Lexus ES300h Vehicle Dismantling Manual
  1. Manuals
  2. Brands
  3. Lexus Manuals
  4. Automobile
  5. 2015 ES 300h
  6. Vehicle dismantling manual

Lexus ES300h Vehicle Dismantling Manual

Gasoline-electric hybrid drive
Hide thumbs Also See for ES300h:
Table of Contents

Advertisement

Quick Links

ES
E
30
Gasolin
G
ne-Elec
Lexus H
L
Hybrid
00h
h
ctric
d Drive
AXZH10 S Series

Advertisement

Table of Contents
loading

Related Manuals for Lexus ES300h

Summary of Contents for Lexus ES300h

  • Page 1 Gasolin ne-Elec ctric Lexus H Hybrid d Drive AXZH10 S Series...
  • Page 2 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.

  • Page 3: Table Of Contents

    Table of Contents About the ES300h ............................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 ................

  • Page 5: About The Es300H

    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.

  • Page 6: Es300H Identification

    ES300h Identification In appearance, the 2019 model year ES300h is nearly identical to the conventional, non-hybrid Lexus ES350/260/250/200. The ES300h is a 4-door sedan. 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, on the left side B pillar (except China) and on the right side B pillar (for China).

  • Page 7: Exterior

    ES300h Identification (Continued) Exterior  ES300h logo on the luggage compartment door.  logos on the each rear door.  Gasoline fuel filler door located on the left side rear quarter panel.  Exterior Front and Left Side View ...

  • Page 8: Interior

    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 ES350/260/250/200.  A switchable gauge in the combination meter showing either a hybrid system indicator or a tachometer depending on driving mode.
  • Page 9 ES30 00h Ident ification ( (Continue Engi ne Compart tment  5-liter alumi num alloy ga asoline engin  ogo on the en ngine cover.  range colore d high voltag ge power cab bles.   This illu stration is for r an LHD mo o del Engin ne Compartme ent View...

  • Page 10: Engine Compartment

    Hybrid Component Locations & Descriptions Component Location Description Luggage 12 Volt Auxiliary Supplies electricity to the electrical components. Battery  Compartment • Supplies electrical power to MG1 and MG2 in Hybrid Vehicle Cabin Area, (HV) Battery Mounted Under accordance with the driving conditions of the vehicle. Pack...

  • Page 11: Specifications

    Hybrid Component Locations & Descriptions (Continued) Specifications Gasoline Engine: 131 kW, 2.5-liter Aluminum Alloy Engine Electric Motor: 88 kW, Permanent Magnet Motor Transmission: Automatic Only HV Battery: 244.8 Volt Sealed NiMH Battery Curb Weight: 3,693 – 3,836 lbs / 1,675 - 1,740 kg Fuel Tank: 49.3 –...

  • Page 12: Lexus Hybrid Drive Operation

    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.

  • Page 13: Hybrid Vehicle (Hv) Battery Pack And Auxiliary Battery

    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 cabin area under the rear seat.

  • Page 14: Hv Battery Pack Recycling

    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.

  • Page 15: High Voltage Safety

    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 244.8 to 650 Volts DC.

  • Page 16: Service Plug Grip

    High Voltage Safety (Continued) Service Plug Grip  The high-voltage circuit is cut by removing the service plug grip (see page 15). Hybrid Vehicle Computer ➍ 12 Volts Auxiliary Volts DC Battery ➋ Compressor ➋ ❸ ❸ Electric Inverter/ Generator Converter Electric Volts DC...

  • Page 17: Precaution To Be Observed When Dismantling The Vehicle

    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 breaching any orange high voltage power cable or high voltage component.

  • Page 18: Spills

    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. 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 battery module is cracked.

  • Page 19: Dismantling A Vehicle

    The f following 4 p pages contain n general ins structions for r use when w working on an n ES300h. Read d these instru ctions before e proceeding g to the HV b battery remov val instructio...
  • Page 20 Remove batt tery service e hole cover Remove e the clip. Disenga age the 7 claw ws as shown in the illustrati ion. Disenga age the guide e to remove t the battery service h hole cover as s shown in th illustrati ion.
  • Page 21 • To reduce e the risk o of electric s shock, make sur re to wait a at least 10 m minutes after rem oving the s service plu ug grip to fully disc charge the high voltag capacitor r inside the e inverter w with converter...
  • Page 22 HV batte ery, remove e parts by fo ollowing pro ocedures wh hich are similar t to conventio onal Lexus vehicles. For the rem moval of the e HV battery refer to the following p pages.

  • Page 24: Removal Of Hv Battery

    Remo oval of H HV battery RNING: ・ Be e sure to w wear insula ated glove es when h handling h high-voltag rts. ・ Ev ven if the v vehicle is s shut off a nd the rel lays are of ff, be sure e to move the s...
  • Page 25 REMOVE B BATTERY SERVICE H HOLE COV Remove e the clip. Disenga age the 7 claw ws as shown n in the illustrat tion. Disenga age the guide e to remove t the battery service hole cover a as shown in th illustrat tion.
  • Page 26 • To reduce e the risk o of electric s shock, make sur re to wait a t least 10 m minutes after rem oving the s service plu ug grip to fully disc harge the h high voltag capacitor r inside the e inverter w with...
  • Page 27 Move th he lock lever r while pushi ing the lock on the c connector, an nd disconnec ct the inverter with con nverter assem mbly connec ctor. Notice: ・Do not dam mage the te rminals, con nnector housing or r inverter wit th converter r assembly...
  • Page 28 REMOVE R REAR SEAT T CUSHION N ASSEMB Lift the front edge o f the rear sea at cushion assembl ly as shown i in the illustra ation and disengag ge the 2 rear r seat cushion n frame hooks o n the front si ide of the rea ar seat...
  • Page 29 Pass the e rear seat inn ner belt assem mbly LH and rear r center seat lap type belt t assembly as shown i in the illustra ation. Pass the e rear seat inn ner belt assem mbly LH and rear r center seat lap type belt t assembly...
  • Page 30 w/ Seat Heater Syste Disc onnect the 2 connectors. w/ Occu upant Detecti ion Sensor: Disc onnect the 3 connectors. Remove e the rear sea at cushion ass sembly. REMOVE R REAR SEAT T CUSHION N LOCK H HOOK Disenga age the 2 claw ws to remove e the rear...
  • Page 31 REMOVE R REAR DOO OR SCUFF P PLATE LH 1) Disengag ge the claw a as shown in t illustratio Place Ha and Here 2) Disengag ge the 7 claw ws and 2 guid des to remove t the rear door r scuff plate L LH as shown in the illu...
  • Page 32 REMOVE R REAR UND DER SIDE C COVER RH Remove e the 2 clips ( (A). Disenga age the claw, 3 clips (B), 2 clips (C) and guid de to remove e the rear und der side cover RH REMOVE R REAR UND DER COVER Pull the...
  • Page 33 Remove e the 2 clips and No. 1 hy ybrid battery intake d duct from the e battery cool ling blower assembl REMOVE B BATTERY COOLING G BLOWER R ASSEMBL Disconn nect the batte ery cooling b blower assembl ly connector Remove e the bolt, nu ut and battery...
  • Page 34 Using th he service plu ug grip, remo ove the battery c cover lock st triker. Service Plu ug Grip Hint: Turn Button nsert the pro ojection of th he service p plug grip and Projection urn the butto on of the bat ttery cover lo ock striker attery Cover L...
  • Page 35 Disenga age the clamp Disconn nect the elect tric vehicle b battery plug assembl ly connector Disconn nect the HV b battery junct tion block assembl ly connector REMOVE N NO. 2 INDO OOR ELEC TRICAL K KEY ANTEN NNA ASSE EMBLY Disconn nect the conn...
  • Page 36 DISCONNE ECT FLOOR R WIRE Caution: Be sure to w wear insula ated gloves Disenga age the clamp Disconn nect the batte ery voltage se ensor connect REMOVE H HV BATTE Caution: Be sure to w wear insula ated gloves Remove e the 5 bolts and HV batt...

Table of Contents