RX400h · Service Manual HYBRID SYSTEM

INSTALLATION

Removal / installation


1. INSTALL NO.3 WIRE FRAME (for LHD)

  1. Install the No.3 wire frame.

    A110007E03

    CAUTION:
    Wear insulating gloves.


    1. A112448
      Install the No.3 wire frame with the 6 nuts. (H)

      Torque:
      8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

    2. A109004E02
      Pass the No.3 wire frame into the cabin and connect the clamp shown in the illustration. (G)

    3. A113067E02
      Connect the 3 clamps as shown in the illustration. (F)

    4. A110012
      Pass the No.3 wire frame into the cabin and install the 2 nuts and bolt shown in the illustration. (E)

      Torque:
      8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

    5. A108939E01
      Connect the clamp as shown in the illustration. (D)

    6. A108941E01
      Connect the clamp as shown in the illustration. (C)

    7. A110009E02
      Connect the 2 clamps as shown in the illustration. (B)

    8. A109002E01
      Connect the 2 connectors and clamp as shown in the illustration. (A)


2. INSTALL NO.3 WIRE FRAME (for RHD)

  1. Install the No.3 wire frame.

    A108934E01

    CAUTION:
    Wear insulating gloves.


    1. A112448
      Install the No.3 wire frame with the 6 nuts. (H)

      Torque:
      8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

    2. A109004E02
      Pass the No.3 wire frame into the cabin and connect the clamp shown in the illustration. (G)

    3. A113067E02
      Connect the 3 clamps as shown in the illustration. (F)

    4. A110012
      Pass the No.3 wire frame into the cabin and install the 2 nuts and bolt shown in the illustration. (E)

      Torque:
      8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

    5. A108939E01
      Connect the clamp as shown in the illustration. (D)

    6. A108941E01
      Connect the clamp as shown in the illustration. (C)

    7. A108936E01
      Connect the 2 clamps as shown in the illustration. (B)

    8. A109002E01
      Connect the 2 connectors and clamp as shown in the illustration. (A)


3. INSTALL WIRING HARNESS PROTECTOR

  1. A112394
    Install the wiring harness protector with the 4 nuts.

    Torque:
    8.5 N*m{ 87 kgf*cm , 75 in.*lbf }


4. INSTALL REAR TRACTION W/ TRANSAXLE MOTOR ASSEMBLY

CAUTION:
Wear insulating gloves.

  1. C105715
    Connect the No.3 wire frame with the 2 nuts to the rear traction w/ transaxle motor assembly.

    Torque:
    15 N*m{ 153 kgf*cm , 11 ft.*lbf }

  1. C105713J01
    Connect the 2 connectors and clamp to the rear traction w/ transaxle motor assembly.


5. CHECK HIGH VOLTAGE CABLE CONNECTION

NOTICE:
Be sure to wear insulated gloves and protective goggles.

  1. C105715
    Make sure that the frame wire No.3 is securely installed with the nuts.

    NOTICE:
    1. Do not install the frame wire No.3 at an angle.
    2. Be sure to tighten the nuts securely.


6. REMOVE INVERTER COVER

  1. A109654
    Remove the 2 bolts and inverter cover to the w/ converter inverter assembly.


7. CONNECT W/ CONVERTER INVERTER ASSEMBLY

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. A109800E01
    After connecting the cable, press the lever down to connect the No.3 wire frame with the bolt to the w/ converter inverter assembly.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }

  1. A108521
    Connect the No.3 wire frame (high voltage cable of the rear motor) with the 5 bolts to the w/ converter inverter assembly.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }


8. CHECK HIGH VOLTAGE CABLE CONNECTION

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. A108527
    Check that each connector and terminal is firmly installed.

    NOTICE:
    1. Make sure that the connectors are fully engaged.
    2. Make sure that the bolts are fully tightened.


9. INSTALL INVERTER COVER

  1. A108515
    Install the inverter cover with the 12 bolts to the w/ converter inverter assembly.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }

  1. A108511E01
    Install the interlock bracket with the bolt to the w/ converter inverter assembly.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }


10. INSTALL POWER STEERING ECU BRACKET

  1. A108514
    Install the power steering ECU bracket with the bolt to the w/ converter inverter assembly.

    Torque:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }


11. CONNECT INVERTER RESERVE TANK SUB-ASSEMBLY

  1. A108512
    Connect the inverter reserve tank with the 2 bolts to the w/ converter inverter assembly.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }


12. INSTALL POWER STEERING ECU ASSEMBLY

  1. C112235
    Install the power steering ECU assembly with the 2 bolts.

    Torque:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }

  1. C112234
    Connect the 2 wire harness clamps to the power steering ECU assembly.

  1. C108541
    Connect the 2 power steering ECU assembly connectors and securely lock the connectors.

  1. C108539
    Install the ground cable terminal to the power steering ECU assembly with the bolt.

    Torque:
    6.0 N*m{ 61 kgf*cm , 53 in.*lbf }


13. INSTALL INVERTER BRACKET NO.5

  1. C111474
    Install the inverter bracket No.5 with the bolt.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }


14. INSTALL AIR CLEANER W/RESONATOR

  1. A109267
    Install the air cleaner hose No.1 to the throttle body assembly with the hose clamp.

  1. A106878
    Install the air cleaner case w/ resonator with the 5 bolts.

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

  1. A109270
    Connect the MAF meter connector.

  1. Connect the 2 wire harness clamps to the air cleaner.

  1. A109893
    Connect the ventilation hose No.2.


15. INSTALL AIR CLEANER CAP W/INLET

  1. Install the air cleaner filter element to the air cleaner case.

  1. A108124
    Install the 2 bolts, 4 clamps and air cleaner cap w/ inlet.

    Torque:
    7.0 N*m{ 71 kgf*cm , 62 in.*lbf }


16. INSTALL COOL AIR INTAKE DUCT SEAL

  1. Install the 4 clips and cool air intake duct seal.


17. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER

  1. Remove the 4 shock absorber nuts.

  1. A112528E01
    Install the 4 bolts, 2 nuts and cowl top panel sub-assembly.

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

  1. Install the 4 shock absorber nuts (B).

    Torque:
    80 N*m{ 815 kgf*cm , 59 ft.*lbf }

  1. Install the wire harness clamp and grommet (A).


18. INSTALL WINDSHIELD WIPER LINK ASSEMBLY

  1. E110471
    Install the windshield wiper motor and link assembly with the 5 bolts.

    Torque:
    7.0 N*m{ 71 kgf*cm , 62 in.*lbf }

  1. Connect the connector.


19. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

20. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH

  1. B108016E03
    Operate the front wiper, and stop the front wiper motor at the automatic stop position.

  1. Clean the wiper arm serrations.

  1. Clean the wiper pivot serrations with a wire brush (when reinstalling).

  1. E069045E01
    Install the front wiper arm and blade assembly LH with the nut at the position as shown in the illustration.

    Torque:
    24 N*m{ 245 kgf*cm , 18 ft.*lbf }

    HINT:
    Hold the arm hinge by hand to fasten the nut.


21. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH

  1. B108016E03
    Clean the wiper arm serrations.

  1. Clean the wiper pivot serrations with a wire brush (when reinstalling).

  1. E069046E01
    Install the front wiper arm and blade assembly RH with the 2 nuts at the position as shown in the illustration.

    Torque:
    24 N*m{ 245 kgf*cm , 18 ft.*lbf }

    HINT:
    Hold the arm hinge by hand to fasten the nut.

  1. Operate the front wipers while spraying water or washer fluid on the windshield.

  1. Make sure that the wipers function properly and there is no interference with the vehicle body.


22. INSTALL ENGINE ROOM SIDE LH COVER

  1. A108719
    Fit the clips and install the engine room side LH cover.


23. CONNECT HYBRID VEHICLE RELAY ASSEMBLY

CAUTION:
Wear insulating gloves.

  1. A109522
    Connect the No.3 wire frame with the 2 nuts to the hybrid vehicle relay assembly.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

  1. Connect the No.3 wire frame connector to the hybrid vehicle relay assembly.

  1. A108252
    Install the No.3 wire frame with the bolt.

    Torque:
    8.0 N*m{ 82 kgf*cm , 80 in.*lbf }


24. CHECK HIGH VOLTAGE CABLE CONNECTION

CAUTION:
Wear insulating gloves and protective glasses.

  1. Check that each wire harness is being installed securely.

    A108335E01

    NOTICE:
    1. The connectors should be connected securely.
    2. The nuts should be fastened securely.
    3. Make sure that the 4 plastic covers are engaged securely.


25. INSTALL HYBRID VEHICLE BATTERY SERVICE HOLE COVER

  1. A109851E01
    Install the battery cover lock striker, then push the button to lock.

  1. Install the battery service hole cover with the 2 bolts.

    Torque:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf }


26. INSTALL FLOOR CARPET ASSEMBLY FRONT

  1. Install the front floor carpet.


27. INSTALL AIR INTAKE COVER CENTER

  1. A108249E01
    Install the air intake cover with the 2 screws.

  1. Install the 2 hole covers.


28. INSTALL AIR INTAKE COVER

  1. Install the air intake cover RH.

    1. A108248E01
      Install the air intake cover RH with the 2 screws.

    2. Install the 2 hole covers.

  1. Install the air intake cover LH.

    1. A108247E01
      Install the air intake cover LH with the 2 screws.

    2. Install the 2 hole covers.


29. INSTALL REAR SEAT ASSEMBLY LH

  1. Place the rear seat assembly LH in the vehicle and align the adjuster pin with the hole on the vehicle side.

  1. Move the rear seat assembly LH to the rearmost position by operating the rear seat track adjusting handle.

    NOTICE:
    Check that the seat is locked.

  1. Temporarily install the front side of the rear seat assembly LH with the 2 bolts.

  1. Recline the separate rear seatback forward by operating the rear seat lock control lever sub-assembly.

  1. Move the rear seat assembly LH fully forward.

    NOTICE:
    Check that the seat is locked.

  1. Temporarily install the rear side of the rear seat assembly LH with the 3 bolts.

  1. Return the separate rear seatback to the upright position.

  1. Move the rear seat assembly LH to the rearmost position by operating the rear seat track adjusting handle.

    NOTICE:
    Check that the seat is locked.

  1. Fully tighten the 2 bolts on the front side of the rear seat assembly LH in the order of the inner side bolt and then the outer side bolt.

    Torque:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }

  1. Recline the separate rear seatback forward by operating the rear seat lock control lever sub-assembly.

  1. Move the rear seat assembly LH fully forward.

    NOTICE:
    Check that the seat is locked.

  1. Fully tighten the 3 bolts on the rear side of the rear seat assembly LH in the order of the inner rear side bolt, the inner front side bolt, and then the outer side bolt.

    Torque:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }

  1. Return the separate rear seatback to the upright position.

  1. Move the rear seat assembly LH to the rearmost position by operating the rear seat track adjusting handle.

    NOTICE:
    Check that the seat is locked.

  1. Install the floor anchor side of the fold seat stopper band assembly No.2 with the bolt.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

  1. Install the 3 clips.


30. INSTALL REAR SEAT TRACK BRACKET COVER

31. INSTALL REAR SEAT ASSEMBLY RH

  1. Place the rear seat assembly RH in the vehicle and align the adjuster pin with the hole on the vehicle side.

  1. Move the rear seat assembly RH to the rearmost position by operating the rear seat track adjusting handle.

    NOTICE:
    Check that the seat is locked.

  1. Temporarily install the front side of the rear seat assembly RH with the 2 bolts.

  1. Recline the separate rear seatback forward by operating the rear seat lock control lever sub-assembly.

  1. Move the rear seat assembly RH fully forward.

    NOTICE:
    Check that the seat is locked.

  1. Temporarily install the rear side of the rear seat assembly RH with the 3 bolts.

  1. Return the separate rear seatback to the upright position.

  1. Move the rear seat assembly RH to the rearmost position by operating the rear seat track adjusting handle.

    NOTICE:
    Check that the seat is locked.

  1. Fully tighten the 2 bolts on the front side of the rear seat assembly RH in the order of the inner side bolt and then the outer side bolt.

    Torque:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }

  1. Recline the separate rear seatback forward by operating the rear seat lock control lever sub-assembly.

  1. Move the rear seat assembly RH fully forward.

    NOTICE:
    Check that the seat is locked.

  1. Fully tighten the 3 bolts on the rear side of the rear seat assembly RH in the order of the inner rear side bolt, the inner front side bolt, and then the outer side bolt.

    Torque:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }

  1. Return the separate rear seatback to the upright position.

  1. Move the rear seat assembly RH to the rearmost position by operating the rear seat track adjusting handle.

    NOTICE:
    Check that the seat is locked.

  1. Install the floor anchor side of the fold seat stopper band assembly No.1 with the bolt.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

  1. Install the 5 clips.


32. INSTALL REAR SEAT TRACK BRACKET COVER

33. INSPECT SLIDE ADJUSTER LOCK SIMULTANEOUSLY

  1. Check that the left and right adjusters lock simultaneously when sliding the seat.

  1. If the left and right adjusters do not lock simultaneously, adjust by loosening the bolts securing the seat.


34. CONNECT POWER STEERING CONVERTER ASSEMBLY

  1. A108806E01
    Connect the 4 connectors and clamp to the power steering converter assembly.

  1. Connect the No.3 wire frame with the nut to the power steering converter assembly.

    Torque:
    5.5 N*m{ 56 kgf*cm , 49 in.*lbf }


35. CHECK HIGH VOLTAGE CABLE CONNECTION

CAUTION:
Be sure to wear insulated gloves.

  1. C108561E01
    Check that the high voltage cable connector is securely connected to the DC-DC converter assembly.


36. INSTALL POWER STEERING CONVERTER COVER

  1. C108558
    Install the power steering converter cover with the 3 nuts.

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

  1. Install the wire harness clamp to the power steering converter cover.


37. INSTALL DECK BOARD CHECK NO.1

  1. C108557
    Install the deck board check No.1 with the 4 nuts.


38. INSTALL DECK SIDE TRIM BOX RH

39. INSTALL DECK SIDE TRIM BOX LH

  1. B111781
    Install the deck side trim box with the 2 clips.


40. INSTALL DECK BOARD SUB-ASSEMBLY NO.3

  1. B110025
    Install the deck No.3 board sub-assembly with the 2 bolts and 2 nuts.


41. INSTALL DECK BOARD SUB-ASSEMBLY NO.2

  1. B110024
    Install the deck No.2 board sub-assembly with the 4 bolts and 2 nuts.


42. INSTALL DECK FLOOR BOX FRONT

  1. B110022
    Install the deck floor box front with the 2 clips.


43. INSTALL REAR FLOOR FINISH PLATE

  1. B110477
    Engage the 2 claws and 6 clips, and install the rear floor finish plate.

  1. Install the 2 clips.


44. INSTALL DECK FLOOR BOX REAR

  1. B110023
    Install the deck floor box rear with the 2 clips.


45. INSTALL DECK BOARD SUB-ASSEMBLY

  1. B110455
    Install the deck board sub-assembly with the 2 bolt.

  1. Engage the 5 clips.


46. INSTALL SERVICE PLUG GRIP

NOTICE:
Before connecting the service plug, check that no parts and tools remain and that the high voltage terminals and connectors are connected securely.

  1. A115547
    Wear insulation gloves, then insert the service plug.

  1. Push down on the grip to lock.

  1. Close the battery service hole cover.

    NOTICE:
    Check that the 2 battery service hole cover clips are securely connected to the battery carrier bracket (click sound).


47. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

48. PERFORM INITIALIZATION
Some systems need initialization when reconnecting the battery cable. (Click here)
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