and lead to serious injury. Furthermore, if a mistake is made when servicing SRS, it is possible that the SRS may fail to operate properly. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following section carefully.