Lexus RX 400h MHU33, RX 400h MHU38 Series, RX 400h Series Manual
Gasoline-Electric
Hybrid Synergy Drive
MHU33/38 Series
ii
Foreword
This guide was developed to educate and assist dismantlers in the safe handling of the Lexus RX400h
gasoline-electric hybrid vehicle. RX400h dismantling procedures are similar to other 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 RX400h as they may not be
familiar to dismantlers.
High voltage electricity powers an electric motor, generator, power steering, electric inverter compressor
(for air conditioner) and inverter. All other conventional automotive electrical devices such as the
headlights, radio, and gauges are powered from a separate 12-Volt battery. Numerous safeguards have
been designed into the RX400h 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
laptop computers, cell phones, 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:
N Lexus RX400h identification.
N Major hybrid component locations and descriptions.
By following the information in this guide, dismantlers will be able to handle the RX400h
hybrid-electric vehicle as safely as the dismantling of a conventional gasoline engine automobile.
¤ 2005 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
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Table of Contents
ABOUT THE RX400h ............................................................................................................................... 1
RX400h IDENTIFICATION ..................................................................................................................... 2
Exterior...........................................................................................................................................................................3
Interior............................................................................................................................................................................4
Engine Compartment...................................................................................................................................................... 5
HYBRID COMPONENT LOCATIONS & DESCRIPTIONS............................................................... 6
Specifications .................................................................................................................................................................7
HYBRID SYNERGY DRIVE OPERATION ........................................................................................... 8
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 .................................................................................................................................................................12
PRECAUTION TO BE OBSERVED WHEN DISMANTLING THE VEHICLE.............................. 13
Necessary items............................................................................................................................................................13
SPILLAGE ............................................................................................................................................... 14
DISMANTLING A VEHICLE ................................................................................................................ 15
REMOVAL OF HV BATTERY...............................................................................................................18
HV battery removal...................................................................................................................................................... 18
HV Battery Caution Label............................................................................................................................................24
1
About the RX400h
The RX400h (MHU33/38 series) is the first gasoline-electric hybrid vehicle for Lexus.
The gasoline-electric hybrid system has been named Hybrid Synergy Drive. Hybrid
Synergy Drive means that the vehicle contains a gasoline engine and an electric motor
for power. Two energy sources are stored onboard 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
electric motor.
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 RX400h 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 RX400h operates in various driving
modes.
On light acceleration at low speeds, the vehicle is powered by the electric motor.
The gasoline engine is shut off.
During normal driving, the vehicle is powered mainly by the gasoline engine.
The gasoline engine is also used to recharge the battery pack.
During full acceleration, such as climbing a hill, both the gasoline engine and the
electric motor power the vehicle.
During deceleration, such as braking, the vehicle regenerates the kinetic energy
from the front wheels to produce electricity that recharges the battery pack.
While the vehicle is stopped, the gasoline engine and electric motor are off,
however, the vehicle remains on and operational.
H
2
RX400h Identification
In appearance, the RX400h is nearly identical to the conventional, non-hybrid Lexus
RX330. The RX400h is a 5-door SUV. Exterior, interior, and engine compartment
illustrations are provided to assist in identification.
The alphanumeric 17 character Vehicle Identification Number (VIN) is provided in the front
windshield cowl, driver doorpost and passenger side frame.
Example VIN:
JTJGW31U840020208 (2WD)
JTJHW31U850011201 (4WD)
An RX400h is identified by the first 6 alphanumeric characters;
JTJGW3 (2WD) and JTJHW3 (4WD).
VIN Plate Locations
3
Exterior
RX400h logo on back door.
Gasoline fuel filler door located on left side quarter panel.
Lexus logo on the hood.
Exterior Rear & Left Side View
Exterior Left Side View
Exterior Front View
RX40
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h
4
RX400h Identification (Continued)
Interior
G Instrument cluster (speedometer, fuel gauge, warning lights) located in the dash behind the
steering wheel, is different than the one on the conventional, non-hybrid RX330.
H In place of a tachometer, a power meter showing KW output is used.
Interior View
Instrument Cluster & LCD Monitor
5
Engine Compartment
3.3-liter aluminum alloy gasoline engine.
High voltage inverter/converter assembly with logo on the cover.
Orange colored high voltage power cables.
HYBRID SYNERGY DRIVE Logo on
Inverter
Engine Compartment
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