RX400h · Service Manual HYBRID SYSTEM

REMOVAL

Removal / installation


1. PRECAUTION
(Click here)

2. READ OUTPUT DTC

  1. Check the DTC.

    NOTICE:
    Check the DTC, and confirm that P0AA6 (High voltage insulation is unusual) is not output before doing removal or installation work inside the battery. If the DTC is output, perform troubleshooting procedures first.


3. DISCONNECT CABLE FROM BATTERY NEGATIVE TERMINAL

4. 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.


5. REMOVE REAR SEAT TRACK BRACKET COVER

  1. B115707
    Move the rear seat assembly LH to the rearmost position by operating the rear seat track adjusting handle.

  1. Using a screwdriver, disengage the 4 claws.

    HINT:
    Tape the screwdriver tip before use.

  1. Pull the 2 rear seat track bracket covers toward the rear of the vehicle and remove them.


6. REMOVE REAR SEAT ASSEMBLY LH

  1. Using a clip remover, remove the 3 clips.

  1. Remove the bolt and disconnect the floor anchor side of the fold seat stopper band assembly No.2.

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

  1. Remove the 2 bolts on the front side.

  1. Move the rear seat assembly LH fully forward by operating the rear seat track adjusting handle.

  1. Remove the 3 bolts on the rear side.

  1. Move the rear seat assembly LH to the center position and adjust the seatback to the vertical position.

  1. Remove the rear seat assembly LH.


7. REMOVE REAR SEAT TRACK BRACKET COVER

  1. B115707
    Move the rear seat assembly RH to the rearmost position by operating the rear seat track adjusting handle.

  1. Using a screwdriver, disengage the 4 claws.

    HINT:
    Tape the screwdriver tip before use.

  1. Pull the 2 rear seat track bracket covers toward the rear of the vehicle and remove them.


8. REMOVE REAR SEAT ASSEMBLY RH

  1. Using a clip remover, remove the 5 clips.

  1. Remove the bolt and disconnect the floor anchor side of the fold seat stopper band assembly No.1.

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

  1. Remove the 2 bolts on the front side.

  1. Move the rear seat assembly RH fully forward by operating the rear seat track adjusting handle.

  1. Remove the 3 bolts on the rear side.

  1. Move the rear seat assembly RH to the center position and adjust the seatback to the vertical position.

  1. Remove the rear seat assembly RH.


9. REMOVE AIR INTAKE COVER

  1. Remove the air intake cover LH.

    1. A108244E01
      Release the claw by using the screwdriver with the tip taped, and remove the 2 hole covers.

    2. A108247E01
      Remove the 2 screws, then release the 2 claws and remove air intake cover LH.

  1. Remove the air intake cover RH.

    1. A108245E01
      Release the claw by using the screwdriver with the tip taped, and remove the 2 hole covers.

    2. A108248E01
      Remove the 2 screws, then release the 2 claws and remove air intake cover RH.


10. REMOVE AIR INTAKE COVER CENTER

  1. A108246E01
    Release the claw by using the screwdriver with the tip taped, and remove the 2 hole covers.

  1. A108249E01
    Remove the 2 screws, then release the 2 claws and remove air intake cover center.


11. SEPARATE FLOOR CARPET ASSEMBLY FRONT

  1. Turn back the front floor carpet assembly.


12. REMOVE REAR CENTER SEAT INNER BELT ASSEMBLY

  1. B109591
    Remove the bolt and rear center seat inner belt assembly.


13. REMOVE BATTERY CARRIER BRACKET

  1. A108250
    Remove the 2 bolts and battery carrier bracket.


14. REMOVE BATTERY CARRIER DUCT

  1. A109681
    Remove the 2 bolts and battery carrier duct (LH).

  1. A109795
    Remove the 2 bolts and battery carrier duct (CTR).

  1. A109796
    Remove the 2 bolts and battery carrier duct (RH).


15. REMOVE HV BATTERY SERVICE HOLE COVER

  1. A108251E01
    Using the service plug grip, remove the battery cover lock striker.

    HINT:
    Insert the projection part of the service plug grip, and turn the button of the battery cover lock striker counterclockwise, and release the lock.

  1. Remove the 2 bolts and battery service hole cover.


16. REMOVE BATTERY COVER SUB-ASSEMBLY

CAUTION:
Wear insulating gloves.

  1. A108252
    Remove the bolt, then disconnect the No.3 wire frame.

  1. Using the service plug grip, remove the battery cover lock striker.

    A108253E01

    HINT:
    Insert the projection part of the service plug grip, and turn the button of the battery cover lock striker counterclockwise, and release the lock.

  1. Remove the 28 bolts, 6 nuts and battery cover.


17. REMOVE BATTERY SMART UNIT

NOTICE:
Wear insulating gloves and protective glasses.

  1. A108254E01
    Disconnect the 5 connectors and 2 clamps.

  1. A108255
    Remove the 4 bolts and battery smart unit.


18. REMOVE HV BATTERY

CAUTION:
Wear insulating gloves and protective glasses.

NOTICE:
Insulate the removed terminals with insulating tape.

  1. Remove the HV battery LH.

    1. A108256
      Remove the battery room ventilation hose between the HV batteries LH and CTR.

    2. A108257
      Disconnect the wire harness clamp of the battery thermo sensor.

    3. A108308
      Remove the nut and main battery cable from the HV battery LH.

      NOTICE:
      1. Insulate the tool with insulating tape.
      2. Do not use the universal joint.

    4. A108309
      Remove the nut, then disconnect the EV battery plug from the HV battery.

      NOTICE:
      1. Insulate the tool with insulating tape.
      2. Do not use the universal joint.

    5. A108310
      Remove the HV battery LH.

  1. Remove the HV battery CTR.

    1. A108311
      Disconnect the 2 connectors from the HV relay assembly.

    2. A108312
      Disconnect the 2 connectors and clamp.

    3. A108313
      Remove the battery room ventilation hose between the HV batteries CTR and RH.

    4. A108314
      Remove the HV battery CTR.

  1. Remove the HV battery RH

    1. A108315
      Disconnect the 2 clamps.

    2. A108316
      Remove the nut, then disconnect the main battery cable connector.

    3. A108317E01
      Disconnect the clamp.

    4. A108944E01
      Remove the battery room ventilation hose.

    5. A108318
      Remove the HV battery RH.

    6. A108802
      Remove the nut and main battery cable No.2 from the HV battery RH.

    7. A109121
      Remove the nut and main battery cable from the HV battery RH.


19. REMOVE BATTERY COOLING BLOWER ASSEMBLY

HINT:
Exchange the HV battery lower case as a set when liquids collect at the HV battery lower case and powder sticks.

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

  1. A115320
    Remove the 9nuts and 3 battery cooling blower assemblies.


20. REMOVE ELECTRIC VEHICLE BATTERY PLUG ASSEMBLY

  1. A115322E01
    Disconnect the connector and clamps.

  1. A115321
    Remove the 2 bolts, nut and EV battery plug.


21. REMOVE HYBRID VEHICLE RELAY ASSEMBLY

  1. A115319
    Remove the 3 nuts and hybrid vehicle relay assembly.


22. REMOVE HV BATTERY SERVICE HOLE COVER

  1. A108319E01
    Disconnect the connector and clamp, then remove the HV battery lower case.


23. REMOVE BATTERY COVER

  1. A112658
    Remove the battery cover from the HV battery lower case.


24. REMOVE BATTERY PACKING NO.2

  1. A112657
    Remove the battery packing No.2 from the HV battery lower case.


25. REMOVE BATTERY PACK WIRE

  1. A111107
    Disconnect the clamp, then remove the battery pack wire from the HV battery lower case.

  1. A108320
    Disconnect the 2 clamps, then remove the battery pack wire from the HV battery lower case.

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