RX400h · Service Manual HYBRID SYSTEM

REMOVAL

Removal / installation


1. PRECAUTION
(Click here)

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

3. REMOVE SERVICE PLUG GRIP

CAUTION:
  1. Remove the service plug to interrupt a high voltage circuit at the time of the check.
  2. Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle.
  3. All the high voltage wiring connectors are colored in orange.

  1. A115547
    Remove the 2 clips, then open the battery service hole cover.

  1. Wear insulation glove, and remove the service plug grip, after sliding up the lever of the service plug grip.

    CAUTION:
    1. Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle.
    2. After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes.

    NOTICE:
    After removing the service plug grip, do not operate the ignition switch as it may damage the hybrid vehicle control ECU.


4. REMOVE ENGINE ROOM SIDE COVER LH

  1. A108719
    Using a clip remover, remove the engine room side cover.


5. REMOVE INVERTER BRACKET NO.5

  1. C111474
    Remove the bolt and inverter bracket No.5.


6. REMOVE POWER STEERING ECU ASSEMBLY

  1. C108539
    Remove the bolt and ground cable terminal from the power steering ECU assembly.

  1. C108540
    Release the locks of the 2 power steering ECU assembly connectors and disconnect the connectors.

  1. C112234
    Separate the 2 wire harness clamps from the power steering ECU assembly.

  1. C112235
    Remove the 2 bolts and the power steering ECU assembly.


7. SEPARATE INVERTER RESERVE TANK SUB-ASSEMBLY

  1. A108512
    Remove the 2 bolts and inverter reserve tank sub-assembly.


8. REMOVE POWER STEERING ECU BRACKET

  1. A108514
    Remove the bolt, and disconnect the power steering ECU bracket.


9. REMOVE INVERTER COVER

  1. A108511E01
    Remove the bolt and interlock bracket.

  1. A109673E01
    Insulate the removed terminal with insulating tape.

    NOTICE:
    Make sure that the terminal does not stick out from the insulating tape.

  1. A108515
    Remove the 12 bolts and inverter cover.


10. VERIFY THAT VOLTAGE OF W/ CONVERTER INVERTER ASSEMBLY IS 0V

CAUTION:
Wear insulating gloves.

NOTICE:
  1. Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly. (Click here)
  2. Do not allow any foreign objects or waterdrops to enter the w/ converter inverter assembly.

  1. A108528E01
    Using the voltmeter, measure the voltage between the terminals of the 2 phase connectors (N-P).

    Standard voltage:
    0 V

    HINT:
    Use measuring range of DC 750 V or more on the voltmeter.


11. INSTALL INVERTER COVER

  1. A109654
    Temporarily install the inverter cover with the 2 bolts to prevent any foreign objects or waterdrops from entering the w/ converter inverter assembly.


12. DRAIN HYBRID TRANSAXLE FLUID

  1. C105705E01
    Using a socket hexagon wrench 10 mm, remove the filler plug and gasket.

  1. Using a socket hexagon wrench 10 mm, remove the drain plug and gasket.

  1. Using a socket hexagon wrench 10 mm, install the drain plug and a new gasket.

    Torque:
    39 N*m{ 398 kgf*cm , 29 ft.*lbf }


13. REMOVE REAR WHEELS

14. REMOVE EXHAUST PIPE ASSEMBLY
(Click here)

15. REMOVE REAR AXLE SHAFT LH NUT

  1. C108170E01
    Using SST and a hammer, release the staked part of the axle shaft nut.
    SST
    09930-00010  

    NOTICE:
    Loosen the staked part of the nut completely, otherwise the screw of the drive shaft may be damaged.

  1. While applying the brakes, remove the axle shaft nut.


16. REMOVE REAR AXLE SHAFT RH NUT

HINT:
Removal procedure of the RH side is the same as that of the LH side.


17. DISCONNECT HEIGHT CONTROL SENSOR

  1. E112351
    Disconnect the connector.

  1. Remove the "torx" nut and separate the height control sensor link.

  1. I036885
    Remove the 2 bolts and height control sensor.


18. SEPARATE REAR STRUT ROD ASSEMBLY

  1. C105707
    Support the rear axle carrier with a wooden block placed between the jack and axle carrier.

  1. C105708
    Remove the bolt, nut and strut rod assembly rear.

    NOTICE:
    Hold the nut to turn the bolt.


19. SEPARATE REAR SUSPENSION ARM ASSEMBLY NO.1 LH

  1. C105709
    Remove the bolt and nut, and separate the rear suspension arm assembly No.1.

    NOTICE:
    Hold the nut to turn the bolt.


20. SEPARATE REAR SUSPENSION ARM ASSEMBLY NO.1 RH

HINT:
Removal procedure of the RH side is the same as that of the LH side.


21. SEPARATE REAR SUSPENSION ARM ASSEMBLY NO.2 LH

  1. C105710
    Remove the bolt and nut, and separate the rear suspension arm assembly No.2.

    NOTICE:
    Hold the nut to turn the bolt.


22. SEPARATE REAR SUSPENSION ARM ASSEMBLY NO.2 RH

HINT:
Removal procedure of the RH side is the same as that of the LH side.


23. REMOVE REAR DRIVE SHAFT ASSEMBLY LH

  1. C108295E01
    Put matchmarks on the rear drive shaft assembly and differential side gear shaft.

  1. Remove the 4 nuts, washers and rear drive shaft assembly.


24. REMOVE REAR DRIVE SHAFT ASSEMBLY RH

HINT:
Removal procedure of the RH side is the same as that of the LH side.


25. SEPARATE PARKING BRAKE CABLE ASSEMBLY NO.3

  1. C105712
    Remove the 2 nuts, and separate the parking brake cable assembly No.3.


26. SEPARATE PARKING BRAKE CABLE ASSEMBLY NO.2

HINT:
Removal procedure of the RH side is the same as that of the LH side.


27. SEPARATE NO.3 WIRE FRAME

NOTICE:
Wear insulating gloves.

  1. C105713J01
    Disconnect the 2 connectors and clamp.

  1. C105722
    Remove the 2 nuts, and separate the ground cable.

  1. C105714
    Remove the nut, and separate the wire harness clamp.

  1. C105715
    Wear the insulated gloves. Remove the 2 nuts, and separate the frame wire No.3 from the rear traction motor.


28. REMOVE REAR SUSPENSION MEMBER SUB-ASSEMBLY

  1. C105718
    Support the rear suspension member with a jack.

    HINT:
    Remove the rear suspension member together with the rear traction motor.

  1. C105717E02
    Remove the 2 bolts and 4 nuts, and separate the rear suspension member.

    NOTICE:
    When removing the bolts and nuts on the rear side, be sure to hold the bolt.


29. REMOVE REAR TRACTION W/ TRANSAXLE MOTOR ASSEMBLY

  1. C105719E02
    Remove the 4 bolts, rear traction w/ transaxle motor assembly.


30. REMOVE FRONT DIFFERENTIAL SUPPORT ASSEMBLY

  1. C105720
    Remove the 2 bolts and front differential support assembly.


31. REMOVE EXTENSION WIRE ASSEMBLY

  1. C105721
    Remove the 3 bolts and extension wire assembly.

  1. C105723
    Remove the bolt, nut, ground cable, and wire harness clamp bracket.

  1. C105724
    Remove the bolt and wire harness clamp bracket.

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