Lexus GS200t 2016 User manual

2016 GS200t/350/450h/F Pre-Delivery Service Manual
Lexus Technician:
Before you perform 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)andRepairManual
  informationforthisvehicle
 •ReadandunderstandthePDSPrecautionsintheTSIBsandonpages0,5and56.
 •Attendthe“TechnicalIntroductiontoLexusCourseL005”attheLexusAreaOfce
When performing PDS on this vehicle:
 •UsethePDSManualwhenperformingthisservice
 •ChecktheTechnicalInformationSystem(TIS)foranyupdatedPDSTSIBsandapplicableRepairManualinformation.
 •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
The following TSIBs and Repair Manual information are available on TIS (on TIS, click on Check Sheet links):
 BatteryMaintenanceforIn-StockVehicles&Pre-Delivery
 D/CCutFuseInstallationduringPDS
 EnformApps&DataServicesDownload&InstallationProcess
 FloorMatInstallationduringPDS
 FrontLicensePlate&MountingBracketInstallation
 FrontWheelOpeningExtensionPadInstallationduringPDS
 HybridSystemElectricalSafetyPrecautions
 Long-TermVehicleStorageGuidelines
 MaintenanceforHV&AuxiliaryBatteries
 ParkingAssistMonitorSystemInitialization
 TirePositioningBeforeNewVehicleDelivery
 TirePressureWarningSystemInitialization
 VGRS/LDHSystemInitialization
 WheelFilmforBrakeRotorRustPrevention
 XMActivationConrmationduringPDS
To obtain PDS material:
Manual
 •DownloadfromTISwebsiteorLexusCustomerServiceswebsiteonDealerDaily
CheckSheet
 •DownloadandprintfromTISwebsiteorLexusCustomerServiceswebsiteonDealerDaily
 •Sheetistwo-sided;backsidehasproceduretips
OtherPDSTSIBsandRepairManualinformation
 •DownloadfromTISwebsite
Contact your District Service & Parts Manager if you have any questions.
ENGINE = POWER switch on hybrid models
©2015Lexus,aDivisionofToyotaMotorSalesUSA,Inc.
TPWS Operation Verication
1.ConnectTechstreamtoDLC3.
2.Adjustalltires,exceptthecompactsparetire*,tothestandardtireinationpressureasindicatedonthetire
 andloadinginformationlabelonvehicle.
NOTE:
  • Toadjusttirepressurecorrectlywhenoutsidetemperatureissignicantlycolderorwarmerthanshop
   temperature,performaHealthCheckusingTechstreamandselectthe“CompensationTirePressure”
   checkbox.CompensationpressureswillbedisplayedontheHealthCheckresultsscreen.
  • Adjustthetirepressurewhenthetiresarecold.
*Ifequipped
JBS20151117

2016MY
GS200t/350/450h/F
Pre-Delivery
Service Manual

TheGS450hhasuniqueoperatingmodes,soalwaysfollowtheprecautionsbelowwhen
performingthePDSoperation:
 • TheGS450hcontainshighvoltage(upto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,puttheselectorleverin“P”,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sidesoftherearseatstocoolthehybridvehiclebattery.Donot
  blocktheseairvents.
 • Donotsplashwaterontheelectriccomponentsintheenginecompartment.
READ AND UNDERSTAND TSIB “Hybrid System Electrical Safety Precautions.”
GS200t/350/450h/F
PRECAUTIONS
0

INSPECTION DETAILS
 A.ENGINECOMPARTMENT........................................................ 1
 B.LOCKSANDLIGHTS................................................................ 6
 C.LEFTFRONT............................................................................. 13
 D.LEFTREAR............................................................................... 39
 E.CARGOAREA........................................................................... 43
 F. RIGHTREAR............................................................................. 45
 G.RIGHTFRONT.......................................................................... 46
 H.FRONTBUMPER...................................................................... 49
 I. UNDERVEHICLE(SAFETY/DAMAGE).................................... 50
 J. ROADTEST.............................................................................. 54
COMPLETION....................................................................................... 64
INDEX ................................................................................................... 67
I
TABLE OF CONTENTS
GS200t/350/450h/F

1Fuseboxes............................................................................................................-
2Battery.................................................................................................................. 3
3Engineoilleveldipstick........................................................................................ 2
4Enginecoolantreservoir....................................................................................... 5
5Engineoilllercap................................................................................................ -
6Brakeuidreservoir.............................................................................................. 4
7Washeruidtank.................................................................................................. 4
8Electriccoolingfans............................................................................................ 56
9Condenser............................................................................................................. -
10Radiator.................................................................................................................-
Page
NOTE:
Install protective fender covers prior to beginning the under-hood inspection.
Gasoline Vehicle - GS350
II
TABLE OF CONTENTS
GS200t/350/450h/F

Page
Gasoline Vehicle - GS200t
1Fuseboxes............................................................................................................ -
2Battery.................................................................................................................. 3
3Intercoolercoolantreservoir................................................................................. 5
4Engineoilleveldipstick........................................................................................ 2
5Engineoilllercap................................................................................................ -
6Enginecoolantreservoir....................................................................................... 5
7Brakeuidreservoir.............................................................................................. 4
8Washeruidtank.................................................................................................. 4
9Condenser............................................................................................................. -
10Electriccoolingfans............................................................................................ 56
  Radiator.................................................................................................................-
11
NOTE:
Install protective fender covers prior to beginning the under-hood inspection.
III GS200t/350/450h/F
TABLE OF CONTENTS

1Fuseboxes............................................................................................................ -
2Battery.................................................................................................................. 3
3Engineoilleveldipstick........................................................................................ 2
4Enginecoolantreservoir....................................................................................... 5
5Engineoilllercap................................................................................................ -
6Brakeuidreservoir.............................................................................................. 4
7Washeruidtank.................................................................................................. 4
8Electriccoolingfans............................................................................................ 56
9Condenser............................................................................................................. -
10Radiator.................................................................................................................-
Page
NOTE:
Install protective fender covers prior to beginning the under-hood inspection.
Gasoline Vehicle - GS F
IV GS200t/350/450h/F
TABLE OF CONTENTS

1Engineoilleveldipstick........................................................................................ 2
2Enginecoolantreservoir....................................................................................... 5
3Engineoilllercap................................................................................................ -
4Powercontrolunitcoolantreservoir..................................................................... 5
5Brakeuidreservoir.............................................................................................. 4
6Fusebox................................................................................................................-
7Washeruidtank.................................................................................................. 4
8Electriccoolingfans............................................................................................ 56
9Condenser............................................................................................................. -
10Radiator.................................................................................................................-
Page
Hybrid Vehicle - GS450h
NOTE:
Install protective fender covers prior to beginning the under-hood inspection.
VGS200t/350/450h/F
TABLE OF CONTENTS

Engineswitch....................................................................................................... 9
Shiftlever............................................................................................................ 55
Meters................................................................................................................ 22
Multi-informationdisplay..................................................................................... 27
Parkingbrakeswitches....................................................................................... 57
Turnsignallever................................................................................................. 11
Windshieldwiperandwasherswitch.................................................................. 20
Emergencyasherswitch................................................................................... 12
Trunkopener..................................................................................................... 21
Hoodlockreleaselever....................................................................................... 2
Tiltandtelescopicsteeringcontrolswitch*......................................................... 27
Airconditioningsystem....................................................................................... 28
Audiosystem...................................................................................................... 29
Trunkopenermainswitch.................................................................................. 48
Page
1
2
3
4
5
6
7
8
9
10
11
12
*Ifequipped
13
14
VI
TABLE OF CONTENTS
GS200t/350/450h/F

Audioremotecontrolswitches............................................................................30
Paddleshiftswitches.............................................................................................-
Talkswitch..........................................................................................................30
Metercontrolswitches........................................................................................30
Vehicle-to-vehicledistancebutton*.....................................................................60
Cruisecontrolswitch*.........................................................................................60
LKA(Lane-KeepingAssist)switch*....................................................................58
Telephoneswitches............................................................................................30
Page
*Ifequipped
1
2
3
4
5
6
7
8
GS 200t
GS 350
GS 450h
GS F
VII
TABLE OF CONTENTS
GS200t/350/450h/F

*Ifequipped
Insiderearviewmirror.........................................................................................36
Sunvisors...........................................................................................................36
Vanitymirrors......................................................................................................36
Interiorlight.........................................................................................................35
Personallights....................................................................................................35
Moonroofswitches..............................................................................................37
“SOS”button*.....................................................................................................38
Garagedooropenerswitches............................................................................38
Page
1
2
3
4
5
6
7
8
VIII
TABLE OF CONTENTS
GS200t/350/450h/F

Drivingpositionmemoryswitches.......................................................................16
Outsiderearviewmirrorswitches........................................................................18
Doorlockswitches..............................................................................................17
Powerwindowswitches.......................................................................................17
Windowlockswitch............................................................................................17
Page
1
2
3
4
5
IX
TABLE OF CONTENTS
GS200t/350/450h/F

*Ifequipped
Seatheaterswitches*......................................................................................... 35
Seatventilatorswitches*.................................................................................... 35
RemoteTouch.................................................................................................... 31
Intuitiveparkingassistswitch*............................................................................ 34
Rearsunshadeswitch........................................................................................ 37
Drivingmodeselectswitch................................................................................. 61
Snowmodeswitch.............................................................................................. 57
TVDswitch**..........................................................................................................-
Page
1
2
3
4
5
6
7
8
**GSFonly-notshownhere
(locatednearSnowmodeswitch)
X
TABLE OF CONTENTS
GS200t/350/450h/F

VSCOFFswitch................................................................................................. 62
Heatedsteeringwheelswitch*........................................................................... 34
Automatichighbeamswitch*............................................................................. 12
Instrumentpanellightcontrolswitches............................................................... 19
Odometer/Tripmeterandtripmeterresetbutton............................................... 19
HUD(Head-UpDisplay)switches*..................................................................... 19
Brakeholdswitch*.............................................................................................. 58
ASC(ActiveSoundControl)switch*................................................................... 63
Page
1
2
3
4
5
6
*Ifequipped
7
8
GS 200t
GS 350
GS 450h
GS F
XI
TABLE OF CONTENTS
GS200t/350/450h/F

INSPECTION DETAILS
GS200t/350/450h/F

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moonroofarea
e)Aroundthequrterwindow
f)Aroundtherearwindow
PAINT FINISH (PAINT DEFECTS, DAMAGE)
Visuallyandbyhandinspectallbodypanels(doors,trunk,
fenders,enginehood,roofpanel)forsurfacedamagefrom
shipmentorforanyabnormalities(surfacerust,paintaking,
chips,dentsorscratches).
NOTE:
Carefullyinspectallpaintedsurfacesinawell-illuminated
area(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rearviewmirrors
e)Exteriorlightssuchasheadlights,turnsignallights,side
 markerlights andtaillightlenses
f)Doors,enginehoodandfuelllerdoor
g)Moonroof
h)Front/Reardoorpanelprotector
i)Outsidedoorhandle
j)Radiatorgrille
k)Vehiclenameemblems
1GS200t/350/450h/F
INSPECTION DETAILS - A. ENGINE COMPARTMENT

ENGINE HOOD RELEASE LEVER
Usetheenginehoodreleaselevertocheckthatthelatch
operatesproperly.Ensurethattheenginehoodopensand
closessmoothly.
ENGINE OIL LEVEL (ENGINE 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.
1Low
2Normal
   Excessive
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.
3
2GS200t/350/450h/F
INSPECTION DETAILS - A. ENGINE COMPARTMENT

BATTERY TERMINAL TIGHTNESS AND
CHARGE
a)Checktheelectrolytelevel.Iftheelectrolytelevelislow, 
 checkthebatterycaseforleakage.
b)Checkthebatterycharge.Measuretheopen-circuit 
 batteryvoltagebetweentheterminals.Ifthevoltage 
 readingislessthan12.6volts,rechargethebattery.
NOTE:
Beforemeasuringthevoltage,turnofftheengineandall
electricalsystems.Wait60secondstoremovethesurface
charge.Iftheenginewasrunningbeforemeasuringthe
voltage,wait20minutesaftertheenginestopstoremove
thesurfacecharge.
c)Checkthatthebatteryterminalsareproperlyconnected 
 andthattheclampisrmlyinstalled.
   Terminals
   Hold-downclamp
d)Printoutbatterychargetest.
Gasolinevehicles
Hybridvehicles
1
2
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.
3GS200t/350/450h/F
INSPECTION DETAILS - A. ENGINE COMPARTMENT

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atthe“MAX”line
(within0.2inches[5.0mm]below).
NOTE:
RefertotheRepair Manualforuidspecications.
GS200t/350/450h
GSF
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
towithin2inchesofthecap.
4GS200t/350/450h/F
INSPECTION DETAILS - A. ENGINE COMPARTMENT

ENGINE COOLANT LEVEL / HYBRID
SYSTEM POWER CONTROL UNIT
COOLANT LEVEL*
Visuallycheckthecoolantlevelthroughthecoolant
reservoirtankwhentheengine/hybridsystemiscool.
Thecoolantlevelissatisfactoryifthelevelisbetweenthe
“FULL”and“LOW.”
1Reservoircap
2FULL/“F”line
3LOW/“L”line
Onlyuse“ToyotaSuperLongLifeCoolant.”
CAUTION:
Toavoidburningyourself,donotremovetheradiatorcap
whentheengine/hybridsystemishot.
Enginecoolant
(GS350shown;GS200t&GS450hsimilar)
PowerControlUnitcoolant
(GS450honly)
*Ifequipped
Enginecoolant
(GSF)
Intercoolercoolantreservoir
(GS200tonly)
5GS200t/350/450h/F
INSPECTION DETAILS - A. ENGINE COMPARTMENT