Lexus ES300h Dismantling Manual
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Lexus ES300h Dismantling Manual

Lexus gasoline-electric hybrid synergy drive
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ES300h
Gasoline-Electric
Hybrid Synergy Drive
AVV60 Series

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Summary of Contents for Lexus ES300h

  • Page 1 ES300h Gasoline-Electric Hybrid Synergy Drive AVV60 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 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...

  • Page 5: About The Es300H Hybrid

    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 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.

  • Page 7: Exterior

    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 Others U.S.A.

  • 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 or ES250. A switchable gauge in the instrument cluster showing either a hybrid system indicator or a tachometer depending on driving mode.

  • Page 9: Engine Compartment

    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...

  • Page 10: Hybrid Component Locations & Descriptions

    Hybrid Component Locations & Descriptions Component Location Description 12 Volt Right Side of A lead-acid battery that supplies power to the low Auxiliary Battery Trunk voltage devices. Hybrid Vehicle Trunk Area, 244.8 Volt Nickel Metal Hydride (NiMH) battery pack (HV) Battery Mounted behind consisting of 34 low voltage (7.2 Volt) modules Pack...

  • Page 11: Specifications

    Hybrid Component Locations & Descriptions (Continued) Specifications Gasoline Engine: 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) Electric Motor: 141 hp (105 kW), AC Motor Transmission: Automatic Only HV Battery: 244.8 Volt Sealed NiMH Battery Curb Weight: 3,660 to 3,781 lbs/1,660 to 1,715 kg Fuel Tank: 17 gals/64.35 liters (U.S.A.

  • 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 trunk area behind 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, routed along the propeller shaft and transmission tunnel to the inverter/converter.

  • 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). 12 Volt Volt DC Hybrid Vehicle Computer Auxiliary Battery Compressor Electric Inverter/ Generator Converter Electric Volt DC Motor 3-Phas HV Battery Assembly...

  • 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 opening 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 metal battery module is cracked.

  • Page 19: Dismantling The Vehicle

    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.
  • Page 20 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.
  • Page 21 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.

  • Page 23: Removal Of Hv Battery

    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. ・...
  • Page 24 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 Remove the 2 nuts and No. 8 hybrid vehicle battery shield panel. 7.
  • Page 25 9. CHECK TERMINAL VOLTAGE 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.
  • Page 26 Disengage the 4 clips and remove the rear floor finish plate. 12. REMOVE LUGGAGE HOLD BELT STRIKER ASSEMBLY (for LH Side) Remove the bolt. Disengage the guide and remove the luggage hold belt striker assembly. 13. REMOVE ROPE HOOK (for LH Side) Disengage the 2 claws and remove the rope hook as shown in the illustration.
  • Page 27 15. REMOVE LUGGAGE HOLD BELT STRIKER ASSEMBLY (for RH Side) Remove the bolt. Disengage the guide and remove the luggage hold belt striker assembly. 16. REMOVE ROPE HOOK (for RH Side) Disengage the 2 claws and remove the rope hook as shown in the illustration. 17.
  • Page 28 20. REMOVE REAR SEAT CUSHION Rear Seatback Hinge Hook ASSEMBLY 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> Disengage the 2 hooks <B> on the rear <A>...
  • Page 29 Using a screwdriver with its tip wrapped with protective tape, disengage the claw and disconnect the rear center seat shoulder belt guide. Disconnect the 2 rear seat airbag assembly connectors. Disengage the 2 clamps and disconnect the 2 rear seat airbag assembly wire harnesses.
  • Page 30 25. REMOVE NO. 1 HYBRID BATTERY INTAKE DUCT 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. Remove the 3 clips and No. 1 hybrid battery intake duct.
  • Page 31 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.
  • Page 32 Place a piece of cardboard in the luggage compartment. 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. Using a tire lever to hold up the HV battery, insert the cardboard until it cannot Hold Up Insert...
  • Page 33 (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.

  • Page 34: Hv Battery Caution Label

    HV Battery Caution Label 1. For U.S.A. 2. For Canada...
  • Page 35 3. For Russia 4. For General...

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