ES300h - Prius20.ru

ES300h - Prius20.ru
ES300h
Gasoline-Electric
Hybrid Synergy Drive
AVV60 Series
Foreword
This guide was developed to educate and assist dismantlers in the safe handling of Lexus ES300h
gasoline-electric hybrid vehicles. ES300h 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 ES300h, as they
may not be familiar to dismantlers.
High voltage electricity powers the A/C compressor, electric motor, 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
ES300h to help ensure the high voltage, approximately 244.8 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 ES300h identification.
•
Major hybrid component locations and descriptions.
By following the information in this guide, dismantlers will be able to handle ES300h hybrid-electric
vehicles as safely as the dismantling of a conventional gasoline engine automobile.
© 2012 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.
ii
Table of Contents
About the ES300h hybrid ..........................................................................................................................1
ES300h 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 ............................................................................................................................19
HV Battery Caution Label.......................................................................................................................30
i
About the ES300h hybrid
The ES300h joins the LS600h L, GS450h, RX450h, HS250h and CT200h as a hybrid
model for Lexus. Lexus Hybrid Drive means that the vehicle contains a gasoline engine
and an electric motor 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
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 ES300h 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 ES300h operates in various driving
modes.
During 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 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
electric motor power the vehicle.
During deceleration, such as when braking, the vehicle regenerates the kinetic
energy from the rear 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.
Starting
Electricity
Normal Driving
Electricity and gasoline
Acceleration
Electricity and gasoline
(additional electricity
extracted from batteries)
1
Deceleration
Charging batteries
Stopping
Engine automatically
stopped
ES300h Identification
In appearance, the 2013 model ES300h is a nearly identical to the conventional,
non-hybrid Lexus ES350 or ES250. The ES300h is a 4-door sedan. 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, under the right side front seat, and on the left side B pillar.
Example VIN: JTHBW1GG0D2000101
A ES300h is identified by the first 8 alphanumeric characters JTHBW1GG.
Left Side Windshield Cowl, Right Side Floor and Left Side B Pillar
2
ES300h Identification (Continued)
Exterior
* and
logos on the trunk.
logo on the front doors.
Gasoline fuel filler door located on the left side rear quarter panel.
*: Except U.S.A. and Canada models
Exterior Left Side View
Exterior Front View
U.S.A. and Canada Models
Others
Exterior Rear View
Exterior Rear and Left Side View
3
ES300h 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 ES350 or ES250.
A switchable gauge in the instrument cluster 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.
READY Indicator
For U.S.A.
Others
Instrument Cluster View (Hybrid System Indicator)
For U.S.A.
Others
Instrument Cluster View (Tachometer)
4
ES300h Identification (Continued)
Engine Compartment
2.5-liter aluminum alloy gasoline engine.
Logo on the plastic engine cover.
Orange colored high voltage power cables.
Engine Compartment View
Power Cables
5
Hybrid Component Locations & Descriptions
Component
Location
Description
12 Volt
Right Side of
Auxiliary Battery Trunk
A lead-acid battery that supplies power to the low
voltage devices.
Hybrid Vehicle
(HV) Battery
Pack
Power Cables
Trunk Area,
Mounted behind
Rear Seat
Undercarriage
and Engine
Compartment
Inverter/
Converter
Engine
Compartment
Gasoline
Engine
Engine
Compartment
Electric
Motor
Engine
Compartment
Electric
Generator
Engine
Compartment
A/C Compressor
(with Inverter)
DC-DC
Converter
for 12 Volt
Auxiliary
Battery
Fuel Tank and
Fuel Line
Engine
Compartment
Engine
Compartment
244.8 Volt Nickel Metal Hydride (NiMH) battery pack
consisting of 34 low voltage (7.2 Volt) modules
connected in series.
Orange colored power cables carry high voltage Direct
Current (DC) between the HV battery pack,
inverter/converter, and A/C compressor. These cables
also carry 3-phase Alternating Current (AC) between the
inverter/converter, electric motor, and generator.
Boosts and inverts the high voltage electricity from the
HV battery pack to 3-phase AC electricity that drives the
electric motor. The inverter/converter also converts AC
electricity from the electric generator and electric motor
(regenerative braking) to DC that recharges the HV
battery pack.
Provides two functions:
1) Powers vehicle.
2) Powers generator to recharge the HV battery pack.
The engine is started and stopped under control of the
vehicle computer.
3-phase high voltage AC permanent magnet electric
motor contained in the transaxle and drives the front
wheels.
3-phase high voltage AC electric generator that is
contained in the transaxle and recharges the HV battery
pack.
3-phase high voltage AC electrically driven motor
compressor.
Converts 244.8 Volts from the HV battery pack to 12
Volts for low voltage vehicle power.
Undercarriage
and Left Side
and Center
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.
6
Hybrid Component Locations & Descriptions (Continued)
Specifications
Gasoline Engine:
Electric Motor:
Transmission:
HV Battery:
Curb Weight:
Fuel Tank:
Frame Material:
Body Material:
Seating Capacity:
155 hp (116 kW), 2.5-liter Aluminum Alloy Engine (U.S.A. and Canada
Models)
158 hp (118 kW), 2.5-liter Aluminum Alloy Engine (Others)
141 hp (105 kW), AC Motor
Automatic Only
244.8 Volt Sealed NiMH Battery
3,660 to 3,781lbs/1,660 to 1,715 kg
17 gals/64.35 liters (U.S.A. and Canada Models)
17 gals/65 liters (Others)
Steel Unibody
Steel Panels
5 passenger
U.S.A. and Canada Models
Others
7
Hybrid Component Locations & Descriptions (Continued)
Lexus Hybrid Drive Operation
Once the READY indicator is illuminated in the instrument cluster, 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 ES300h, 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 electric motor only.
2. A combination of both the electric motor and the gasoline engine.
Instrument Cluster READY Indicator
8
Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery
The ES300h 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 trunk area
behind the rear seat. The metal case is isolated from high voltage and concealed by fabric
covers in the trunk.
•
The HV battery pack consists of 34 low voltage (7.2 Volt) NiMH battery modules connected
in series to produce approximately 244.8 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
Number of NiMH battery modules in the pack
NiMH battery module voltage
NiMH battery module dimensions
NiMH module weight
NiMH battery pack dimensions
NiMH battery pack weight
244.8 V
34
7.2 V
10.9 x 0.8 x 4.2 in
(276 x 19.6 x 106 mm)
2.3 lbs (1.0 kg)
32.1 x 17.5 x 12.9 in
(817 x 445 x 325 mm)
102.5 lbs (46.5 kg)
Components Powered by the HV Battery Pack
•
•
•
Electric Motor
Power Cables
Electric Generator
•
•
•
Inverter/Converter
A/C Compressor
DC-DC Converter for 12 Volt Auxiliary
Battery
9
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 (see page 30) or the nearest Lexus dealer.
Auxiliary Battery
•
The ES300h 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 negative terminal of the auxiliary battery is grounded to the metal
chassis of the vehicle.
•
The auxiliary battery is located in the trunk area.
left side in the rear quarter panel well.
244.8 Volt HV Battery Pack
It is concealed by a fabric cover on the
12 Volt Auxiliary Battery Mounted in Trunk Area
HV Battery Pack Mounted in Trunk Area
10
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, routed along the propeller shaft and transmission tunnel to the
inverter/converter. The inverter/converter contains a circuit that boosts the HV battery voltage
from 244.8 to 650 Volts DC. The inverter/converter creates 3-phase AC to power the motor.
Power cables are routed from the inverter/converter to each high voltage motor (electric motor,
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
•
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.
* provides short circuit protection in 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 chassis, so there is
no possibility of electric shock when touching the metal chassis.
•
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
in the instrument cluster and
computer * will illuminate the master warning light
indicate “CHECK HYBRID SYSTEM” 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.
11
High Voltage Safety (Continued)
Service Plug Grip
•
The high voltage circuit is cut by removing the service plug grip (see page 15).
0.0
Volt DC
Hybrid Vehicle Computer
12 Volt
Auxiliary
Battery
A/C
Compressor
Electric
Generator
Inverter/
Converter
0.0
Volt DC
Electric
Motor
AC
3-Phas
HV Battery Assembly
High Voltage Safety System – Vehicle Shut Off (READY-OFF)
244.8
Volt DC
Hybrid Vehicle Computer
12 Volt
Auxiliary
Battery
A/C
Compressor
Electric
Generator
Inverter/
Converter
244.8
Volt DC
Electric
Motor
AC
3-Phase
HV Battery Assembly
High Voltage Safety System – Vehicle On and Operational (READY-ON)
12
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.
13
Spills
The ES300h 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.
caustic alkaline (pH 13.5) that is damaging to human tissues.
The NiMH battery electrolyte is a
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.
is approximately in the middle of this scale.
A safe (neutral) substance
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.
14
Dismantling the vehicle
The following 2 pages contain general instructions for use when working on an ES300h.
Read these instructions before proceeding to the HV battery removal instructions on page 19.
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 12 Volt auxiliary battery
cover.
(2) Disconnect the battery negative terminal.
(3) Remove the luggage compartment floor
mat.
2. Remove the luggage compartment front
trim cover.
(1) Disengage the 8 fasteners and remove the
luggage compartment front trim cover.
15
3. Remove the No. 8 hybrid vehicle battery
shield panel.
(1) Remove the 2 nuts and No. 8 hybrid
battery shield panel.
4. Remove the service plug grip.
Caution:
Wear insulated gloves for the following
4 steps.
(1) Slide the handle of the service plug grip to the right.
(2) Raise the release handle of the service plug grip
(3) Remove the service plug grip.
(4) Apply insulating tape to the socket of the service plug grip to insulate it.
5. Carry the removed service plug grip in your pocket to prevent other staff from
accidentally reinstalling it while you are dismantling the vehicle.
6. Make other staff aware that a high-voltage system is being dismantled by using
thefollowing sign: CAUTION: HIGH-VOLTAGE. DO NOT TOUCH (see page 18).
7. If the service plug grip cannot be removed due to damage to the vehicle, remove the
IG2 MAIN fuse (25 A).
Caution:
This operation shuts off the HV system. Be sure to wear insulated gloves
because high voltage is not shut off inside the HV battery. When it is possible to
remove the service plug grip, remove it and continue the procedure.
IG2 MAIN Fuse
16
8. After disconnecting or exposing a
high-voltage connector or terminal, insulate it
immediately using insulating tape. Before
disconnecting or touching a bare high-voltage
terminal, wear insulated gloves.
9. Check the HV battery and nearby area
forleakage. If you find any liquid, it may be
strong alkaline electrolyte. Wear rubber gloves and goggles and neutralize the liquid
using a saturated boric acid solution or vinegar. Then wipe up the liquid using waste
rags etc.
10. If the electrolyte comes into contact with your skin, wash the skin immediately using a
saturated boric acid solution or a large amount of water. If the electrolyte adheres to any
article of clothing, take the clothing off immediately.
11. If the electrolyte comes into contact with your eye(s), call out loudly for help. Do not
rub your eye(s). Instead, wash the eye(s) with a dilute boric acid solution or a large
amount of water and seek medical care.
12. With the exception of the HV battery, remove parts by following procedures which are
similar to conventional Lexus vehicles. For the removal of the HV battery, refer to the
following pages.
17
18
Removal of HV battery
WARNING:
・ Be sure to wear insulated gloves when handling high-voltage parts.
・ Even if the vehicle is shut off and the relays are off, be sure to remove
the service plug grip before performing any further work.
・ Power remains in the high voltage electrical system for 10 minutes
even after the HV battery pack is shut off because the circuit has a
condenser that stores power.
・ Make sure that the tester reading is 0 V before touching any
high-voltage terminals which are not insulated.
・ The SRS may remain powered for up to 90 seconds after the vehicle is
shut off or disabled. To prevent serious injury or death from
unintentional SRS deployment, avoid cutting the SRS components.
1. SHUT OFF IGINITION (READY
indicator is off)
2. REMOVE LUGGAGE 12 VOLT
AUXILIARY BATTERY COVER
3. REMOVE 12 V AUXILIARY BATTERY
(1) Disconnect the cable from the auxiliary
battery negative (-) terminal.
(2) Disconnect the cable from the auxiliary
battery positive (+) terminal.
(3) Remove the 12 Volt auxiliary battery.
4. REMOVE LUGGAGE COMPARTMENT
FLOOR MAT
19
5. REMOVE LUGGAGE COMPARTMENT
FRONT TRIM COVER
(1) Disengage the 8 fasteners and remove the
luggage compartment front trim cover.
6. REMOVE NO. 8 HYBRID VEHICLE
BATTERY SHIELD PANEL
(1) Remove the 2 nuts and No. 8 hybrid
vehicle battery shield panel.
7. REMOVE SERVICE PLUG GRIP
Caution:
Wear insulated gloves for the following 4
steps.
(1) Slide the handle of the service plug grip.
(2) Raise the release handle of the service plug grip as shown in the illustration below.
(3) Remove the service plug grip.
(4) Apply insulating tape to the socket of the service plug grip to insulate it.
8. REMOVE CONNECTOR COVER
ASSEMBLY
Caution:
Wear insulated gloves.
(1) Remove the 2 bolts and connector cover
assembly.
20
9. CHECK TERMINAL VOLTAGE
(1) Check voltage at the terminals in
inspection point in the power control unit.
Caution:
Wear insulated gloves.
To prevent serious injury or death, do
not proceed with dismantling of the HV
system until the voltage at the terminals
in the inspection point is 0 V.
Standard voltage: 0 V
Hint:
Set the tester to the DC 750 Volts range to measure the voltage.
This inspection is performed to verify that it is safe to remove the HV battery.
10. REMOVE LUGGAGE HOLD BELT
STRIKERASSEMBLY (for Rear Side)
(1) Remove the 2 bolts.
(2) Disengage the 2 guides and remove the 2
luggage hold belt striker assemblies.
11. REMOVE REAR FLOOR FINISH PLATE
(1) Using a clip remover, remove the 3 clips.
21
(2) Disengage the 4 clips and remove the rear
floor finish plate.
12. REMOVE LUGGAGE HOLD BELT
STRIKER ASSEMBLY (for LH Side)
(1) Remove the bolt.
(2) Disengage the guide and remove the
luggage hold belt striker assembly.
13. REMOVE ROPE HOOK (for LH Side)
(1) Disengage the 2 claws and remove the
rope hook as shown in the illustration.
14. REMOVE LUGGAGE COMPARTMENT
INNER TRIM COVER LH
(1) Using a clip remover, remove the 3 clips.
(2) Disengage the 2 fasteners and remove the
luggage compartment inner trim cover
LH.
22
15. REMOVE LUGGAGE HOLD BELT
STRIKER ASSEMBLY (for RH Side)
(1) Remove the bolt.
(2) Disengage the guide and remove the luggage
hold belt striker assembly.
16. REMOVE ROPE HOOK (for RH Side)
(1) Disengage the 2 claws and remove the rope
hook as shown in the illustration.
17. REMOVE LUGGAGE COMPARTMENT
INNER TRIM COVER RH (w/o Power
Trunk Lid System)
(1) Using a clip remover, remove the 3 clips.
(2) Disengage the 2 fasteners and remove the
luggage compartment inner trim cover RH.
18. REMOVE LUGGAGE COMPARTMENT
INNER TRIM COVER RH (w/ Power Trunk
Lid System)
(1) Using a clip remover, remove the 2 clips.
(2) Disengage the 4 fasteners and remove the
luggage compartment inner trim cover
RH.
19. REMOVE REAR SEAT HEAD REST
ASSEMBLY
23
20. REMOVE REAR SEAT CUSHION
ASSEMBLY
Rear Seatback Hinge Hook
(1) Disengage the 2 hooks <A> on the front
side of the rear seat cushion assembly
<B>
from the vehicle body as shown in the
<B>
illustration.
<A>
(2) Disengage the 2 hooks <B> on the rear
<A>
side of rear seat cushion assembly from
the rear seatback hinge hook.
(3) Remove the buckle of the rear seat inner
with center belt assembly LH and buckle
of the rear seat inner with center belt
assembly RH from the rear seat cushion
assembly.
(4) Remove the rear seat cushion assembly.
21. REMOVE REAR SEATBACK ASSEMBLY
(1) Using a screwdriver with its tip wrapped
with protective tape, disengage the claw
and disconnect the rear seat shoulder belt
guide LH.
(2) Using a screwdriver with its tip wrapped
with protective tape, disengage the claw
and disconnect the rear seat shoulder belt
guide RH.
24
(3) Using a screwdriver with its tip wrapped
with protective tape, disengage the claw
and disconnect the rear center seat
shoulder belt guide.
(4) Disconnect the 2 rear seat airbag assembly
connectors.
(5) Disengage the 2 clamps and disconnect
the 2 rear seat airbag assembly wire
harnesses.
(6) Remove the 4 bolts.
(7) Disconnect the rear seat 3 point type outer
belt assembly LH, rear seat 3 point type
outer belt assembly RH and rear seat inner
with center belt assembly LH from the
rear seatback assembly.
(8) Disengage the 2 hooks and remove the
rear seatback assembly.
22. REMOVE REAR DOOR SCUFF PLATE
LH
23. REMOVE REAR SEAT SIDE GARNISH
LH
(1) Disengage the 5 claws and remove the
rear seat side garnish LH.
24. REMOVE ROOM PARTITION PANEL
INSULATOR
(1) Remove the 4 clips and room partition
panel insulator.
25
25. REMOVE NO. 1 HYBRID BATTERY
INTAKE DUCT
(1) Remove the 3 clips and No. 1 hybrid
battery intake duct.
26. REMOVE NO. 4 HYBRID BATTERY
SHIELD PANEL
Caution:
Wear insulated gloves for the following 2
steps.
(1) Remove the 3 clips and No. 1 hybrid
battery intake duct.
Hint:
Insert the projecting part of the service plug
grip and turn the button of the battery cover
lock striker counterclockwise to release the
lock.
(2) Remove the bolt, 2 nuts and No. 4 hybrid
battery shield panel.
27. REMOVE NO. 4 FLOOR WIRE
Caution:
Wear insulated gloves.
Notice:
Insulate the terminals of the removed
frame wire with insulating tape.
(1) Disconnect the 2 connectors shown in the
illustration.
(2) Disconnect the shielded wire ground and
disconnect the No. 4 floor wire.
26
28. DISCONNECT LOW VOLTAGE
CONNECTOR
(1) Disconnect the connector and clamp
shown in the illustration.
(2) Disconnect the 2 connectors.
29. REMOVE HV BATTERY
Caution:
Wear insulated gloves.
Notice:
Since the HV battery is very heavy, 2 people are needed to remove the HV battery.
When removing the HV battery, do not damage the parts around it.
(1)
Remove the 6 bolts from the HV battery.
27
(2)
Place a piece of cardboard in the luggage
compartment.
(3)
Cut and shape a piece of cardboard so that
it fits the area between the HV battery bolt
attachment positions, and then insert it as
shown in the illustration.
(4)
Using a tire lever to hold up the HV
battery, insert the cardboard until it cannot
Hold Up
be inserted any further.
Cardboard
(5)
Pull the HV battery toward the center of
the luggage compartment.
Pull
(6)
Remove the 2 nuts and No. 2 hybrid
vehicle battery upper cover bracket.
28
Insert
(6) Remove the clip.
(7) Disengage the 2 claws and remove the No.
2 hybrid battery intake duct.
(8) Disconnect the connector from the battery
cooling blower assembly.
(9) Remove the 3 nuts and battery cooling
blower assembly.
(10) Turn the HV battery 180°.
(11) Pull the HV battery together with the
cardboard toward the rear of the vehicle.
(12) Using a suitable adaptor such as a rope,
remove the HV battery while tilting the
HV battery.
(13) The HV battery pack is recyclable. Contact your Lexus distributor (if included on the HV
battery caution label) or contact the nearest Lexus dealer (see the next 2 pages for samples
of the HV battery caution label).
Caution:
After removing the HV battery, do not reinstall the service plug grip to the HV
battery.
29
HV Battery Caution Label
1. For U.S.A.
2.
For Canada
30
3.
For Russia
4. For General
31
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