Hybrid Battery (Service Information): Overview Lexus GS III рестайлинг

Scheme 147

Scheme 148

Scheme 149

Scheme 150

Scheme 151

Scheme 152

Scheme 153

Scheme 154

Scheme 155

Scheme 156

Scheme 157

Scheme 158

Scheme 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

Scheme 166

Scheme 167

Scheme 168

Scheme 169

Scheme 170

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Scheme 175

Scheme 176

Scheme 177

Scheme 178

Scheme 179

Scheme 180

Scheme 181

Scheme 182

Scheme 183

Scheme 184

Scheme 185

Scheme 186

1. PRECAUTION Refer to «PRECAUTION»(ref-386951-S09233005632011022400000)
2. CHECK DTC OUTPUT Check for DTCs . Refer to «DTC CHECK / CLEAR»(ref-387110-S19578152292011022400000) . NOTE: Confirm that P0AA6 (high voltage insulation is unusual) is not output before doing removal or installation work inside the battery. If the DTC is output, perform the troubleshooting procedure for the DTC first.
3. REMOVE LUGGAGE COMPARTMENT FLOOR MAT
4. REMOVE BATTERY SERVICE HOLE COVER LH Remove the 2 clips and battery service hole cover.
5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
6. REMOVE SERVICE PLUG GRIP WARNING: Remove the service plug grip to interrupt a high voltage circuit at the time of the check. Keep the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle. All the high voltage wiring connectors are colored in orange. Remove the battery service hole cover. Wear insulated gloves. Remove the service plug grip after sliding the lever of the service plug grip. WARNING: Keep the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle. After removing the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals. NOTE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU.
7. REMOVE NO. 2 ENGINE ROOM SIDE RH COVER . Refer to «REMOVAL - Step 9»(ref-387078-S30394130242011022400000)
8. REMOVE CONNECTOR COVER ASSEMBLY . Refer to «REMOVAL - Step 20»(ref-387078-S30394130242011022400000)
9. CHECK TERMINAL VOLTAGE . Refer to «REMOVAL - Step 21»(ref-387078-S30394130242011022400000)
10. INSTALL CONNECTOR COVER ASSEMBLY . Refer to «INSTALLATION - Step 8»(ref-387078-S21717171232011022400000)
11. INSTALL NO. 2 ENGINE ROOM SIDE RH COVER . Refer to «INSTALLATION - Step 24»(ref-387078-S21717171232011022400000)
12. REMOVE LUGGAGE COMPARTMENT TRIM SIDE COVER RH
13. REMOVE TOOL BOX
14. REMOVE ROPE HOOK ASSEMBLY Remove the 2 bolts and 2 rope hook assemblies.
15. REMOVE LUGGAGE COMPARTMENT FRONT TRIM COVER . Refer to «REMOVAL - Step 19»(ref-387104-S08102091462011022400000)
16. INSTALL TOOL BOX
17. REMOVE NO. 2 HV BATTERY INTAKE DUCT See step 7
18. REMOVE NO. 6 HV BATTERY INTAKE DUCT
19. REMOVE BATTERY COOLING BLOWER ASSEMBLY See step 9
20. REMOVE NO. 3 HV BATTERY EXHAUST DUCT Remove the 2 clips and No. 3 HV battery exhaust duct. WARNING: Wear insulated gloves.
21. DISCONNECT FRAME WIRE Remove the nut and 2 clamps, and disconnect the frame wire (battery positive cable). Remove the nut and clamp, and disconnect the frame wire (AMD cable). WARNING: Wear insulated gloves. Using the service plug grip, release the interlock button. WARNING: Wear insulated gloves. Remove the 3 nuts and battery cover. WARNING: Wear insulated gloves. Remove the 2 nuts and clamp, and disconnect the frame wire (high voltage cable). WARNING: Wear insulated gloves. NOTE: Insulate the removed terminals with insulating tape. Remove the battery shield contact. WARNING: Wear insulated gloves.
22. REMOVE BATTERY BRACKET SUB-ASSEMBLY Remove the 3 bolts and battery bracket sub-assembly. WARNING: Wear insulated gloves.
23. REMOVE BATTERY CARRIER SUB-ASSEMBLY Disconnect the 3 connectors and 2 clamps. WARNING: Wear insulated gloves. NOTE: Insulate the removed terminals with insulating tape. Remove the 2 bolts and 2 nuts, and pull out the battery carrier. WARNING: Wear insulated gloves. NOTE: Place cardboard or a similar object as cushioning over the toolbox to prevent damage and pull out the battery carrier. Do not forcibly pull out the battery carrier because it is connected to high voltage wire harnesses.
24. REMOVE NO. 6 BATTERY CARRIER PANEL Remove the 7 bolts and No. 6 battery carrier panel from the battery carrier sub-assembly. WARNING: Wear insulated gloves. NOTE: Do not drop the bolts in the cooling air inlet.
25. SEPARATE BATTERY CARRIER SUB-ASSEMBLY Remove the 4 connectors and 4 clamps, and disconnect the 2 frame wires (high voltage cable). WARNING: Wear insulated gloves. NOTE: Insulate the removed terminals with insulating tape. Remove the 4 bolts and disconnect the hybrid vehicle converter. WARNING: Wear insulated gloves. While holding up the hybrid vehicle converter, disconnect the 3 connectors and clamp. Disconnect the battery pack wire. WARNING: Wear insulated gloves.
26. REMOVE BATTERY Disconnect the thermometer sensor connector and battery ventilation hose from the battery. Disconnect the connector, 2 clamps and fuse holder from the battery. Remove the nut, bolt, and battery clamp. Remove the battery.
27. REMOVE BATTERY CARRIER Disconnect the clamp from the battery carrier. Remove the 3 bolts and battery carrier.
28. REMOVE NO. 2 HV BATTERY EXHAUST DUCT Remove the 2 clips and No. 2 HV battery exhaust duct.
29. REMOVE NO. 1 HV BATTERY EXHAUST DUCT Remove the clip, connector clamp and No. 1 HV battery exhaust duct. WARNING: Wear insulated gloves.
30. DISCONNECT BATTERY ROOM VENTILATION HOSE Remove the clamp grommet and battery room ventilation hose. NOTE: Secure the removed ventilation hose to the HV battery with tape.
31. REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to «REMOVAL - Step 1»(ref-386977-S11477294662011022400000)
32. REMOVE REAR SEAT HEADREST ASSEMBLY LH AND RH
33. REMOVE REAR SEAT HEADREST ASSEMBLY CENTER
34. REMOVE REAR SEATBACK ASSEMBLY . Refer to «REMOVAL - Step 4»(ref-386977-S11477294662011022400000)
35. REMOVE NO. 1 ROOM PARTITION PAD Turn back the No. 1 room partition pad.
36. REMOVE UPPER BACK PANEL CORNER PLATE RH Release the 6 claws and remove the upper back panel corner plate RH.
37. REMOVE UPPER ROOF SIDE INNER COVER Remove the 2 upper roof side inner covers.
38. INSTALL LUGGAGE COMPARTMENT FLOOR MAT Reverse the luggage compartment floor mat to install it to the vehicle.
39. REMOVE BATTERY CARRIER BRACKET Remove the 3 bolts from the HV battery. WARNING: Wear insulated gloves. Remove the 6 bolts. WARNING: Wear insulated gloves. Remove the 4 nuts. WARNING: Wear insulated gloves. Use an extension bar (1000 mm) to hold up the HV battery and remove the battery carrier brackets. WARNING: Wear insulated gloves. NOTE: Before holding up the HV battery, check that the extension bar goes through to the front side of the battery from the cabin side.
40. REMOVE HV BATTERY NOTE: Make sure that the HV battery is not tilted over 80° during transport, removal, and installation. Disconnect the battery pack wire. Prepare a piece of cardboard of 780 mm (30.71 in.) X 700 mm (27.56 in.) or larger. Using an extension bar (1000 mm) to hold up the HV battery, insert the cardboard until it cannot be inserted any further. WARNING: Wear insulated gloves. NOTE: Bind the frame wire with electrical tape to prevent it from getting caught with the parts. Before holding up the HV battery, check that the extension bar goes through to the front side of the battery from the cabin side. Pull the HV battery together with the cardboard toward the rear of the vehicle. WARNING: Wear insulated gloves. Using an engine sling device, remove the HV battery while tilting the HV battery 45° at the rear end. WARNING: Wear insulated gloves. NOTE: Place a piece of cardboard or other similar object to protect the HV battery and vehicle body from damage.
41. REMOVE NO. 4 HV BATTERY INTAKE DUCT Release the 2 claws and remove the No. 4 HV battery intake duct. WARNING: Wear insulated gloves.
42. REMOVE BATTERY PACK WIRE Remove the 11 clamps, 2 connectors, and battery pack wire. WARNING: Wear insulated gloves.
43. REMOVE BUSHING Remove the nut and bushing. WARNING: Wear insulated gloves.

Scheme 187

Scheme 188

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

Scheme 195

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

1. INSTALL BUSHING Install the bushing with the nut. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) WARNING: Wear insulated gloves.
2. INSTALL BATTERY PACK WIRE Connect the battery pack wire with the 11 clamps and then connect the 2 connectors. WARNING: Wear insulated gloves.
3. INSTALL NO. 4 HV BATTERY INTAKE DUCT Install the No. 4 HV battery intake duct with the 2 claws. WARNING: Wear insulated gloves.
4. INSTALL HV BATTERY Place a piece of cardboard in the luggage compartment. Using an engine sling device, install the HV battery while tilting the HV battery 45° at the rear end. WARNING: Wear insulated gloves. NOTE: Place a piece of cardboard or other similar object to protect the HV battery and vehicle body from damage. Push the HV battery together with the cardboard toward the front of the vehicle. WARNING: Wear insulated gloves. NOTE: Align the position of the holes for HV battery holding bolts. Use an extension bar (1000 mm) to hold up the HV battery and pull out the cardboard. WARNING: Wear insulated gloves. NOTE: Before holding up the HV battery, check that the extension bar goes through to the front side of the battery from the cabin side. Connect the battery pack wire.
5. INSTALL BATTERY CARRIER BRACKET Use an extension bar (1000 mm) to hold up the HV battery and set to the battery carrier brackets. WARNING: Wear insulated gloves. NOTE: Before holding up the HV battery, check that the extension bar goes through to the front side of the battery from the cabin side. While holding the HV battery, temporarily install the battery carrier bracket with the 6 bolts and 4 nuts. WARNING: Wear insulated gloves. Lower the HV battery and pull out the extension bar, and tighten the 6 bolts and 4 nuts. Bolt Torque: 8.0 N*m ( 82 kgf*cm, 71 in.*lbf) Nut Torque: 20 N*m ( 204 kgf*cm, 15 ft.*lbf) WARNING: Wear insulated gloves. Install the 3 bolts to the HV battery. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) WARNING: Wear insulated gloves.
6. REMOVE LUGGAGE COMPARTMENT FLOOR MAT
7. INSTALL UPPER ROOF SIDE INNER COVER Install the 2 upper roof side inner covers.
8. INSTALL UPPER BACK PANEL CORNER PLATE RH Install the upper back panel corner plate RH with the 6 claws.
9. INSTALL NO. 1 ROOM PARTITION PAD Fold down the No. 1 room partition pad.
10. INSTALL REAR SEATBACK ASSEMBLY . Refer to «INSTALLATION - Step 1»(ref-386977-S42246080722011022400000)
11. INSTALL REAR SEAT HEADREST ASSEMBLY CENTER
12. INSTALL REAR SEAT HEADREST ASSEMBLY LH AND RH
13. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to «INSTALLATION - Step 4»(ref-386977-S42246080722011022400000)
14. CONNECT BATTERY ROOM VENTILATION HOSE Connect the battery room ventilation hose with the clamp and grommet. NOTE: After installing the grommet, make sure that there is no clearance between the grommet and body. Visually check that the grommet is securely installed from the bottom of the body.
15. INSTALL NO. 1 HV BATTERY EXHAUST DUCT Set the No. 1 HV battery exhaust duct to the beaded portion on the HV battery. Slide the No. 1 HV battery exhaust duct to install it to the HV battery. WARNING: Wear insulated gloves. Install the clip and connector clamp to the No. 1 HV battery exhaust duct. WARNING: Wear insulated gloves.
16. INSTALL NO. 2 HV BATTERY EXHAUST DUCT Install the No. 2 HV battery exhaust duct with the 2 clips. NOTE: Be sure to engage the claws on the duct securely.
17. INSTALL BATTERY CARRIER Install the battery carrier with the 3 bolts. Torque: 4.9 N*m ( 50 kgf*cm, 43 in.*lbf) Connect the clamp to the battery carrier.
18. INSTALL BATTERY Install the battery. Install the battery clamp with the nut and bolt. bolt Torque: 4.9 N*m ( 50 kgf*cm, 43 in.*lbf) nut Torque: 2.9 N*m ( 30 kgf*cm, 26 in.*lbf) Connect the fuse holder to the battery clamp with the connector and 2 clamps. Connect the battery thermometer sensor connector and battery ventilation hose to the battery.
19. CONNECT BATTERY CARRIER SUB-ASSEMBLY Place the hybrid vehicle converter on the tool box in the luggage compartment. NOTE: Protect the tool box in the luggage compartment with a piece of cardboard or other similar object before connecting the battery carrier. While holding up the hybrid vehicle converter, disconnect the 3 connectors and clamp. Connect the battery pack wire. WARNING: Wear insulated gloves. NOTE: Do not allow the wire harnesses to get pinched when holding up the hybrid vehicle converter. Install the hybrid vehicle converter with the 4 bolts. Torque: 8.0 N*m ( 82 kgf*cm, 71 in.*lbf) WARNING: Wear insulated gloves. Connect the 2 frame wires (high voltage cable) with the 4 connectors and 4 clamps. WARNING: Wear insulated gloves. NOTE: Connect the wire wrapped with red tape to the terminal indicated by the "+" mark of the HV relay and the wire not wrapped with red tape to the terminal indicated by the "-" mark of the HV battery. Make sure that the connectors are engaged securely.
20. INSTALL NO. 6 BATTERY CARRIER PANEL Install the No. 6 battery carrier panel with the 7 bolts. Torque: 8.0 N*m ( 82 kgf*cm, 71 in.*lbf) WARNING: Wear insulated gloves. NOTE: Do not drop the bolts in the cooling air inlet.
21. INSTALL BATTERY CARRIER SUB-ASSEMBLY Insert the battery carrier. NOTE: Place cardboard or a similar object as cushioning over the toolbox to prevent damage and insert the battery carrier. Install the battery carrier sub-assembly with the 2 bolts and 2 nuts. Torque: 8.0 N*m ( 82 kgf*cm, 71 in.*lbf) WARNING: Wear insulated gloves. Connect the 3 connectors and 2 clamps. WARNING: Wear insulated gloves.
22. INSTALL BATTERY BRACKET SUB-ASSEMBLY Pass the stud bolts on the battery carrier through holes A in the battery bracket. Install the battery bracket with the 3 bolts. Torque: 8.0 N*m ( 82 kgf*cm, 71 in.*lbf) WARNING: Wear insulated gloves. NOTE: Be sure to push the bracket onto the carrier when tightening the 3 bolts.
23. CONNECT FRAME WIRE Install the battery shield contact. WARNING: Wear insulated gloves. NOTE: Be sure to install the battery shield contact in the correct direction. Connect the 2 frame wires (high voltage cable) with the 2 nuts and clamp. Torque: 9.0 N*m ( 92 kgf*cm, 80 in.*lbf) WARNING: Wear insulated gloves. NOTE: Be sure to match the red marks on the frame wires to the red marks on the HV relay assembly and install the frame wires. Install the battery cover and press the interlock button. Secure the battery cover with the 3 nuts. Torque: 8.0 N*m ( 82 kgf*cm, 71 in.*lbf) WARNING: Wear insulated gloves. Connect the frame wire (AMD cable) with the nut and clamp. Torque: 9.0 N*m ( 92 kgf*cm, 80 in.*lbf) WARNING: Wear insulated gloves. Connect the frame wire (battery positive cable) with the nut and 2 clamps. Torque: 5.4 N*m ( 55 kgf*cm, 48 in.*lbf)
24. INSTALL NO. 3 HV BATTERY EXHAUST DUCT Install the No. 3 HV battery exhaust duct with the 2 clips. WARNING: Wear insulated gloves. NOTE: Be sure to engage the claws on the duct securely. Make sure that the high-voltage terminals and connectors are securely connected.
25. INSTALL BATTERY COOLING BLOWER ASSEMBLY See step 1
26. INSTALL NO. 6 HV BATTERY INTAKE DUCT
27. INSTALL NO. 2 HV BATTERY INTAKE DUCT See step 3
28. REMOVE TOOL BOX
29. INSTALL LUGGAGE COMPARTMENT FRONT TRIM COVER . Refer to «INSTALLATION - Step 4»(ref-387104-S11194699402011022400000)
30. INSTALL ROPE HOOK ASSEMBLY Install the 2 rope hook assemblies with the 2 bolts.
31. INSTALL TOOL BOX
32. INSTALL LUGGAGE COMPARTMENT TRIM SIDE COVER RH
33. INSTALL SERVICE PLUG GRIP WARNING: Wear insulated gloves. NOTE: Before connecting the service plug grip, make sure that no parts or tools remain in the luggage compartment. Wear insulated gloves and insert the service plug grip in the order shown in the illustration. Tilt the service plug grip 90° and slide it to the left until a "click" sound is heard. Install the battery service hole cover. NOTE: Make sure that the battery service hole cover is installed securely.
34. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
35. INSTALL BATTERY SERVICE HOLE COVER LH Install the battery service hole cover LH with the 2 clips.
36. INSTALL LUGGAGE COMPARTMENT FLOOR MAT
37. PERFORM INITIALIZATION Perform initialization procedure . Refer to «INITIALIZATION»(ref-386951-S21829001392011022400000) . NOTE: Some vehicle systems require initialization after reconnecting the cable to the negative battery terminal.

Scheme 202

Scheme 203

1. PRECAUTION Refer to «PRECAUTION»(ref-386951-S09233005632011022400000)
2. CHECK DTC OUTPUT See step 2
3. REMOVE LUGGAGE COMPARTMENT FLOOR MAT
4. REMOVE BATTERY SERVICE HOLE COVER LH See step 4
5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
6. REMOVE SERVICE PLUG GRIP See step 6
7. REMOVE NO. 2 ENGINE ROOM SIDE RH COVER . Refer to «REMOVAL - Step 9»(ref-387078-S30394130242011022400000)
8. REMOVE CONNECTOR COVER ASSEMBLY . Refer to «REMOVAL - Step 20»(ref-387078-S30394130242011022400000)
9. CHECK TERMINAL VOLTAGE . Refer to «REMOVAL - Step 21»(ref-387078-S30394130242011022400000)
10. INSTALL CONNECTOR COVER ASSEMBLY . Refer to «INSTALLATION - Step 8»(ref-387078-S21717171232011022400000)
11. INSTALL NO. 2 ENGINE ROOM SIDE RH COVER . Refer to «INSTALLATION - Step 24»(ref-387078-S21717171232011022400000)
12. REMOVE LUGGAGE COMPARTMENT TRIM SIDE COVER RH
13. REMOVE TOOL BOX
14. REMOVE ROPE HOOK ASSEMBLY See step 14
15. REMOVE LUGGAGE COMPARTMENT FRONT TRIM COVER . Refer to «REMOVAL - Step 19»(ref-387104-S08102091462011022400000)
16. INSTALL TOOL BOX
17. REMOVE NO. 3 HV BATTERY EXHAUST DUCT See step 20
18. DISCONNECT FRAME WIRE See step 21
19. REMOVE BATTERY BRACKET SUB-ASSEMBLY See step 22
20. REMOVE BATTERY CARRIER SUB-ASSEMBLY See step 23
21. REMOVE NO. 6 BATTERY CARRIER PANEL See step 24
22. REMOVE HV RELAY ASSEMBLY See step 22
23. REMOVE BATTERY SMART UNIT Remove the nut and battery smart unit from the battery carrier. WARNING: Wear insulated gloves.