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