Lexus RX450h Dismantling Manual
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Lexus RX450h Dismantling Manual

Lexus RX450h Dismantling Manual

Gasoline-electric hybrid drive for hybrid vehicle gyl20/gyl25 series.
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RX450h
Gasoline-Electric
Lexus Hybrid Drive
GYL20/GYL25 Series

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Summary of Contents for Lexus RX450h

  • Page 1 RX450h Gasoline-Electric Lexus Hybrid Drive GYL20/GYL25 Series...
  • Page 2 Foreword This guide was developed to educate and assist dismantlers in the safe handling of Lexus RX450h gasoline-electric hybrid vehicles. RX450h dismantling procedures are similar to other non-hybrid Lexus vehicles with the exception of the high voltage electrical system. It is important to recognize and understand the high voltage electrical system features and specifications of the Lexus RX450h, as they may not be familiar to dismantlers.

  • Page 3: Table Of Contents

    Table of Contents About the RX450h ............................1 RX450h Identification ..........................2 Exterior................................3 Interior .................................4 Engine Compartment ..........................5 Hybrid Component Locations & Descriptions..................6 Specifications ..............................7 Lexus Hybrid Drive Operation .........................8 Vehicle Operation............................8 Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery..............9 HV Battery Pack............................9 Components Powered by the HV Battery Pack...................9...

  • Page 5: About The Rx450H

    The result of combining these two power sources is improved fuel economy and reduced emissions. The gasoline engine also powers an electric generator to recharge the battery pack; unlike a pure all electric vehicle, the RX450h never needs to be recharged from an external electric power source.

  • Page 6: Rx450H Identification

    RX450h Identification In appearance, the 2016 model year / 2015 calendar year RX450h is nearly identical to the conventional, non-hybrid Lexus RX350/200t. The RX450h is a 5-door wagon. Exterior, interior, and engine compartment illustrations are provided to assist in identification.

  • Page 7: Exterior

    RX450h Identification (Continued) Exterior  RX450h logo on the back door.  logos on the rocker molding.  Gasoline fuel filler door located on the left side rear quarter panel.   Exterior Front and Left Side View  ...

  • Page 8: Interior

    RX450h Identification (Continued) Interior  The instrument cluster (hybrid system indicator, READY indicator and warning lights) located in the dash behind the steering wheel, is different than the one on the conventional, non-hybrid RX350/200t.  A switchable gauge in the combination meter showing either a hybrid system indicator or a tachometer depending on driving mode.

  • Page 9: Engine Compartment

    RX450h Identification (Continued) Engine Compartment  3.5-liter aluminum alloy gasoline engine.  Logo on the engine cover.  Orange colored high voltage power cables.   Engine Compartment View  Power Cables...

  • Page 10: Hybrid Component Locations & Descriptions

    Hybrid Component Locations & Descriptions Component Description 12 Volt Auxiliary Battery When the power switch is on (ACC) or on (IG), the auxiliary battery  supplies power to the electrical equipment and ECUs.  Supplies electrical power to MG1, MG2 and MGR*1 and the Hybrid Vehicle (HV) Battery Pack ...

  • Page 11: Specifications

    Hybrid Component Locations & Descriptions (Continued) Specifications Gasoline Engine: 193 kW, 3.5-liter Aluminum Alloy Engine Electric Motors Front: 123 kW, Permanent Magnet Motor Rear: 50 kW, Permanent Magnet Motor (for AWD models) Transmission: Automatic Only HV Battery: 288 Volt Sealed NiMH Battery Curb Weight: 1,915 to 2,210 kg / 4,320 to 4,872 lbs Fuel Tank: 72 liters / 19.0 Us.

  • Page 12: Lexus Hybrid Drive Operation

    Lexus Hybrid Drive Operation Once the READY indicator is illuminated in the combination meter, the vehicle may be driven. However, the gasoline engine does not idle like a typical automobile and will start and stop automatically. It is important to recognize and understand the READY indicator provided in the instrument cluster.

  • Page 13: Hybrid Vehicle (Hv) Battery Pack And Auxiliary Battery

    Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery The RX450h features a high voltage Hybrid Vehicle (HV) battery pack that contains sealed Nickel Metal Hydride (NiMH) battery modules. HV Battery Pack  The HV battery pack is enclosed in a metal case and is rigidly mounted to the cabin area floor pan cross member under the second row seats.

  • Page 14: Hv Battery Pack Recycling

    Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (Continued) HV Battery Pack Recycling  The HV battery pack is recyclable. Contact either your Lexus Distributor as mentioned on HV battery Caution Label or the nearest Lexus dealer. Auxiliary Battery ...

  • Page 15: High Voltage Safety

    High Voltage Safety The HV battery pack powers the high voltage electrical system with DC electricity. Positive and negative orange colored high voltage power cables are routed from the battery pack, under the vehicle floor pan, to the inverter/converter. The inverter/converter contains a circuit that boosts the HV battery voltage from 288 to 650 Volts DC.

  • Page 16: Service Plug Grip

    High Voltage Safety (Continued) Service Plug Grip  The high voltage circuit is cut by removing the service plug grip (see page 15). Hybrid Vehicle Computer ➍ Volts DC ➋ Compressor ➋ Rear ❸ ❸ Electric Electric Inverter/ Generator Motor Converter Front Electric...

  • Page 17: Precaution To Be Observed When Dismantling The Vehicle

    Precaution to be observed when dismantling the vehicle WARNING: ・ The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled. To prevent serious injury or death from severe burns or electric shock, avoid touching, cutting, or opening any orange high voltage power cable or high voltage component.

  • Page 18: Spills

    Spills RX450h contains the same common automotive fluids used in other non-hybrid Lexus vehicles, with the exception of the NiMH electrolyte used in the HV battery pack. The NiMH battery electrolyte is a caustic alkaline (pH 13.5) that is damaging to human tissues. The electrolyte, however, is absorbed in the cell plates and will not normally spill or leak out even if a metal battery module is cracked.

  • Page 19: Dismantling The Vehicle

    Dismantling the vehicle RX450h The following 5 pages contain general instructions for use when working on an Read these instructions before proceeding to the HV battery removal instructions on page 21. WARNING: ・ The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled.
  • Page 20 (5) Loosen the nut, and disconnect the cable from the negative (-) auxiliary battery terminal. 2. Remove the battery service hole cover. (1) Remove the clip. (2) Disengage the clip and 2 guides to remove the battery service hole cover.
  • Page 21 3. Remove the service plug grip. Caution: ・Wear insulated gloves. ・Do not inspect or perform service on the high voltage system with the service plug grip installed. ・To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.
  • Page 22 Notice: ・After removing the service plug grip, turning the power switch on (READY) may cause a malfunction. Do not turn the power switch on (READY) unless instructed by the repair manual. ・Do not touch the terminals of the service plug grip. Hint: Waiting for at least 10 minutes is required to discharge the high voltage capacitor inside the inverter with converter assembly.
  • Page 23 Instead, wash the eye(s) with a dilute boric acid solution or a large amount of water and seek medical care. 11. With the exception of the HV battery, remove parts by following procedures which are similar to conventional Lexus vehicles. For the removal of the HV battery, refer to the following pages.

  • Page 25: Removal Of Hv Battery

    Removal of HV battery WARNING: ・ Be sure to wear insulated gloves when handling high-voltage parts. ・ Even if the vehicle is shut off and the relays are off, be sure to remove the service plug grip before performing any further work.
  • Page 26 6. REMOVE REAR DECK FLOOR BOX (w/o Spare Tire) Remove the 4 clips. Disengage the 2 guides to remove the rear deck floor box. 7. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL (1) Loosen the nut, and disconnect the cable from the negative (-) auxiliary battery terminal.
  • Page 27 REMOVE BATTERY SERVICE HOLE COVER (1) Remove the clip. (2) Disengage the clip and 2 guides to remove the battery service hole cover. 10. REMOVE SERVICE PLUG GRIP Caution: ・Wear insulated gloves. ・Do not inspect or perform service on the high voltage system with the service plug grip installed.
  • Page 28 ・Keep the removed service plug grip in your pocket to prevent other technicians from accidentally installing it while you are servicing the vehicle. ・Place a "HIGH VOLTAGE WORK IN PROGRESS. DO NOT TOUCH." sign, in order to prevent other technicians from accidentally reconnecting the power while work is in progress.
  • Page 29 12. REMOVE INLET AIR CLEANER ASSEMBLY Disengage the 3 inverter drain hose clamps. Remove the 3 bolts and inlet air cleaner assembly from the air cleaner assembly with air cleaner hose. 13. REMOVE FRONT FENDER REINFORCEMENT SUB-ASSEMBLY TOP LH (1) Remove the center hood cushion and 2 clips. (2) Disengage the 2 clips to disconnect the cowl top ventilator louver sub-assembly.
  • Page 30 15. REMOVE FRONT WIPER ARM HEAD CAP (1) Using a screwdriver, disengage the 3 claws to remove the front wiper arm head cap. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (1) Remove the nut and front wiper arm and blade assembly LH.
  • Page 31 REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (1) Remove the 2 clips. (2) Disengage the 2 clips to disconnect the windshield outside moulding LH and windshield outside moulding RH. (3) Disengage the 6 claws and 3 guides as shown in the illustration.
  • Page 32 (4) Disengage the 9 guides and remove the cowl top ventilator louver sub-assembly as shown in the illustration. 19. REMOVE FRONT WIPER MOTOR AND LINK ASSEMBLY (1) Disconnect the connector. (2) Disengage the clamp. (3) Remove the 5 bolts and front wiper motor and link assembly.
  • Page 33 b) Disengage the 2 clamps and separate the wire harness from the outer cowl top panel sub-assembly. (3) Disengage the clamp and separate the wire harness from the outer cowl top panel sub-assembly. (4) Remove the 6 bolts, 6 nuts and outer cowl top panel sub-assembly.
  • Page 34 (3) Remove the 6 bolts, 6 nuts and outer cowl top panel sub-assembly. 22. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE (1) Remove the 2 bolts from the air cleaner assembly with air cleaner hose. (2) Disconnect the intake mass air flow meter sub-assembly connector.
  • Page 35 23. REMOVE NO. 3 INVERTER BRACKET (1) Disengage the clamp. (2) Remove the bolt, nut and No. 3 inverter bracket. 24. REMOVE NO. 6 INVERTER BRACKET (1) Remove the bolt, nut and No. 6 inverter bracket. 25. REMOVE INVERTER TERMINAL COVER Interlock Caution: Wear insulated gloves.
  • Page 36 27. REMOVE REAR SEAT HEADREST ASSEMBLY Remove the rear seat headrest assembly. Place Hand Here 28. REMOVE REAR SEAT OUTER TRACK BRACKET COVER LH Disengage the 2 claws and 2 guides to remove the rear seat outer track bracket cover LH as shown in the illustration.
  • Page 37 31. DISCONNECT NO. 2 REAR SEAT RECLINING CONTROL CABLE (for Manual Seat) Lift the seat track adjusting handle and move the rear seat assembly LH to the foremost position. Pull out the lock lever to release the adjuster spring as shown in the illustration. Adjuster Spring Lock Lever Using a screwdriver, disconnect the No.
  • Page 38 Lift and hold the No. 1 reclining adjuster release handle LH at the uppermost position as shown in the illustration. Using a screwdriver, disconnect the No. 2 rear seat reclining control cable as shown in the illustration. Using a screwdriver, disconnect the reclining remote control lever sub-assembly RH as shown in the illustration.
  • Page 39 32. REMOVE REAR SEAT ASSEMBLY LH for Power Seat: Lift the seat track adjusting handle and move the rear seat assembly LH to the foremost position. Disconnect the rear seat airbag assembly connector under the rear seat assembly LH. Notice: When disconnecting any airbag connector, take care not to damage the airbag wire harness.
  • Page 40 Remove the 2 bolts and rear seat assembly LH. 33. REMOVE REAR SEAT HEADREST ASSEMBLY Remove the rear seat headrest assembly. 34. REMOVE REAR SEAT CENTER HEADREST ASSEMBLY Remove the rear seat center headrest assembly. Place Hand Here 35. REMOVE REAR SEAT OUTER TRACK BRACKET COVER RH Disengage the 2 claws and 2 guides to remove the rear seat outer track bracket cover RH as shown in...
  • Page 41 38. DISCONNECT REAR SEAT RECLINING CONTROL CABLE (for Manual Seat) Lift the seat track adjusting handle and move the rear seat assembly RH to the foremost position. Pull out the lock lever to release the adjuster spring as shown in the illustration. Adjuster Spring Lock Lever Using a screwdriver, disconnect the rear seat reclining...
  • Page 42 Lift and hold the No. 1 reclining adjuster release handle RH at the uppermost position as shown in the illustration. Using a screwdriver, disconnect the rear seat reclining control cable as shown in the illustration. Using a screwdriver, disconnect the reclining remote control lever sub-assembly RH as shown in the illustration.
  • Page 43 39. REMOVE REAR SEAT ASSEMBLY RH for Power Seat: Lift the seat track adjusting handle and move the rear seat assembly RH to the foremost position. Disconnect the rear seat airbag assembly connector under the rear seat assembly RH. Notice: When disconnecting any airbag connector, take care not to damage the airbag wire harness.
  • Page 44 40. REMOVE REAR DOOR SCUFF PLATE LH Disengage the claw as shown in the illustration. Hint: Use the same procedure for the front side and rear side. Place Hand Here Disengage the 8 claws and 2 guides to remove the rear door scuff plate LH as shown in the illustration.
  • Page 45 Disengage the claw as shown in the illustration. Place Hand Here Disengage the 4 claws and 4 clips to remove the rear seat side garnish LH as shown in the illustration. 43. REMOVE REAR DOOR SCUFF PLATE RH Hint: Use the same procedure as for the LH side. 44.
  • Page 46 Remove the air intake cover (for Center). Using a screwdriver, disengage the 2 claws and open the 2 hole covers. Remove the 2 screws. Disengage the 2 claws and remove the air intake cover (for Center). Remove the air intake cover (for RH Side). Using a screwdriver, disengage the 2 claws and open the 2 hole covers.
  • Page 47 49. REMOVE BATTERY CARRIER DUCT Remove the 2 nuts and battery carrier duct (for LH Side) from the HV battery. Remove the 2 nuts and battery carrier duct (for Center) from the HV battery. Remove the 2 nuts and battery carrier duct (for RH Side) from the HV battery.
  • Page 48 51. DISCONNECT HV FLOOR UNDER WIRE Lock Lever (w/ Active Stabilizer System) (1) Move the lock lever as shown in the illustration and disconnect the 3 active stabilizer control computer assembly connectors. (2) Disconnect the active stabilizer control computer assembly connector. (3) Remove the bolt to disconnect the HV floor under wire.
  • Page 49 Using the service plug grip, remove the battery cover lock striker from the upper HV battery cover Service Plug Grip sub-assembly. Projection Hint: Lock Striker Turn Insert the projection of the service plug grip, turn the button of the battery cover lock striker counterclockwise, and release the lock.
  • Page 50 Remove the 2 nuts and battery voltage sensor from the lower HV battery carrier panel. 55. REMOVE HV BATTERY Caution: Be sure to wear insulated gloves and protective goggles. Notice: ・To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.
  • Page 51 Open the terminal cover. Using an insulated tool, remove the nut and disconnect the HV battery module (for Center) cable from the HV battery module (for LH Side). Notice: ・Do not use a universal joint with a socket extension. Using a universal joint may cause the socket extension to drop and create a short circuit.
  • Page 52 Disconnect the No. 2 HV battery pack wire connector. Disengage the clamp. Disconnect the HV battery junction block assembly connector. Notice: Insulate the disconnected connectors with Insulating tape. Disconnect the HV battery module (for RH Side) cable connector. Notice: Insulate the disconnected connectors with Insulating tape.
  • Page 53 Disconnect the HV battery junction block assembly connector. Notice: Insulate the disconnected connectors with Insulating tape. Open the terminal cover. Using an insulated tool, remove the nut and disconnect the No. 2 HV battery pack cable from the HV battery module (for RH Side). Notice: ・Do not use a universal joint with a socket extension.

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