Mihanicos

Hi, Remove the inverter radiator cap. Loosen the air bleed plug [6mm] at the front driver's side and connect the air bleed hose. Insert the other end of the hose into the filler tank and drain the coolant. Refit the bleeder plug, tighten to 1.5 Nm. no more, risk of deformation. Find the hose which connects to a pipe going down and making a 90 degree bent at the bottom of the engine. This pipe is held in position by a a drain plug. Release it and drain the coolant. Tighten it to 13 Nm. At the bottom of the engine, there is another drain 10mm plug. release it and drain the coolant. Tighten to 39 Nm. Collect and measure the total amount drained. RHD capacity is 2.8 litres. Loosen the 6 mm bleeder plug and connect the hose. keep the other end of the hose next to the filler tank. Add coolant until the coolant in the tank is at the maximum and the same level with bleeder hose. Hold the hose next to the tank. Remove the hose and tighten the plug to 1.5 Nm, no more. Connect the techstream or a similar scanner and operate the active test on the pump. Add coolant to the max level of the tank while operating the pump for about 3 minutes and stop for 1 minute. If the water pump operates for more than 5 seconds without enough water, it will stop for 15 seconds and restart. Excessive coolant will cause an overflow. Keep adding coolant for 1 minute and stopping for 1 minute. When there are no more air bubbles and the sound of the pump is quiet, the air bleeding is complete. Make sure that you have added more coolant than the amount drained. Driving the car with air in the circuit, it will display trouble codes. To eliminate the remotest possibility of air being trapped put the car heater on full and with the engine running squeeze the heater water hoses one at a time. With the radiator cap removed, observe that every time the heater hose is squeezed, the water level in the radiator rises and falls. Also make sure you can feel hot coolant in the hoses indicating circulation.This expels all air from the coolant in the heat exchanger Test drive the car and drive slowly for a few minutes. Stop and check the coolant level. Drive for longer time and keep checking. Make sure you check the coolant level every time the engine cools down. If you need to add coolant it means that you still had air in the system or you have a leak. It is of paramount importance to eliminate all air from the system. Trapped air impairs the coolant circulation resulting in insufficient cooling of the electronic components thereby shortening their life and eventually leading to a failure. It also causes engine temperature rise. Chris.

Hi, There is an oil filter, some models have a very fine mesh wish can be cleaned and reinstalled. Other models have a paper filter which must be replaced. On some models like the RX there is a filler bolt with WS embossed on on it. If I remember correctly, it is on the high side of the gearbox may be passenger side and there is a protective shield to remove. If there is no filler plug, very unlikely, you will have to do add oil by disconnecting the hose connected to the lower pipe on the side of the gearbox. These are the flow and return oil hoses to the transmission fluid oil cooler. In this case, the drain plug is also the oil level plug. You will find another plastic tube within the drain plug, removable too, which sets the oil level. The amount drained is about half the total capacity of the gearbox. WS is the transmission fluid used by Toyota. There others, fully synthetic better, and so on , but I always use the manufacturer's recommendations. Put the car on a level surface and drain the oil. Add about 500 ml more oil of the amount drained. Re install the WS filler plug on the top side and the drain plug. Instead some models have two plugs on the gearbox sump, one is the drain, the other is the oil level plug. With both removed, you will know which is which. You can also identify them by looking inside them with a mirror. Start the engine and observe the oil temperature using the Techstream or an infrared thermometer. Move the gear lever throughout the range about 3 times remaining at each gear for about 3 seconds. Leave the engine running in Park. Before draining any oil, make sure that the Line Pressure is OFF with the power switch ON, " ready ". When the oil temperature is between 30C and 40C, open the drain plug and let the excess oil drain. Refit the oil plug. If there is no oil coming out, repeat the filling procedure, adding more oil. For cold climates, drain at 35C. To make the engine run continuously, put it in service mode : Turn the power switch ON Shift to P and press the accelerator Fully twice Shift to N and " " " Shift to P and " " " Check that " Maintenance Mode" is displayed. Turn the power switch ON It is imperative that you have no Line Pressure. Normally, if the oil level is correct and there are no blockades in the flow and return lines, you do not get Line Pressure. Test drive, drive it fast if you can and make sure you have no Pressure Line DTC Chris.

RCM.pdf Attached herewith is the circuit diagram of the mirrors for a Lexus GS 450H. I hope it will be of some help to you. Chris.

When the engine is not sufficiently warm, the ECM uses internally stored default values for the fuel trims. This is open loop operation. When the engine is hot and a preset coolant temperature is reached and the O2 sensor is hot enough to give a good signal, the closed loop operation comes into effect and the O2 sensor is used to adjust the air to fuel ratio. The base line for both short and long term fuel trims is 0%. Lean conditions are represented by positive values and rich by negative values. Fuel trims are generally considered good if they are within + or - 10%. Most manufacturers will set a trouble code when the fuel trims either or individually achieve a value grater than 20% for a prolonged period of time. Wrong engine timing will influence the fuel trims. Chris.

In 2016 ACEA introduced the C5 specification applicable to 0W20 and 5W20 engine oils in response to engine manufacturers specifications. These oils have a High Temperature High Shear [ HTHS ] viscosity lower than 2.9 mPa.s so C1 - C4 categories were unsuitable. C5 requires a mid SAPS oil, same as C2 and C3 but an HTHS viscosity between 2.6 and 2.9 mPa.s. Also the fuel economy for C5 must be better than 2% compare to C3. It follows from the foregoing that C5 specification is a less viscous oil and that means is for engines with tighter tolerances. Hence the oil film between the engine gaps is thinner in order to be able to lubricate the moving parts adequately. For older engines the gaps are bigger, requiring a more viscous oil. Using the oil selector of Eneos Europe, for a Lexus LS 460, 2007, the recommended oil is Eneos Hyper X, API SN, C2, C3. For a Lexus LS 430 2002, Eneos Ultra SN, C3 is recommended. In the ACEA standards specification it is stated in each C specification that it may be unsuitable for some engines and it is recommended that the manufacturer's recommendations should be adhered to. You can use the oil selector of other oil producers to find which oil they recommend for your car and you can compare and choose the best oil. Chris.

It is very important for many reasons to have the precise engine timing. Before you remove the timing belt or chain of any engine, you must always verify its timing and all the reference timing marks. There are a few special tools which can set precisely the engine timing and some engines may have only the TDC marked on the crankshaft. Find the inlet and exhaust valve timing of the engine with respect to the crankshaft position, from a repair manual. Mount a graduated disc in degrees on the engine's crankshaft and align the 0 degrees point of the disc with the TDC mark on the crankshaft. Turn the engine clockwise and observe when the inlet and exhaust valves when they just begin to open on No.1 cylinder. Check this reading against the engine's valve timing. Chris.

Here below are Toyota/ Lexus OBD II pin assignments: 1 PS GND, Pin switched to ground 2 J1850+ 5 GND Ground 6 CAN + 7 K- line 9 PS GND, Pin switched to ground 12 PS 5, Pin switched to +5 v 14 CAN- 15 SCI 16 V Battery Check that the respective data from each pin is available on the OBD II connector. Chris.

Upon further consideration of the causes that you have the displayed codes, the ECU goes into limp mode when the range of the sensors is not within the parameters programmed to the ECU . I would suggest before condemning the ECU, check that the voltage levels at the various sensors are available and the transmitted signals to the ECU are also available. P0102, 112,117 are caused due to being open or short circuited or due to the ECU malfunctioning. Chris.

Check the battery is fully charged. Like other learned members have already pointed out, make sure the body, the engine, the gearbox and the ECU have a good ground. Remove the ground cables and clean the common contact areas so the contact resistance is zero especially on the ECU. Check that all connectors and connections to the various sensors have clean and corrosion free contacts. Chris.

Supply to igct No.2 fuse comes from the auxiliary contact of the Ignition relay via a blue wire which terminates on terminal 9 of junction connector A9. It comes out from terminal 11 with a white wire which goes to igct No. 2 fuse. It exits the fuse with a blue wire to terminal 8b of junction connector 10A. It leaves the connector from terminals 3A and 3B, blue wires, connected together within the connector, [ one is used for RHD and the other is for LHD ] and they terminate to the inverter at terminals 30A ,30B and 31A 31B respectively. [ same provision for RHD and LHD ] I hope the foregoing is of some help. Chris.

When I had to choose a top quality fully synthetic oil for my car, I had to read a lot and ask the advice of professionals. You have to choose the viscosity best suited for the climate the car is used. For my car, 0W20 is recommended for Europe. But for countries like Israel, 5W30 is recommended because of the higher ambient temperatures. For UAE countries, a much higher viscosity is recommended, because of the higher ambient temperatures.If you use a lower viscosity oil, it will give you better mileage but the engine may burn some oil and it may wear out sooner, depending on its tolerances and gaps designed by the manufacturer. Some manufacturers design their engines to burn some oil in order to gain mileage. However, if the engine is fitted with a catalytic converter, the burnt oil will eventually blog the catalytic converter which will lead to replacement. The cost involved is usually quite high. Another important factor to always consider is the ACEA C specification suitable for an engine in question. This is the compatibility of the oil with respect to the catalytic converter fitted by the manufacturer, in terms of the amount of SAPS content [Sulfated ash, Phosphorus and Sulfur] of the oil. Using the wrong ACEA C specification will lead to possible engine damage and blockade of the catalytic converter. For Toyota and Lexus, C2 ACEA [ a minimum of High Temperature High Shear viscosity of 2.9 m Pa.s] specification is recommended. Toyota, as far as I know, please correct me if I am wrong, does not state the C specification of their engine oils. Chris.

Hi, From the repair manual, POA1B 163,164, 192, 193, 195, 198, 511, 512, 786, 794, all refer to errors relevant to the inverter converter assembly. The recommended repair is to replace the complete assembly. You have to wait at least 10 minutes after you remove the service plug to allow the capacitors within the assembly to discharge completely before you begin any work. Like other learned members already mentioned, you must find the cause of the problem and cure it before you replace the inverter assembly. The some parts within the assembly are available from Toyota. I know for sure that the capacitors are available. Chris.

Hi, Check that the brake pad clips are fitted correctly. The clip side facing the rotor should be in contact with the caliper side facing the rotor. When fitted correctly in this way, there is about 1cm gap between the rotor and the clip. Chris.

Hi, Heat the bolts with a butane flame and wrap a wet cloth around the bushings so they do not get burnt. Then cool the bolts and hit them with a hammer. Take care not to bend them. Make sure you have the nut fitted on the bolt so it just covers the bolt. This way you do not damage the thread of the bolt. Repeat the process until the bolts are free. Use WD 40 or a similar lubricant. Another way is to cut off the bolts to the size of the bushings, then drill through the bolts beginning with a small bit and use a bigger bit as you go on. Be careful you do not drill the bushing as well for obvious reasons. Alternatively, you could remove the bushings using the tool. Use heat while the bushings are being pressed to cause expansion to help freeing them. It may be worth replacing the bushes now, considering the trouble to remove them. Regards, Chris.

Hi, Before considering anything more serious and expensive, check that the 12v battery is charged to a minimum of 11 volts. Do this after the car has been switched off for some time. When it falls below that, you get unrelated Diagnostic Trouble Codes on starting. Another sign of a 12v battery being on its way is when the car is parked, you start it, wait for the engine to stop, leave the ignition on and wait a few minutes. If the 12V battery is below 11 volts, the engine restarts to charge it. The fuel consumption also increases by about 3 miles to the gallon or more, depending on ambient temperature and driving conditions. Regards, Chris

Hi, That is the tool I described!

Hi, Check and adjust the valve clearances. If the gaps are too big, the valves sound like your car's. Change the engine oil and filter, make sure you choose an oil to the manufacturer's viscosity and SAE specifications.

Hi, There is a tool set for removing control arm bushings and bearings. It is like a puller using a long thin threaded bolt and steel tubes of various sizes. Using the right combination of tubes and thick washers of the set, the bushing can be pushed out. Using the same tool, another bushing can be installed. The same principle applies to bearings. If you do not have this tool, before installing an interference fit bearing, put the new bearing in the freezer when you begin work to remove the bearing. By warming the bearing housing with a camping gas flame, the new bearing can be put in position by hand. You must be quick because when it gets hot from the housing, it will need some persuasion to move. Chris.

Hi, The Japanese car industry standards are much higher than those corresponding to European manufacturers. The most important check I would make for a any used car is that it has not been involved in an accident. There are also some checks you can do to determine the engine's condition. Toyota and Lexus have very reliable electronics and you should not worry about having any issues relating thereto. The traction battery, is easy to repair, usually you may have to change one or two modules which are readily available from Ebay and other sources. You can also buy Panasonic reconditioned traction batteries from Alibaba, last time I read they sell a minimum of five for $500 each. There are also new chinese traction batteries for your car for about $1500 each with three years guarantee or 30000 miles whichever comes first. There are many sources in the Internet. Chris.

Hi, The voltage monitoring of the traction battery cells is per two cells connected in series. Hence 14.4 is the nominal voltage of two cells in series. On this occasion, the traction battery had about 15v across each pair of two cells, therefore as it proved, it was ok to start the engine. The traction battery has 40 cells connected in series, each with a nominal voltage of 7.2 volts. The total battery voltage is 288 volts. Chris.

Hi, Looking at the circuit diagram of your car and considering the Diagnostic Trouble Codes you have, there are three interlocks before the engine starts. 1. The service plug link must be closed, make sure the plug is in and pushed towards the arrow direction to lock into position to establish the interlock. 2. The cover of the air conditioning inverter with the converter must be in position. 3. The air conditioning harness must be in position. From your description, it would appear that the service plug interlock is not made, assuming the other two interlocks are made hence the lock out relay prevents the engine from starting, purely on safety issues. The nominal voltage of each cell of the traction battery is 7.2 volts. Normally, they are charged to about 8 to 8.5 volts. The engine should start when the service plug interlock has been established. Kindest regards, Chris.

Hi, Thank you very much for the update and all the information regarding the problem. It is reassuring to see that the electronics of this car are very reliable and can withstand the wear and tear. Kindest regards, Chris.

Hi, P0868 894, refers to the difference between the value of the transmission revolution sensor rotational speed times the gear ratio of the 2nd stage motor speed reduction planetary gear unit and the MG2 rotational speed, exceeding a specific value continuously for a specified time at a speed of 22 mph or more. Before touching anything on the inverter converter and any high voltage equipment, remove the HV plug from the trunk and wait 10 minutes for the capacitors to discharge. Wear insulated gloves and measure the voltage present on the equipment you are about to touch. The problem could be at the wire harness or connectors of all relative equipment, Hybrid vehicle transmission assembly, oil pump with motor pump assembly, hybrid control ECU, Fusible Link and the oil pump relay. Check the hybrid ECU connector. Check for corrosion, dirt and anything that makes a bad contact. Oil pump motor controller connector. Check hybrid transmission SL1, SL2 solenoid valves and Solenoid valve connectors Transmission rev. sensor connector pin 1 and ground, 11 to 15 Ohms at 20C SL1 connector pin 3 and pin 2 , 5 to 5.6 Ohms at 20C SL2 '' '' 22 '' '' 21, '' '' '' '' '' '' In engine bay, check the fusible link of the oil pump. Check the oil pump relay resistance values. Pins 1 and 2 , 151 to 203 Ohms. Pins 3 and 5, 10 KOhms or more. With 12v across pins 1 and 2, resistance between pins 3 and 5 shoul be less than 1 Ohm. Check the harness and connector between HV control ECU and oil pump motor controller. There are measurements to take on the connectors which I will try to leave on another post if you want to pursue the issue further. P2797-865 , refers to the auxiliary transmission fluid pump control performance.The oil pump motor controller, controls the rotation speed of the oil pump motor [ 3 phase brushless motor ] in accordance with the rotation speed request signal sent from the hybrid control ECU. The controller also displays the oil pump motor status as a signal to the hybrid control ECU. To diagnose what is causing this DTC involves a lot of measurements and I will try to send them to you if you have the time to go through the tests. They are measurements on the connectors on the equipment involved. Concluding, make sure that the 12v battery is ok and it never falls below 11volts. Make certain that the ground points are good and without resistance between the battery negative terminal and the ground point in question. Male sure that all connectors are clean, corrosion free and sealed from rain, moisture, dirt and dust. make sure that they fit firmly and securely. Pay particular attention to the pins of the connectors, clean them if necessary with suitable solvents for electronic electronic equipment. Check for damaged harnesses and repair. Kindest regards, Chris.

I have been doing some research on the Internet about Inverter applications for cars. Researchgate.net and Freescale have some papers on high temperature electronics, such as Insulated Gate BipolarTransistor [ IGBT ] modules for electric and hybrid vehicles. As far as I could make, IGBT are used in conjunction with other semiconductors and the operating temperature limit of their circuits is 150C mainly due to solder considerations. Research is going on to improve the operating temperatures.