RX400h · Service Manual HYBRID SYSTEM

INSTALLATION

Removal / installation


1. INSTALL BATTERY PACK WIRE

  1. A108320
    Connect the 2 clamps, then install the battery pack wire on the HV battery lower case.

  1. A111107
    Connect the clamp, then install the battery pack wire on the HV battery lower case.


2. INSTALL BATTERY PACKING NO.2

  1. A111962
    Install the battery packing No.2 to the HV battery lower case.

    NOTICE:
    Make sure that there is no clearance between the battery packing and the lower case.


3. INSTALL BATTERY COVER

  1. A111961
    Install the battery cover to the HV battery lower case.

    NOTICE:
    Be suer to attach the butyl tape portion of the battery cover securely to the lower case.


4. INSTALL HV BATTERY LOWER CASE

  1. A108319E01
    Install the HV battery lower case on the vehicle.

  1. Connect the connector and clamp on the HV battery lower case.


5. INSTALL HYBRID VEHICLE RELAY ASSEMBLY

  1. A115319
    Install the hybrid vehicle relay assembly with the 3 nuts.

    Torque:
    4.5 N*m{ 46 kgf*cm , 40 in.*lbf }


6. INSTALL ELECTRIC VEHICLE BATTERY PLUG ASSEMBLY

  1. A115321
    Install the EV battery plug with the 2 bolts and nut.

    Torque:
    Bolt:
    5.4 N*m{ 55 kgf*cm , 48 in.*lbf }
    Nut:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf }

  1. A115322E01
    Connect the connector and clamps.


7. INSTALL BATTERY COOLING BLOWER ASSEMBLY

  1. A115320
    Install the 3 battery cooling blower assemblies with the 9nuts.

    Torque:
    4.5 N*m{ 46 kgf*cm , 40 in.*lbf }

  1. A115323E01
    Connect each battery cooling blower assembly connector and clamp.


8. INSTALL HV BATTERY

CAUTION:
Wear insulating gloves and protective glasses.

  1. Attach the bar-code label. (In case that the lower case is not replaced)

    1. A114401
      Attach the new label to immediate right of the original one.

      HINT:
      A bar-code label is supplied with the new battery.

  1. Attach the bar-code label. (In case that the lower case is replaced)

    1. A111108
      Attach the new label to the original position.

      HINT:
      A bar-code label is supplied with the new lower case.

  1. Install the HV battery RH.

    1. A109950
      Install the main battery cable on the HV battery RH with a new nut.

      Torque:
      5.4 N*m{ 55 kgf*cm , 48 in.*lbf }

      NOTICE:
      Be sure to engage the plastic cover securely.

    2. A109949
      Install the main battery cable No.2 on the HV battery RH with a new nut.

      Torque:
      5.4 N*m{ 55 kgf*cm , 48 in.*lbf }

      NOTICE:
      Be sure to engage the plastic cover securely.

    3. A109847E01
      Install the HV battery RH.

      NOTICE:
      After installing the HV battery RH, pull the ropes for lifting out the battery toward the front of the vehicle to eliminate any slack in the ropes.

    4. A112663E01
      Install the battery room ventilation hose.

      NOTICE:
      Align the projections of the battery room ventilation hose and the rubber tube, and install the hose.

    5. A108317E01
      Connect the clamp.

    6. A108316
      Connect the main battery cable with the nut and connector.

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

    7. A108315
      Connect the 2 clamps.

  1. Install the HV battery CTR.

    1. A109845E01
      Install the HV battery CTR.

      NOTICE:
      After installing the HV battery CTR, pull the ropes for lifting out the battery toward the front of the vehicle to eliminate any slack in the ropes.

    2. A112662E01
      Install the battery room ventilation hose between the HV batteries CTR and RH.

      NOTICE:
      Align the projections of the battery room ventilation hose and the rubber tube, and install the hose.

    3. A108312
      Connect the 2 connectors and clamp.

    4. A108311
      Connect the 2 connectors on the HV relay assembly.

  1. Install the HV battery LH.

    1. A109846E01
      Install the HV battery LH.

      NOTICE:
      After installing the HV battery LH, pull the ropes for lifting out the battery toward the front of the vehicle to eliminate any slack in the ropes.

    2. A109849
      Connect the EV battery plug on the HV battery with a new nut.

      Torque:
      5.4 N*m{ 55 kgf*cm , 48 in.*lbf }

      NOTICE:
      1. Be sure to engage the plastic cover securely.
      2. Insulate the tool with insulting tape.
      3. Do not use the universal joint.

    3. A109848
      Connect the main battery cable on the HV battery with a new nut.

      Torque:
      5.4 N*m{ 55 kgf*cm , 48 in.*lbf }

      NOTICE:
      1. Be sure to engage the plastic cover securely.
      2. Insulate the tool with insulting tape.
      3. Do not use the universal joint.

    4. A108257
      Connect the wire harness clamp of the battery thermo sensor.

    5. A112661E01
      Connect the battery room ventilation hose between the HV batteries LH and CTR.

      NOTICE:
      Align the projections of the battery room ventilation hose and the rubber tube, and install the hose.


9. INSTALL BATTERY SMART UNIT

NOTICE:
Wear insulating gloves and protective glasses.

  1. A108255
    Install the battery smart unit with the 4 bolts.

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

  1. A108254E01
    Connect the 5 connectors and 2 clamps.


10. 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.


11. INSTALL BATTERY COVER SUB-ASSEMBLY

CAUTION:
Wear insulating gloves.

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

    A109850E01

  1. Install the battery cover with the 28 bolts and 6 nuts.

    NOTICE:
    Use a ground bolt for position B.

    Torque:
    Bolt A:
    25 N*m{ 255 kgf*cm , 19 ft.*lbf }
    Bolt B:
    25 N*m{ 255 kgf*cm , 19 ft.*lbf }
    Bolt C:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf }
    Nut:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf }

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

    Torque:
    8.0 N*m{ 82 kgf*cm , 72 in.*lbf }


12. INSTALL HV 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 }


13. INSTALL BATTERY CARRIER DUCT

  1. A109796
    Install the battery carrier duct (RH) with the 2 bolts.

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

  1. A109795
    Install the battery carrier duct (CTR) with the 2 bolts.

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

  1. A109681
    Install the battery carrier duct (LH) with the 2 bolts.

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


14. INSTALL BATTERY CARRIER BRACKET

  1. A108250
    Install the battery carrier bracket with the 2 bolts.

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


15. INSTALL REAR CENTER SEAT INNER BELT ASSEMBLY

  1. B109592E01
    Install the rear center seat inner belt assembly with the bolt.

    Torque:
    42 N*m{ 428 kgf*cm , 31 ft.*lbf }

    NOTICE:
    1. Tighten the bolt while the claws of the rear center seat inner belt assembly are in contact with the vehicle body.
    2. Claw 1 shown in the illustration can have a clearance of up to 2.0 mm (0.08 in.) between the claw and the vehicle body.

    HINT:
    Place the buckle of the rear center seat inner belt assembly on the floor carpet so that the buckle does not interfere with installation of the seat.


16. INSTALL FLOOR CARPET ASSEMBLY FRONT

  1. Install the front floor carpet.


17. INSTALL AIR INTAKE COVER CENTER

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

  1. Install the 2 hole covers.


18. 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.


19. 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.


20. INSTALL REAR SEAT TRACK BRACKET COVER

21. 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.


22. INSTALL REAR SEAT TRACK BRACKET COVER

23. 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.


24. 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).


25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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