Lexus RX450h User manual

RX450h
Gasoline-Electric
Lexus Hybrid Drive
GYL20/GYL25 Series

Foreword
This guide was developed to educate and assist dismantlers in the safe handling of Lexus RX450h
gasoline-electric hybrid vehicles. RX450h dismantling procedures are similar to other non-hybrid Lexus
vehicles with the exception of the high voltage electrical system. It is important to recognize and
understand the high voltage electrical system features and specifications of the Lexus RX450h, as they
may not be familiar to dismantlers.
High voltage electricity powers theA/C compressor, front and rear electric motors, generator, and
inverter/converter. All other conventional automotive electrical devices such as the head lights, radio,
and gauges are powered from a separate 12 Volt auxiliary battery. Numerous safeguards have been
designed into the RX450h to help ensure the high voltage, approximately 288 Volt, Nickel Metal
Hydride (NiMH) Hybrid Vehicle (HV) battery pack is kept safe and secure in an accident.
The NiMH HV battery pack contains sealed batteries that are similar to rechargeable batteries used in
some battery operated power tools and other consumer products. The electrolyte is absorbed in the cell
plates and will not normally leak out even if the battery is cracked. In the unlikely event the electrolyte
does leak, it can be easily neutralized with a dilute boric acid solution or vinegar.
High voltage cables, identifiable by orange insulation and connectors, are isolated from the metal chassis
of the vehicle.
Additional topics contained in the guide include:
Lexus RX450h identification.
Major hybrid component locations and descriptions.
By following the information in this guide, dismantlers will be able to handle RX450h hybrid-electric
vehicles as safely as the dismantling of a conventional gasoline engine automobile.
2015 Toyota Motor Corporation
All rights reserved. This book may not be reproduced or
copied, in whole or in part, without the written permission
of Toyota Motor Corporation.

Table of Contents
About the RX450h......................................................................................................................................1
RX450h Identification................................................................................................................................2
Exterior........................................................................................................................................................3
Interior.........................................................................................................................................................4
Engine Compartment ..................................................................................................................................5
Hybrid Component Locations & Descriptions.........................................................................................6
Specifications..............................................................................................................................................7
Lexus Hybrid Drive Operation .................................................................................................................8
Vehicle Operation........................................................................................................................................8
Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery......................................................................9
HV Battery Pack..........................................................................................................................................9
Components Powered by the HV Battery Pack...........................................................................................9
HV Battery Pack Recycling .......................................................................................................................10
Auxiliary Battery........................................................................................................................................10
High Voltage Safety ..................................................................................................................................11
High Voltage Safety System......................................................................................................................11
Service Plug Grip......................................................................................................................................12
Precaution to be observed when dismantling the vehicle......................................................................13
Necessary Items .......................................................................................................................................13
Spills ..........................................................................................................................................................14
Dismantling the vehicle............................................................................................................................15
Removal of HV battery............................................................................................................................21

1
About the RX450h
The RX450h 5-door wagon joins the hybrid model for Lexus Hybrid Drive means that
the vehicle contains a gasoline engine and front and rear electric motors for power.
The two hybrid power sources are stored on board the vehicle:
1. Gasoline stored in the fuel tank for the gasoline engine.
2. Electricity stored in a high voltage Hybrid Vehicle (HV) battery pack for the
front and rear electric motors.
The result of combining these two power sources is improved fuel economy and
reduced emissions. The gasoline engine also powers an electric generator to recharge
the battery pack; unlike a pure all electric vehicle, the RX450h never needs to be
recharged from an external electric power source.
Depending on the driving conditions one or both sources are used to power the vehicle.
The following illustration demonstrates how the RX450h operates in various driving
modes.
During light acceleration at low speeds, the vehicle is powered by the front and rear
electric motors. The gasoline engine is shut off.
During normal driving, the vehicle is powered mainly by the gasoline engine. The
gasoline engine also powers the generator to recharge the battery pack and to drive
the motor.
During full acceleration, such as climbing a hill, both the gasoline engine and the
front and rear electric motors power the vehicle.
During deceleration, such as when braking, the vehicle regenerates the kinetic
energy from the front and rear wheels to produce electricity that recharges the
battery pack.
While the vehicle is stopped, the gasoline engine and front and rear electric motors
are off, however the vehicle remains on and operational.
Starting Normal Driving Acceleration Deceleration Stopping
Electricity Electricity and gasoline Electricity and gasoline
(additional electricity
extracted from batteries)
Charging batteries Engine automatically
stopped

2
RX450h Identification
In appearance, the 2016 model year / 2015 calendar year RX450h is nearly identical to
the conventional, non-hybrid Lexus RX350/200t. The RX450h is a 5-door wagon.
Exterior, interior, and engine compartment illustrations are provided to assist in
identification.
The alphanumeric 15 character Vehicle Identification Number (VIN) is provided in the
left side windshield cowl, under the right side front seat and on the B pillar.
Example VIN: JTJBGMCA2000101 or JTJEGMCA2000101 (for TMK made)
2T2ZFMCAC000101 or 2T2BGMCAC000101 (for TMMC made)
An RX450h is identified by the first 8 alphanumeric characters JTJBGMCA,
JTJEGMCA, 2T2ZFMCA or 2T2BGMCA.
Left Side Windshield Cowl, Under the Right Side Front Seat and B Pillar

3
RX450h Identification (Continued)
Exterior
RX450h logo on the back door.
logos on the rocker molding.
Gasoline fuel filler door located on the left side rear quarter panel.
Exterior Front and Left Side View
Exterior Rear and Left Side View






4
RX450h Identification (Continued)
Interior
The instrument cluster (hybrid system indicator, READY indicator and warning
lights) located in the dash behind the steering wheel, is different than the one on the
conventional, non-hybrid RX350/200t.
A switchable gauge in the combination meter showing either a hybrid system
indicator or a tachometer depending on driving mode.
Notice:
If the vehicle is shut off, the instrument cluster gauges will be “blacked out”, not
illuminated.
Interior View
Combination Meter View
READY Indicato
r


for O
p
titron Meter for TFT LCD Meter

READY Indicato
r
This illustration is for an LHD model

5
RX450h Identification (Continued)
Engine Compartment
3.5-liter aluminum alloy gasoline engine.
Logo on the engine cover.
Orange colored high voltage power cables.
Engine Compartment View
Power Cables




6
Hybrid Component Locations & Descriptions
Component Description
12 Volt Auxiliary Battery
When the power switch is on (ACC) or on (IG), the auxiliary battery
supplies power to the electrical equipment and ECUs.
Hybrid Vehicle (HV)
Battery Pack Supplies electrical power to MG1, MG2 and MGR*1 and the
compressor with motor assembly in accordance with the driving
conditions of the vehicle.
Charged by MG1 and MG2 in accordance with the State Of Charge
(SOC) of the HV battery and the driving conditions of the vehicle.
Has a nominal (approximate) voltage of DC 288 V (actual voltage
will vary depending on various conditions such as temperature,
charge or discharge).
Power Cables Connects the HV battery to the inverter with converter assembly, the
inverter with converter assembly to MG1, MG2 and MGR*1, and the
inverter with converter assembly to the compressor with motor
assembly.
DC-DC
Converter 
for 12 Volt
Auxiliary
Battery
Drops the HV battery voltage of DC 288 V into approximately DC 14
V in order to supply electricity to body electrical components, as well
as to recharge the auxiliary battery.
Motor
Generator
ECU
Controls the inverter and boost converter in accordance with signals
received from the hybrid Vehicle Control ECU assembly, thus
operating MG1, MG2, or MGR*1 as either a generator or motor.
Boost
Converter Boosts the voltage of the HV battery from DC 288V to a maximum of DC 650 V and vice versa (drops DC 650 V to DC 288 V).
Inverter/
Converter

Inverter A device that converts high-voltage DC (HV battery) into AC (MG1,
MG2 and MGR*1) and vice versa (convertsAC into DC).
Gasoline Engine 
The 2GR-FXS engine is a high-expansion ratio Atkinson cycle engine which is compatible with the hybrid system and which generates drive
force for driving and energy for electricity generation.
Front Motor
Driven by electrical power from MG1 and/or the HV battery, and
generates motive force for the front wheels.
Generates electricity to recharge the HV battery (regenerative
braking) during braking or when the accelerator pedal is not
depressed.
Electric
Motor
Rear
Motor*1

Driven by electrical power from MG1 and/or the HV battery, it
generates motive force for the rear wheels.
During braking, or when the accelerator pedal is not depressed, it
generates electricity to recharge the HV battery (Regenerative
braking).
Electric Generator Driven by the engine and generates high-voltage electricity in order
to operate MG2 and MGR*1 and/or to charge the HV battery.Also,
MG1 functions as a starter to start the engine.
Operated to allow the gear ratio of the power split planetary gear
unit to optimally suit the driving conditions of the vehicle.
A/C Compressor
(with inverter) Driven at a speed calculated by the air conditioning amplifier assembly, receives drive requests from the hybrid vehicle control ECU
assembly and takes in, compresses and discharges refrigerant.
Fuel Tank and Fuel Line
The fuel tank provides gasoline via a fuel line to the engine. The fuel
line is routed along the left side and center tunnel under the floor pan.
*Numbers in the component column apply to the illustrations on the following page.
*1: for AWD models

7
Hybrid Component Locations & Descriptions (Continued)
Specifications
Gasoline Engine: 193 kW, 3.5-liter Aluminum Alloy Engine
Electric Motors
Front: 123 kW, Permanent Magnet Motor
Rear: 50 kW, Permanent Magnet Motor (for AWD models)
Transmission: Automatic Only
HV Battery: 288 Volt Sealed NiMH Battery
Curb Weight: 1,915 to 2,210 kg / 4,320 to 4,872 lbs
Fuel Tank: 72 liters / 19.0 Us. gals / 15.8 Imp. gals (for TMMC made)
65 liters / 17.2 Us. gals / 14.3 Imp. gals / 57.2 Imp. qts (for TMK made)
Frame Material: Steel Unibody
Body Material: Steel Panels
Seating Capacity: 5 passenger


















8
Lexus Hybrid Drive Operation
Once the READY indicator is illuminated in the combination meter, the vehicle may be
driven. However, the gasoline engine does not idle like a typical automobile and will
start and stop automatically. It is important to recognize and understand the READY
indicator provided in the instrument cluster. When illuminated, it informs the driver that
the vehicle is on and operational even though the gasoline engine may be off and the
engine compartment is silent.
Vehicle Operation
With the RX450h, the gasoline engine may stop and start at any time while the READY
indicator is on.
Never assume that the vehicle is shut off just because the engine is off. Always look for the
READY indicator status. The vehicle is shut off when the READY indicator is off.
The vehicle may be powered by:
1. The front and rear electric motors only.
2. A combination of both the front and rear electric motors and the gasoline engine.
Combination Meter READY Indicator
for O
p
titron Meter for TFT LCD Meter

9
Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery
The RX450h features a high voltage Hybrid Vehicle (HV) battery pack that contains
sealed Nickel Metal Hydride (NiMH) battery modules.
HV Battery Pack
The HV battery pack is enclosed in a metal case and is rigidly mounted to the cabin area
floor pan cross member under the second row seats. The metal case is isolated from high
voltage and concealed by fabric covers in the cabin area.
The HV battery pack consists of 30 low voltage (9.6 Volt) NiMH battery modules
connected in series to produce approximately 288 Volts. Each NiMH battery module is
non-spillable and sealed in a metal case.
The electrolyte used in the NiMH battery module is an alkaline mixture of potassium and
sodium hydroxide. The electrolyte is absorbed into the battery cell plates and will not
normally leak, even in a collision.
HV Battery Pack
Battery pack voltage 288 V
Number of NiMH battery modules in the pack 30
NiMH battery module voltage 9.6 V
Components Powered by the HV Battery Pack
Front Electric Motor
Rear Electric Motor (for AWD models)
Power Cables
A/C Compressor
Electric Generator
Inverter/Converter
-DC-DC Converter for 12 Volt Auxiliary Battery

10
Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (Continued)
HV Battery Pack Recycling
The HV battery pack is recyclable. Contact either your Lexus Distributor as mentioned on
HV battery Caution Label or the nearest Lexus dealer.
Auxiliary Battery
The RX450h also contains a sealed lead-acid 12 Volt battery. This 12 Volt auxiliary battery
powers the vehicle electrical system similar to a conventional vehicle. As with other
conventional vehicles, the auxiliary battery is grounded to the metal chassis of the vehicle.
The auxiliary battery is located in the luggage compartment area. It is concealed by a fabric
cover on the left side in the luggage compartment.
288 Volt HV Battery Pack 12 Volt Auxiliary Battery Mounted in Luggage Compartment Area
(Left Side)
HV Battery Pack Mounted in CabinArea

11
High Voltage Safety
The HV battery pack powers the high voltage electrical system with DC electricity. Positive and
negative orange colored high voltage power cables are routed from the battery pack, under the
vehicle floor pan, to the inverter/converter. The inverter/converter contains a circuit that boosts
the HV battery voltage from 288 to 650 Volts DC. The inverter/converter creates 3-phase AC to
power the motors. Power cables are routed from the inverter/converter to each high voltage
motors (front and rear electric motors, electric generator, and A/C compressor). The following
systems are intended to help keep occupants in the vehicle and emergency responders safe from
high voltage electricity:
High Voltage Safety System
A high voltage fuse * provides short circuit protection in the HV battery pack.
Positive and negative high voltage power cables * connected to the HV battery pack are
controlled by 12 Volt normally open relays *. When the vehicle is shut off, the relays stop
electricity flow from leaving the HV battery pack.
WARNING:
・ The high voltage system may remain powered for up to 10
minutes after the vehicle is shut off or disabled. To prevent
serious injury or death from severe burns or electric shock,
avoid touching, cutting, or opening any orange high voltage
power cable or high voltage component.
Both positive and negative power cables * are insulated from the metal body. High
voltage electricity flows through these cables and not through the metal vehicle body.
The metal vehicle body is safe to touch because it is insulated from the high voltage
components.
A ground fault monitor * continuously monitors for high voltage leakage to the metal
chassis while the vehicle is running. If a malfunction is detected, the hybrid vehicle
computer * will illuminate the master warning light in the instrument cluster and a
message indicating that the hybrid system is malfunctioning will be displayed on the
multi-information display.
The HV battery pack relays will automatically open to stop electricity flow in a collision
sufficient to activate the SRS.
*Numbers apply to the illustration on the following page.

12
High Voltage Safety (Continued)
Service Plug Grip
The high voltage circuit is cut by removing the service plug grip (see page 15).
High Voltage Safety System – Vehicle Shut Off (READY-OFF)
High Voltage Safety System – Vehicle On and Operational (READY-ON)
HV Battery Pack
Hybrid Vehicle Computer
Volts DC
A/C
Compressor
Electric
Generator
Front
Electric
Motor
0 Volts AC
3-Phase
Inverter/
Converter
12 Volts
Auxiliary
Battery
Volts DC
0.0
➊
➋
➋
❸❸
➍
0.0
Rear
Electric
Motor
HV Battery Pack
Hybrid Vehicle Computer
Volts DC
A/C
Compressor
Electric
Generator
288
650 Volts
AC Max
3-Phase
Inverter/
Converter
288
Volts DC 12 Volts
Auxiliary
Battery
Front
Electric
Motor
Rear
Electric
Motor

13
Precaution to be observed when dismantling the vehicle
WARNING:
・ The high voltage system may remain powered for up to 10
minutes after the vehicle is shut off or disabled. To prevent
serious injury or death from severe burns or electric shock,
avoid touching, cutting, or opening any orange high voltage
power cable or high voltage component.
Necessary Items
Protective clothing such as insulated gloves (electrically insulated), rubber gloves, safety goggles,
and safety shoes.
Insulating tape such as electrical tape that has a suitable electrical insulation rating.
Before wearing insulated gloves, make sure that they are not cracked, ruptured, torn, or damaged in
any way. Do not wear wet insulated gloves.
An electrical tester that is capable of measuring DC 750 Volts or more.

14
Spills
The RX450h contains the same common automotive fluids used in other non-hybrid Lexus vehicles,
with the exception of the NiMH electrolyte used in the HV battery pack. The NiMH battery electrolyte
is a caustic alkaline (pH 13.5) that is damaging to human tissues. The electrolyte, however, is absorbed
in the cell plates and will not normally spill or leak out even if a metal battery module is cracked.
A catastrophic crash that would breach both the metal battery pack case and a metal battery module
would be a rare occurrence.
A caustic alkaline is at the opposite end of the pH scale from a strong acid. A safe (neutral) substance is
approximately in the middle of this scale. Adding a weak acidic mixture, such as a dilute boric acid
solution or vinegar, to the caustic alkaline electrolyte will cause the electrolyte to be neutralized. This is
similar but opposite to the use of baking soda to neutralize a lead-acid battery electrolyte spill.
A Lexus Product Safety Data Sheets (PSDS) is attached to this document.
Handle NiMH electrolyte spills using the following Personal Protective Equipment (PPE):
•Splash shield or safety goggles. A fold down face shield is not acceptable for acid or
electrolyte spills.
•Rubber, latex or nitrile gloves.
•Apron suitable for alkaline.
•Rubber boots.
Neutralize NiMH electrolyte.
•Use a boric acid solution or vinegar.
•Boric acid solution - 800 grams boric acid to 20 liters water or 5.5 ounces boric acid to
1 gallon of water.

15
Dismantling the vehicle
The following 5 pages contain general instructions for use when working on an RX450h.
Read these instructions before proceeding to the HV battery removal instructions on page 21.
WARNING:
・ The high voltage system may remain powered for up to 10
minutes after the vehicle is shut off or disabled. To prevent
serious injury or death from severe burns or electric shock,
avoid touching, cutting, or opening any orange high voltage
power cable or any high voltage component.
1. Shut off the ignition (READY indicator is off).
Then disconnect the cable from the auxiliary battery negative (-) terminal.
(1) Remove the deck board assembly.
(2) for Compact Spare Tire:
a) Remove the spare wheel cover.
(3) w/ Spare Tire:
a) Remove the 3 clips.
b) Disengage the 3 guides to remove the rear
deck floor box.
(4) w/o Spare Tire:
a) Remove the 7 clips and rear floor carpet.
b) Remove the 4 clips.
c) Disengage the 2 guides to remove the rear
deck floor box.

16
(5) Loosen the nut, and disconnect the cable
from the negative (-) auxiliary battery
terminal.
2. Remove the battery service hole cover.
(1) Remove the clip.
(2) Disengage the clip and 2 guides to remove the
battery service hole cover.