Part 1

INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

PRECAUTION

1. BASIC REPAIR HINT
(a) HINTS ON OPERATIONS









(b) PRECOATED BOLTS





(1) Precoated bolts are bolts that have the thread area coated with seal lock adhesive.
(2) 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.
(3) 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.
(4) The adhesive may take a specified amount of time until it hardens.
(c) GASKETS
(1) Gaskets are non-reusable. Always replace them with new ones.
(2) When necessary, use a sealer on gaskets to prevent leaks.
(d) BOLTS, NUTS AND SCREWS
(1) Carefully follow all the specifications for tightening torques. Always use a torque wrench.
(e) 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.






(f) CLIPS
(1) When prying a clip to remove it, always tape the tip of the tool with protective tape to protect the vehicle from damage.
(2) 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.





(g) CLAWS
(1) When prying a claw to detach it, always tape the tip of the tool with protective tape to protect the vehicle from damage.
(2) 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.





(h) NOTICE FOR ENGINE HOOD/DOOR ADJUSTMENT





(1) 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.

(i) 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.
(j) 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 cause damage.





(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, it may leak air. Use a step-down adapter if necessary.
(k) 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 a 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
(a) Engineers must undergo special training to be able to perform high-voltage system inspection and servicing.
(b) 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.
(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 you are servicing the vehicle.





(d) 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.

(e) 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.






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

(g) When servicing the vehicle, do not carry metal objects like mechanical pencils or scales that can be dropped accidentally and cause a short circuit.
(h) 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).






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

(j) The screw of a high-voltage terminal should be tightened firmly to the specified torque. Both insufficient and excessive torque can cause failure.
(k) 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.
(l) Do not place the battery upside down while removing and installing it.
(m) 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.









3. 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

4. ACTIONS TO BE TAKEN WHEN 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 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.
(1) Move the shift lever to the P position and engage the parking brake.
(2) Remove the key from the vehicle.





(3) 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.
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.
(4) 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.





(5) Depress the brake pedal and push the power switch to start the hybrid system.
NOTE: If the hybrid system fails to start, the master warning light flashes, and the multi-information display is as shown in the illustration, the HV battery may be depleted.
(6) 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 LS600h L.

(b) When the HV battery is depleted, replace the HV battery.





HINT: If the HV battery is depleted, the master warning light flashes, the multi-information display is as shown in the illustration, and DTC P3000-388, 389 or 603 is output.

5. ACTIONS TO BE TAKEN FOR VEHICLE DAMAGED BY IMPACT
(a) 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 electrolyte)
- Vinyl tape (for insulating cables)
- Electrical tester

(b) Actions to be taken at the accident site.
(1) Wear insulated or rubber gloves, goggles and safety shoes.
(2) 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.
(3) 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.
(4) 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.
(5) If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the procedure below.





1 Move the shift lever to the P position and engage the parking brake.
2 Remove the key from the vehicle. Then disconnect the cable from the negative (-) terminal of the auxiliary battery.
3 Remove the service plug while wearing insulated gloves.





CAUTION: Do not turn the power switch ON (READY) while removing the service plug.





NOTE: If the service plug cannot be removed due to damage to the rear portion of the vehicle, remove the IGCT NO. 1 fuse from the engine room No. 1 relay block instead.

(c) Moving the damaged vehicle.
HINT: If any of the following applies, 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 READY light is not illuminated when you start the engine.
NOTICE:
- Tow the damaged vehicle with its front and rear wheels lifted off the ground. In an emergency where a tow truck is not available, the vehicle may be temporarily towed using a cable or chain secured to the emergency towing eyelet. Also, make sure that the following conditions are met: 1) the towing should only be performed on paved roads for short distances at low speeds; 2) a driver must be in the vehicle to steer and operate the brakes; and 3) the vehicle's wheels, drive train, axles, steering and brakes must be operating normally.
- 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. Only if none of the above applies and there are no problems that might affect driving, drive the vehicle away from the accident site to a safe place nearby.
- 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 Move the shift lever to the P position and engage the parking brake.
3 Disconnect the 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. If you see any liquid on the road surface, it could be a highly alkaline electrolyte leakage.
Wear rubber gloves and goggles, and 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.
(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 cables)
- Electrical tester

(f) Precautions to be observed when servicing the damaged vehicle.
(1) Wear insulated or rubber gloves, goggles, and safety shoes.
(2) 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.
(3) 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.
(4) If the electrolyte adheres to your skin, wash the skin immediately using saturated boric acid solution or a large amount of water. If the electrolyte adheres to an article of clothing, take the clothing off immediately.
(5) If the electrolyte comes in contact with your eyes, call out loudly for help. Do not rub your eyes. Wash them with a large amount of water and seek medical care immediately.
(6) If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the procedure below.
1 Move the shift lever to the P position and engage the parking brake.
2 Remove the key from the vehicle. Then disconnect the cable from the negative (-) terminal of the auxiliary battery.
3 Wear insulated gloves, and then remove the service plug.
NOTE: If the service plug cannot be removed due to damage to the rear portion of the vehicle, remove the IGCT NO. 1 fuse from the engine room No. 1 relay block instead.

(g) Precautions to be taken when disposing of the vehicle.
When scrapping the vehicle, remove the HV battery from the vehicle and return it to the location specified by the manufacturer. The same applies to any damaged HV battery.
(h) After removing the battery, keep it away from water. Water may heat the battery, which results in a fire.
(i) Do not tow the vehicle with its 4 wheels on the ground.
NOTE: In an emergency where a tow truck is not available, the vehicle may be temporarily towed using a cable or chain secured to the emergency towing eyelet. Also, make sure that the following conditions are met: 1) the towing should only be performed on paved roads for short distances at low speeds; 2) a driver must be in the vehicle to steer and operate the brakes; and 3) the vehicle's wheels, drive train, axles, steering and brakes must be operating normally.