RX400h · Service Manual HYBRID SYSTEM

INSTALLATION

Removal / installation


1. 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.


2. 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.


3. 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 }


4. 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 }


5. 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 }


6. 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 }


7. INSTALL REAR CENTER SEAT INNER BELT

  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.


8. INSTALL FLOOR CARPET ASSEMBLY FRONT

  1. Install the front floor carpet.


9. INSTALL AIR INTAKE COVER CENTER

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

  1. Install the 2 hole covers.


10. 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.


11. 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.


12. INSTALL REAR SEAT TRACK BRACKET COVER

13. 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.


14. INSTALL REAR SEAT TRACK BRACKET COVER

15. 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.


16. 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).


17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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