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Lexus RC300h Manual

Gasoline-electric lexus hybrid drive
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RC300h
Gasoline-Electric
Lexus Hybrid Drive
AVC10 Series

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Summary of Contents for Lexus RC300h

  • Page 1 RC300h Gasoline-Electric Lexus Hybrid Drive AVC10 Series...
  • Page 2 Foreword This guide was developed to educate and assist dismantlers in the safe handling of Lexus RC300h gasoline-electric hybrid vehicles. RC300h 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 RC300h, as they may not be familiar to dismantlers.

  • Page 3: Table Of Contents

    Table of Contents About the RC300h ............................1 RC300h 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..............

  • Page 5: About The Rc300H

    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 RC300h never needs to be recharged from an external electric power source.

  • Page 6: Rc300H Identification

    RC300h Identification In appearance, the 2015 model year RC300h is nearly identical to the conventional, non-hybrid Lexus RC350/300/200t. The RC300h is a 2-door coupe. Exterior, interior, and engine compartment illustrations are provided to assist in identification. The alphanumeric 15 character Vehicle Identification Number (VIN) is provided in the left side windshield cowl, engine compartment cowl and on the left side B pillar.

  • Page 7: Exterior

    RC300h Identification (Continued) Exterior  RC300h logo on the luggage compartment 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

    RC300h 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 RC350/300/200t.  A switchable gauge in the combination meter showing either a hybrid system indicator or a tachometer depending on driving mode.

  • Page 9: Engine Compartment

    RC300h Identification (Continued) Engine Compartment  2.5-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 Supplies electricity to the electrical components.   Supplies electrical power to generator (MG1) and motor (MG2) in Hybrid Vehicle (HV) Battery Pack  accordance with the driving conditions of the vehicle. ...

  • Page 11: Specifications

    Hybrid Component Locations & Descriptions (Continued) Specifications Gasoline Engine: 133 kW, 2.5-liter Aluminum Alloy Engine Electric Motor: 162 kW, Permanent Magnet Motor (for Hong Kong) 164 kW, Permanent Magnet Motor (except Hong Kong) Transmission: Automatic Only HV Battery: 230.4 Volt Sealed NiMH Battery Curb Weight: 1,725 to 1,775 kg / 3,803 to 3,913 lbs (for Europe) 1,735 to 1,775 kg / 3,825 to 3,913 lbs (except Europe) Fuel Tank: 66 liters /17.4 gals...

  • 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 RC300h 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 luggage compartment area.

  • 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 (see page 37) 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 230.4 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 ❸ ❸ Electric Inverter/ Generator Converter Electric Volts DC 12 Volts ➊...

  • 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 RC300h 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 RC300h The following 4 pages contain general instructions for use when working on an Read these instructions before proceeding to the HV battery removal instructions on page 20. WARNING: ・ The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled.
  • Page 20 (3) Disengage the 3 guides and remove the luggage compartment trim box. (4) Remove the 3 nuts and No. 5 HV battery shield panel from the HV battery. 3. Remove the service plug grip. Caution: ・Wear insulated gloves. ・Do not inspect or service 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 21 Hint: Waiting for at least 10 minutes is required to discharge the high voltage capacitor inside the inverter with converter assembly. Wear insulated gloves and remove the service plug grip after sliding the lever of the service plug grip as shown in the illustration. 4.
  • Page 22 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 24: 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 25 5. REMOVE TIRE REPAIR SEAL Disengage the 2 claws to disconnect the tool box band assembly. Disengage the 2 guides and remove the tire repair seal from the battery clamp sub-assembly. 6. REMOVE AUXILIARY BATTERY Disengage the 2 claws and open the battery terminal cap.
  • Page 26 Remove the bolt and battery hold down clamp sub-assembly. Disconnect the battery hose from the auxiliary battery. Remove the auxiliary battery. 7. REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM COVER (1) Remove the No. 1 luggage compartment trim cover. 8. REMOVE LUGGAGE COMPARTMENT TRIM Remove the 6 clips.
  • Page 27 9. REMOVE NO. 5 HV BATTERY SHIELD PANEL Remove the 3 nuts and No. 5 HV battery shield panel from the HV battery. 10. REMOVE SERVICE PLUG GRIP Caution: ・Wear insulated gloves. ・Do not inspect or service 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 28 (1) Wear insulated gloves and rotate the handle of the service plug grip and remove the service plug grip as indicated by the arrows, in the order shown in the illustration. 11. REMOVE CONNECTOR COVER ASSEMBLY for LHD: Caution: Wear insulated gloves. Remove the 2 bolts and connector cover assembly from the inverter with converter assembly.
  • Page 29 13. REMOVE FRONT LUGGAGE COMPARTMENT TRIM COVER Using a clip remover, remove the 3 clips. Disengage the 2 fasteners and 2 guides to remove the Fastener front luggage compartment trim cover. 14. REMOVE REAR LUGGAGE COMPARTMENT TRIM COVER Using a clip remover, remove the 3 clips. Disengage the 6 clips to remove the rear luggage compartment trim cover.
  • Page 30 15. REMOVE REAR SEAT CUSHION ASSEMBLY Bracket Hook Caution: Wear protective gloves. Sharp areas on the seat Frame Hook frame may injure your hands. Lift up the front edge of the rear seat cushion assembly as shown in the illustration and disengage the rear seat cushion frame hook on the front side of the rear seat cushion assembly from the rear seat cushion lock hook.
  • Page 31 18. DISCONNECT REAR SEAT 3 POINT TYPE OUTER BELT ASSEMBLY LH Using a moulding remover, disengage the 3 clips to disconnect the belt guide unit of the rear seat 3 point type outer belt assembly LH. Remove the bolt and disconnect the floor anchor of the rear seat 3 point type outer belt assembly.
  • Page 32 Disengage the 5 fasteners. Fastener Remove the 3 bolts. Disengage the guide to remove the rear seatback assembly RH. 23. REMOVE REAR SEATBACK ASSEMBLY LH Fold the rear seatback assembly LH forward. Fastener Disengage the 3 clips and 2 fasteners. Disengage the 5 fasteners.
  • Page 33 24. REMOVE REAR SEAT SUB FLOOR PANEL Disengage the 3 clips to remove the rear seat sub floor panel. 25. REMOVE NO. 2 ROOM PARTITION COVER Remove the clip. Disengage the 2 claws and clip. Disengage the guide to remove the No. 2 room partition cover.
  • Page 34 28. REMOVE FRONT UPPER LUGGAGE COMPARTMENT TRIM COVER Remove the 8 clips. Disconnect the front upper luggage compartment trim cover as shown in the illustration. Disconnect the front upper luggage compartment trim cover as indicated by the arrows, in the order shown in the illustration.
  • Page 35 Remove the 2 bolts and 2 rope hook assemblies. 30. REMOVE LUGGAGE COMPARTMENT TRIM COVER LH (for LH Side) Using a clip remover, remove the 5 clips. Disengage the claw. Disengage the clip and guide to remove the luggage compartment trim cover LH. 31.
  • Page 36 Remove the 2 bolts and 2 rope hook assemblies. 32. REMOVE LUGGAGE COMPARTMENT TRIM COVER RH (for RH Side) Using a clip remover, remove the 5 clips. Disengage the claw. Disengage the clip and guide to remove the luggage compartment trim cover RH. 33.
  • Page 37 34. REMOVE REAR NO. 1 FLOOR CROSSMEMBER BRACE LH Disengage the clamp. Remove the 2 bolts, 2 nuts and rear No. 1 floor crossmember brace LH. 35. REMOVE NO. 4 HV BATTERY SHIELD PANEL Caution: Service Plug Grip Wear insulated gloves. Projection (1) Using the service plug grip, remove the battery cover Lock Striker...
  • Page 38 37. SEPARATE NO. 3 HYBRID BATTERY INTAKE DUCT Disengage the 3 claws. Slide the No. 3 hybrid battery intake duct as shown in the illustration to separate the No. 3 hybrid battery intake duct from the battery cooling blower assembly. 38.
  • Page 39 Remove the 2 battery drain plugs as indicated by the arrows, in the order shown in the illustration. Push the battery drain plug toward While pushing the battery drain Remove the battery drain plug. the front of the vehicle. plug, disengage the rear claw. Remove the 4 bolts.
  • Page 40 ・Do not touch any high voltage wire harnesses, connectors or parts with bare hands. 41. The HV battery pack is recyclable. Contact your Lexus distributor (if included on the HV battery caution label) or contact the nearest Lexus dealer (see next for sample of the HV battery caution label).

  • Page 41: Hv Battery Caution Label

    HV Battery Caution Label...

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