Lexus CT 200H 2014 User manual

CT 200h Pre-Delivery Service Manual
Lexus Technician:
Before you perform a Pre-Delivery Service (PDS) on this vehicle, be sure you:
 •ReadandunderstandthisPDSManual
 •ReadandunderstandallapplicablePDSTechnicalServiceInformationBulletins(TSIBs)forthisvehicle
 •ReadandunderstandthePDSPrecautionsintheTSIBsandpagesi,9,10.
 •Attendthe“TechnicalIntroductiontoLexusCourseL005”attheLexusAreaOfce
When performing a PDS on this vehicle:
 •UsethePDSManualwhenperformingthisservice
 •ChecktheTechnicalInformationSystem(TIS)foranyupdatedPDSTSIBsthatapplytothemodelyouare 
  servicing
 •VerifythattheVehicleIdenticationNumber(VIN)onrepairorderandvehiclematch
 •Liftvehicleandperformundervehiclesafety/damageinspection
 •Roadtestvehiclelongenoughtotesthotengineanddriveoverroughroad(Bottdots)totestforrattles/ 
  squeaks
 •WhenPDSiscompleted,signVehicleDeliveryCerticate,locatedintheglovebox
The following TSIBs are available on TIS:
 Hybridsystemelectricalsafetyprecautions
 Shortpininstallationduringpds
 Activationandinitializationoftirepressurewarningsystem
 Initialcalibrationofcompass
 Frontwheelopeningextensionpadinstallation
 Frontlicenseplatemountingbracketandlicenseplateinstallation
 Maintenanceforhv/auxiliarybatterybeforedelivery
 Floormatinstallation
To obtain PDS material:
Manual
 •DownloadfromTISwebsiteorLexusCustomerServiceswebsiteonDealerdaily
 •OrderfromMDC,00242-PDSCT-MAN14
CheckSheet
 •DownloadandprintfromTISwebsiteorLexusCustomerServiceswebsiteonDealerDaily,or
 •OrderfromMDC,00242-PDSCT-CK14,eachpacketcontains25CheckSheets
 •Sheetistwo-sided,backsidehasproceduretips
VehicleDeliveryCerticate
 •OrderfromMDC,00242-TIQ14
OtherPDSTSIBs
 •DownloadfromTISwebsite
Contact your District Service & Parts Manager if you have any questions.
MDC#00242-PDSCT-MAN14
JBS 20131130

2014MY
CT 200h
Pre-Delivery
Service Manual
CT200h

TheCT200hhasuniqueoperatingmodes,soalwaysfollowtheprecautionsbelowwhen
performingthePDSoperation:
 • TheCT200hcontainshighvoltage(202-650volts)ACandDCSystems.Allhighvoltage
  wiringandconnectionsareorangeincolor.Donotcarelesslytouchtheseorangecolored
  wiringharnessesandconnectors.
 • Thehybridsystemmaystartupandshutdownsuddenlywheneverthe“READY”lightis
  illuminated.Besuretoputthevehiclein“P”,applytheparkingbrake,andpushthe
  “POWER”switchOFFinordertostopthehybridsystem(the“READY”lightturnsOFF),
  beforeworkingintheenginecompartment.
 • Thehybridtransaxle,engineradiator,andinverterradiatormayreachhightemperatures
  duringinspection.Carefullyobserveallcautionlabelsandinstructionsonthese 
  components.
 • Besuretokeepthevehiclein“P”atalltimesunlessotherwiseinstructed.Whenthe 
  selectorleverisin“N”,thehybridvehiclebatterywillnotchargeevenifthegasolineengine
  isoperating.
 • Whenleavingthevehicle,push“P”parkswitch,applytheparkingbrake,andpushthe
  “POWER”switchOFFinordertostopthehybridsystem(the“READY”lightturnsOFF).
 • Airventsarelocatedontherightrearseatbacktocoolthehybridvehiclebattery.Donot
  blocktheseairvents.
 • Donotsplashwaterontheelectriccomponentsintheenginecompartment.
CT200h
PRECAUTIONS
i

INSPECTION DETAILS ........................................................................ 6
 A.ENGINECOMPARTMENT........................................................ 7
 B.LOCKSANDLIGHTS................................................................ 11
 C.LEFTFRONT............................................................................. 19
 D.LEFTREAR............................................................................... 42
 E.BACKDOOR............................................................................. 44
 F. RIGHTREAR............................................................................. 45
 G.RIGHTFRONT.......................................................................... 47
 H.FRONTBUMPER...................................................................... 49
 I. UNDERVEHICLE(SAFETY/DAMAGE).................................... 50
 J. ROADTEST.............................................................................. 54
COMPLETION....................................................................................... 62
MAINTENANCE FOR HV & AUXILIARY BATTERIES......................... 65
INDEX ................................................................................................... 66
CT200h
TABLE OF CONTENTS
ii

Enginecoolantreservoir........................................................................................... 10
Engineoilleveldipstick.............................................................................................. 9
Engineoilllercap...................................................................................................... -
Powercontrolunitcoolantreservoir........................................................................... 9
Brakeuidreservoir.................................................................................................... 9
Fuseboxes..................................................................................................................-
Radiator.......................................................................................................................-
Condenser...................................................................................................................-
Electriccoolingfans.................................................................................................. 56
Washeruidtank...................................................................................................... 10
Page
NOTE:
Install protective fender covers prior to beginning the under hood inspection.
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1CT200h
TABLE OF CONTENTS

*Ifequipped
Headlightswitch....................................................................................................... 17
Turnsignallever....................................................................................................... 17
Foglightswitch......................................................................................................... 18
Gaugesandmeters.................................................................................................. 27
Multi-informationdisplay........................................................................................... 31
Windshieldwipersandwasherswitch...................................................................... 24
Rearwindowwiperandwasherswitch*................................................................... 24
Power(ignition)switch.............................................................................................. 15
Emergencyasherswitch......................................................................................... 18
Navigationsystem*................................................................................................... 36
Displayaudiosystem*.............................................................................................. 36
Glovebox................................................................................................................. 48
Airconditioningsystem............................................................................................. 33
Audiosystem............................................................................................................ 34
Rearwindowandoutsiderearviewmirrordefoggers.............................................. 23
Tiltandtelescopicsteeringcontrollever.................................................................. 32
Pre-collisionbrakeoffswitch*................................................................................... 19
Parkingbrakepedal.................................................................................................. 56
Hoodlockreleaselever.............................................................................................. 8
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2CT200h
TABLE OF CONTENTS

Audioremotecontrolswitches.................................................................................. 35
Talkswitch................................................................................................................ 35
Multi-informationswitch............................................................................................ 31
Telephoneswitches.................................................................................................. 35
Distanceswitch*....................................................................................................... 59
Cruisecontrolswitch*............................................................................................... 58
Dynamicradarcruisecontrolswitch*....................................................................... 59
Horn.......................................................................................................................... 61
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567
*Ifequipped
3CT200h
TABLE OF CONTENTS

*Ifequipped
Headlightcleanerswitch*......................................................................................... 25
Outsiderearviewmirrorswitches............................................................................ 23
Instrumentpanellightcontrolswitches..................................................................... 23
Intuitiveparkingassistswitch................................................................................... 31
Heatedsteeringwheelswitch.....................................................................................--
Windshieldwiperde-icerswitch*.............................................................................. 25
Fuelllerdooropener............................................................................................... 32
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NOTE:
Inspect interior parts after removing the necessary factory interior protective covering.
To prevent the battery from being discharged, the hybrid system should be running when the
electrical control switches are turned on.
4CT200h
TABLE OF CONTENTS

*Ifequipped
Hybridtransmissionshiftlever.................................................................................. 55
Ppositionswitch....................................................................................................... 15
Securityindicator................................................................................................ 12,13
Seatheaterswitches*............................................................................................... 38
OPENCLOSEswitch*................................................................................................. -
AUXport................................................................................................................... 34
USBport................................................................................................................... 34
Poweroutlet.............................................................................................................. 37
Cupholders.................................................................................................................-
TILTswitch*................................................................................................................. -
Remotetouch*.......................................................................................................... 36
EVdrivemodeswitch............................................................................................... 60
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5CT200h
TABLE OF CONTENTS

INSPECTION DETAILS
6CT200h

WASHING VEHICLE
Afterwashingvehicle,makesurealladhesivewrappinglm
isremoved.
NOTE:
Handwashingisrecommended.
WATER LEAK TEST
Visuallyandbyhandcheckforwaterleaksinthevehicle
interiorfromeachofthefollowingareas(makesurethatthe
trimandoorcarpetarenotdamp):
a )Doorglassweatherstrips
b )Frontcowlsides
c )Aroundthewindshield
d )Aroundthemoonroof*area
e )Aroundthequarterwindow
f )Aroundtherearwindow
PAINT FINISH (PAINT DEFECT, DAMAGE)
Visuallyandbyhandinspectallbodypanels(doors,back
door,fenders,enginehood,roofpanel)forsurfacedamage
fromshipmentoranyabnormalities(surfacerust,paint
aking,chips,dentsorscratches).
NOTE:
Useawell-illuminatedareatoclearlyinspectallpainted
surfaces(800-luxilluminationisrecommended).
EXTERIOR PARTS FOR FIT
Visuallyandbyhandcheckthefollowingpartsforproper
installation,rust,t,misalignmentandlooseitems:
a )Frontandrearbumpers
b )Windowmoldings(front,sideandrear)
c )Lexusemblems(frontandrear)
d )Outsiderearviewmirrors
e )Headlights,turnsignallights,sidemarkerlights,fog 
  lightsandtaillightlenses
f )Doors,enginehoodandfuelllerdoor
g )Moonroof*
h )Front/reardoorpanelprotector
i )Outsidedoorhandle
j )Radiatorgrille
k )Vehiclenameemblems
*Ifequipped
Rear turn signal light
Back-up light
License plate lights
Headlight high beam
thgil gof tnorF thgil gof tnorF
thgil langis nrut tnorF
Rear turn signal light
Back-up light
License plate lights
Headlight high beam
thgil gof tnorF thgil gof tnorF
thgil langis nrut tnorF
7CT200h
INSPECTION DETAILS - A. ENGINE COMPARTMENT

ENGINE HOOD RELEASE LEVER
Checkthattheopeningandclosingoftheenginehood
issmoothandthatthelatchoperatesproperlyusingthe
enginehoodreleaselever.
8CT200h
INSPECTION DETAILS - A. ENGINE COMPARTMENT

SHORT PIN INSTALLATION
RefertotheServiceBulletin.
ENGINE OIL LEVEL (HYBRID SYSTEM NOT
RUNNING)
a) Removetheengineoilleveldipstickandwipeitclean. 
  Reinsertthedipstickandpullitouttochecktheoillevel.
  Thelevelshouldbebetweenthetwomarks.
   Low
   Full
b )Checktheoilfordirtorimpurities.
NOTE:
Iftheoillevelislow,addspeciedengineoilandcheckfor
oilleaks.
BRAKE FLUID LEVEL
Visuallychecktheuidlevelthroughthereservoir.Ifthe
uidlevelislow,replenishthebrakeuidreservoirwith
FMVSSNo.116DOT3orSAEJ1703brakeuidandcheck
foruidleaks.Brakeuidlevelshouldbethe“MAX”line
(within0.2in.[5.0mm]below).
NOTE:
RefertotheRepair Manualforuidspecications.
HYBRID SYSTEM POWER CONTROL UNIT
COOLANT LEVEL
Visuallycheckthecoolantlevelthroughthecoolant
reservoirtankwhenthehybridsystemiscool.Thecoolant
levelissatisfactoryifthelevelisbetweenthe“FULL”and
“LOW”linesonthetank.
Reservoircap
 FULL
 LOW
CAUTION:
Topreventburningyourself,donotremovetheradiatorcap
whenthehybridsystemishot.
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9CT200h
INSPECTION DETAILS - A. ENGINE COMPARTMENT

ENGINE COOLANT LEVEL
Visuallycheckthecoolantlevelthroughthecoolant
reservoirtankwhentheengineiscool.Thecoolantlevelis
satisfactoryifthelevelisbetweenthe“FULL”and“LOW”
linesonthetank.
 Reservoircap
 FULL
 LOW
CAUTION:
Topreventburningyourself,donotremovetheradiatorcap
whentheengineishot.
WASHER FLUID LEVEL
Openthewashertankcapandvisuallycheckthewasher
uidlevelinthewashertank.Theuidlevelshouldbelled
within2inchesofthecap.
WIRING AND HOSES
a )Checkthehoses,hoseconnectorsandvariousclamps 
  fortightness.
b )Visuallyinspecttheconditionofallharnessconnectors 
  andterminalsforproperinstallationandtightness.
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10 CT200h
INSPECTION DETAILS - A. ENGINE COMPARTMENT

WIRELESS DOOR LOCK REMOTE
CONTROL SYSTEM
Inspectthefourfunctionsofthesystem.
   Locksalldoors
   Unlocksalldoors
   Opensthewindows(Pressandhold)
   Soundsalarm(Pressandhold)
a )Lockingthedoors
  1. Closeallthedoors.
  2. Press ontheelectronickeytolockallthedoors 
   fromoutsidethevehicle.
NOTE:
   Atthistime,alltheturnsignallightsashonce 
   soundingonebeep.However,whenyoupress
   withanydoornotclosedsecurely,thebuzzer 
   soundscontinuouslyuntilallthedoorsare  
   closedsecurely.
b )Unlockingthedoors
  1. Press ontheelectronickeyoncetounlockthe 
   driver’sdoor.
  2. Press onceagainwithin3secondsaftertherst
   pressingtounlocktheotherdoors.
NOTE:
   Atthistime,theinteriorlightandouterfootlights 
   comeonandalltheturnsignallightsashtwice, 
   soundingtwobeeps.
  3. Checkthatalldoorsautomaticallyre-lockafter60 
   secondsifanydoorisnotopened.
c )Openingthewindows
  Pressandhold toopenthewindows.
NOTE:
  Abuzzersoundstoindicatethatthewindowsandmoon
  roofareopening.
d )Soundingthealarm
  1. Pressandhold tosoundthealarm.
NOTE:
   Atthistime,alltheheadlights,taillightsandturn 
   signallightsash.
  2. Tostopthealarm,pressanybutton.
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4
11 CT200h
INSPECTION DETAILS - B. LOCKS AND LIGHTS

SMART ACCESS SYSTEM
a )Withelectronickeyinsideofthevehicle,touchthelock 
  sensor(ontheupperpartofthedoorhandle)andback 
  doorlockbutton.Checkthatthebuzzersoundsandthat
  thedoorsdonotlock.
b )Taketheelectronickeyandgetoutofthevehicle.Touch
  thelocksensor(ontheupperpartofthedoorhandle). 
  Checkthatthedoorlocks.
NOTE:
  Recognitionsignalsforthelockoperationwilloperate 
  uptotwoconsecutivetimes.
c )Fromadistanceofatleast2.3ft.(0.7m),approachthe
  vehicleandpullthedriverandpassengersidedoor 
  handles,andthebackdooropener.Checkthatthedoor
  unlocks.
NOTE:
  Thedoorscannotbeunlockedfor3secondsafterthe 
  doorsarelocked.
THEFT DETERRENT SYSTEM
Withthedoorslocked,checkthatthesystemoperates
properly.
System Test:
a )Openthewindows.
b )Lockthedoorsbysmartaccesssystem,wireless 
  remotecontrolormechanicalkey.Besuretowaituntil 
  thesecuritylightonthecenterpanelstartsashing.
c )Unlockoneofthedoorsusingtheinsidedoorlock.The
  systemshouldactivatethealarm(soundingofthehorn,
  blinkingoftheheadlights,taillightsandemergency 
  asher,lightingupinteriorlight).
d )Cancelthesystembyunlockingdoorswiththesmart 
  accesssystem,wirelessremotecontrolormechanical 
  key.
12 CT200h
INSPECTION DETAILS - B. LOCKS AND LIGHTS

IMMOBILIZER SYSTEM
a )Checkthatthesecurityindicatorlightasheswhenthe 
  “POWER”switchisOFF.
b )Checkthatthehybridsystemcanbestartedusingall 
  thekeys.
c )Checkthatthesecurityindicatorlightturnsoffwhen 
  startingthehybridsystem.
DOOR LOCK SYSTEM AND ILLUMINATED
ENTRY SYSTEM
a)Checkthatalldoorsopenandclosesmoothlyusingthe
  insideandoutsidedoorhandles.
b)Checkthatthedoorscannotbeopenedbyusingthe 
  insideandoutsidedoorhandleswhenthelockbuttonis
  inthelockedposition(exceptfrontinsidedoorhandles).
c)Forfrontinsidedoorhandles:Checkthatthefrontdoors
  canbeopenedbyusingtheinsidedoorhandleswhen 
  thelockbuttonisinthelockposition.
d)Checkexteriorkeylockcontrolsystemoperationby 
  mechanicalkey(withdriver’sdoor).
NOTE:
•Toremovethemechanicalkey:Releasethelockandpull 
 thekeyout.
•Tostorethemechanicalkey:Slideandholdtherelease 
 knob,insertthekey.
   Locksalldoors
   Closesthewindows(turnandhold)
   Unlocksthedoor(two-stepunlockfunction):
   1.Turnthekeyoncetounlockthedriver’sdoor.
   2.Turnthekeytwicetounlockallthedoors.
   Opensthewindows(turnandhold)
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2
3
4
Electronic keys
mechanical key
13 CT200h
INSPECTION DETAILS - B. LOCKS AND LIGHTS

e )Checkthattheouterfootlightilluminateswhenthedoor
  isopened.
REMOTE ENGINE STARTER*
a)StartingtheEngine
  1. Closeandlockalldoors.
  2. Quicklypress twiceandthenpressandhold
   for3seconds.
NOTE:
   Whentheenginestarts,thehazardlightswillashfor
   20seconds.
b)StoppingtheEngine
  1. Press orpressandhold for2seconds.
*Ifequipped
OUTERFOOT
LIGHT
14 CT200h
INSPECTION DETAILS - B. LOCKS AND LIGHTS

POWER SUPPLY CHANGEOVER AND
HYBRID SYSTEM START/STOP
Checkforproperactivationofthe“POWER”switch.
Powersupplychangeover
a )Carrytheelectronickeyinthevehicleandapplythe 
  parkingbrake.
b )Withoutdepressingthebrakepedal,pressthe  
  “POWER”switchandchangethepowersupply.
   OFF
   Pressonce:ACCESSORYmode
   Presstwice:ONmode
   Pressthreetimes:OFF
c )Ineachmode,checkthatthepowersupplyhaschanged
  properly.
NOTE:
Ifthe“POWER”switchilluminatorblinksrefertotheRepair
Manual.
Hybrid system start/stop
a )Carrytheelectronickeyinthevehicleandapplythe 
  parkingbrake.
b )Checkthatthe“P”parkswitchisilluminated.
c )Whendepressingthebrakepedal,checkthatthegreen
  “POWER”switchilluminatorcomesonandpushthe 
  “POWER”switchtostartthehybridsystem.
NOTE:
The“READY”indicatorcomesonandabeepsounds.
d )Pushthe“POWER”switchregardlessofbrakeposition 
  tostopthehybridsystem.
NOTE:
Ifthehybridsystemisstoppedwiththevehicleinaposition
otherthan“P”,thepowersupplymodeisswitchedtothe
ACCESSORYmode,nottoOFFandthebatterywill
deplete.
e )Usethe“POWER”switchtoset“READY”mode(leave 
  in“READY”modeuntilfrontbumperprocess).
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1
15 CT200h
INSPECTION DETAILS - B. LOCKS AND LIGHTS

EXTERIOR LIGHTS
Walkaroundthevehicleandcheckthatthefollowinglights
illuminate:
a )Headlights
b )Daytimerunninglight
c )Parkinglights
d )Sidemarkerlights
e )Foglights
f )Turnsignallights
g )Licenseplatelights
h )Taillights
i )Brakelights(whenbrakepedalisdepressed)
j )Back-uplights
Front turn signal light
Headlight low beam
Headlight high beam Front fog light
Rear turn signal light
Back-up light
License plate lights
Headlight high beam
thgil gof tnorF thgil gof tnorF
thgil langis nrut tnorF
Front(HalogenHeadlights)
Front(LEDHeadlights)
Rear turn signal light
Back-up light
License plate lights
Headlight high beam
thgil gof tnorF thgil gof tnorF
thgil langis nrut tnorF
16 CT200h
INSPECTION DETAILS - B. LOCKS AND LIGHTS