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Hybrid Battery (Service Information): Removal & Installation Lexus GS III рестайлинг

Engine Control Systems 24 illustrations ~2012 words

INSTALLATION

  1. INSTALL BATTERY SMART UNIT Install the battery smart unit to the battery carrier with the nut. Torque: 8.0 N*m ( 82 kgf*cm, 71 in.*lbf) WARNING: Wear insulated gloves.
  2. INSTALL HV RELAY ASSEMBLY See step 2
  3. INSTALL NO. 6 BATTERY CARRIER PANEL See step 20
  4. INSTALL BATTERY CARRIER SUB-ASSEMBLY See step 21
  5. INSTALL BATTERY BRACKET SUB-ASSEMBLY See step 22
  6. CONNECT FRAME WIRE See step 23
  7. INSTALL NO. 3 HV BATTERY EXHAUST DUCT See step 24
  8. REMOVE TOOL BOX
  9. INSTALL LUGGAGE COMPARTMENT FRONT TRIM COVER . Refer to «INSTALLATION - Step 4»(ref-387104-S11194699402011022400000)
  10. INSTALL ROPE HOOK ASSEMBLY See step 30
  11. INSTALL TOOL BOX
  12. INSTALL LUGGAGE COMPARTMENT TRIM SIDE COVER RH
  13. INSTALL SERVICE PLUG GRIP See step 33
  14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
  15. INSTALL BATTERY SERVICE HOLE COVER LH See step 35
  16. INSTALL LUGGAGE COMPARTMENT FLOOR MAT
  17. 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 204

Scheme 204: ILLUSTRATION
Scheme 204: ILLUSTRATION

Scheme 205

Scheme 205: REMOVAL
Scheme 205: REMOVAL

Scheme 206

Scheme 206
Scheme 206

Scheme 207

Scheme 207
Scheme 207
  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 Disconnect the 7 connectors and clamp from the HV relay assembly. WARNING: Wear insulated gloves. NOTE: Insulate the removed terminals with insulating tape. Remove the 3 nuts and HV relay assembly from the battery carrier. WARNING: Wear insulated gloves.
  23. REMOVE HIGH VOLTAGE FUSE Remove the 2 bolts and high voltage fuse.

Scheme 208

Scheme 208: INSPECTION
Scheme 208: INSPECTION

Scheme 209

Scheme 209
Scheme 209
  1. HV RELAY ASSEMBLY SMRB inspection If any result is not as specified, replace the HV relay assembly. Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition w4-1 - z23-1 10 kohms or higher Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition w4-1 - z23-1 Below 1 ohms (When battery voltage applied between terminals N6-2 and N6-3) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition N6-3 - GND (N6-2) 18.8 to 32.1 ohms at -35 to 80°C (-31 to 176°F) SMRG inspection If any result is not as specified, replace the HV relay assembly. Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition w5-1 - z25-1 10 kohms or higher Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition w5-1 - z25-1 Below 1 ohms (When battery voltage applied between terminals N6-1 and N6-2) Measure the resistance according to the value(s) in the table below. Standard resistance Tester Connection Specified Condition N6-1 - GND (N6-2) 18.8 to 32.1 ohms at -35 to 80°C (-31 to 176°F)
  1. INSTALL HIGH VOLTAGE FUSE Install the high voltage fuse with the 2 bolts. Torque: 4.5 N*m ( 46 kgf*cm, 40 in.*lbf) NOTE: Be sure to use a torque wrench to tighten the bolts.
  2. INSTALL HV RELAY ASSEMBLY Install the HV relay assembly with the 3 nuts. Torque: 8.0 N*m ( 82 kgf*cm, 71 in.*lbf) WARNING: Wear insulated gloves. Connect the 7 connectors and clamp to the HV relay assembly. 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.
  3. INSTALL NO. 6 BATTERY CARRIER PANEL See step 20
  4. INSTALL BATTERY CARRIER SUB-ASSEMBLY See step 21
  5. INSTALL BATTERY BRACKET SUB-ASSEMBLY See step 22
  6. CONNECT FRAME WIRE See step 23
  7. INSTALL NO. 3 HV BATTERY EXHAUST DUCT See step 24
  8. REMOVE TOOL BOX
  9. INSTALL LUGGAGE COMPARTMENT FRONT TRIM COVER . Refer to «INSTALLATION - Step 4»(ref-387104-S11194699402011022400000)
  10. INSTALL ROPE HOOK ASSEMBLY See step 30
  11. INSTALL TOOL BOX
  12. INSTALL LUGGAGE COMPARTMENT TRIM SIDE COVER RH
  13. INSTALL SERVICE PLUG GRIP See step 33
  14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
  15. INSTALL BATTERY SERVICE HOLE COVER LH See step 35
  16. INSTALL LUGGAGE COMPARTMENT FLOOR MAT
  17. 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 210

Scheme 210: ILLUSTRATION
Scheme 210: ILLUSTRATION

Scheme 211

Scheme 211: REMOVAL
Scheme 211: REMOVAL

Scheme 212

Scheme 212
Scheme 212
  1. PRECAUTION Refer to «PRECAUTION»(ref-386951-S09233005632011022400000)
  2. REMOVE BATTERY SERVICE HOLE COVER LH See step 4
  3. 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.
  4. REMOVE SERVICE PLUG GRIP See step 6
  5. REMOVE ELECTRIC VEHICLE FUSE Release the 2 claws and remove the service plug grip cover. Remove the 2 bolts and electric vehicle fuse.

Scheme 213

Scheme 213: INSPECTION
Scheme 213: INSPECTION
  1. ELECTRIC VEHICLE FUSE Measure the resistance of the high voltage fuse. Standard resistance Below 1 ohms If the value is not as specified, replace the electric vehicle fuse.
  1. INSTALL ELECTRIC VEHICLE FUSE Install the electric vehicle fuse with the 2 bolts. Torque: 5.4 N*m ( 55 kgf*cm, 48 in.*lbf) Install the service plug grip cover with the 2 claws.
  2. INSTALL SERVICE PLUG GRIP See step 33
  3. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
  4. INSTALL BATTERY SERVICE HOLE COVER LH See step 35
  5. 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 214

Scheme 214: INSPECTION
Scheme 214: INSPECTION
  1. INSPECT BATTERY BLOWER RELAY Measure the resistance between the terminals of the relay. Standard resistance Tester Connection Specified Condition 3 - 5 10 kohms or higher 3 - 5 Below 1 ohms (Apply battery voltage to terminals 1 and 2) If the value is not as specified, replace the battery blower relay.

Scheme 215

Scheme 215: ILLUSTRATION
Scheme 215: ILLUSTRATION

Scheme 216

Scheme 216: REMOVAL
Scheme 216: REMOVAL

Scheme 217

Scheme 217
Scheme 217

Scheme 218

Scheme 218
Scheme 218

Scheme 219

Scheme 219
Scheme 219

Scheme 220

Scheme 220
Scheme 220

Scheme 221

Scheme 221
Scheme 221
  1. REMOVE LUGGAGE COMPARTMENT FLOOR MAT
  2. REMOVE BATTERY SERVICE HOLE COVER LH See step 4
  3. REMOVE LUGGAGE COMPARTMENT TRIM SIDE COVER RH
  4. REMOVE TOOL BOX
  5. REMOVE ROPE HOOK ASSEMBLY See step 14
  6. REMOVE LUGGAGE COMPARTMENT FRONT TRIM COVER . Refer to «REMOVAL - Step 19»(ref-387104-S08102091462011022400000)
  7. REMOVE NO. 2 HV BATTERY INTAKE DUCT Remove the 2 clips and No. 2 HV battery intake duct. WARNING: Wear insulated gloves.
  8. REMOVE NO. 6 HV BATTERY INTAKE DUCT Remove the clip and No. 6 HV battery intake duct. WARNING: Wear insulated gloves.
  9. REMOVE BATTERY COOLING BLOWER ASSEMBLY Remove the 2 nuts and battery cooling blower connector. WARNING: Wear insulated gloves. Separate the No. 3 HV battery intake duct and No. 4 HV battery intake duct. WARNING: Wear insulated gloves. Remove the battery cooling blower assembly together with the No. 3 HV battery intake duct from the HV battery. WARNING: Wear insulated gloves. NOTE: Do not touch the fan of the battery cooling blower assembly. Do not hold the wire harness when lifting the battery cooling blower assembly. Remove the No. 3 HV battery intake duct from the battery cooling blower assembly.

Scheme 222

Scheme 222: INSTALLATION
Scheme 222: INSTALLATION

Scheme 223

Scheme 223
Scheme 223

Scheme 224

Scheme 224
Scheme 224
  1. INSTALL BATTERY COOLING BLOWER ASSEMBLY Install the No. 3 HV battery intake duct to the battery cooling blower assembly. NOTE: Be sure to engage the claws securely. Install the battery cooling blower assembly together with the No. 3 HV battery intake duct to the HV battery. WARNING: Wear insulated gloves. NOTE: Do not touch the fan of the battery cooling blower assembly. Do not hold the wire harness when lifting the battery cooling blower assembly. When installing the battery cooling blower assembly, slide the protrusion on the battery cooling blower assembly along the portion indicated by the arrow on the HV battery. Be sure to engage the cutout on the battery cooling blower assembly to the bushing securely. Connect the No. 3 HV battery intake duct to the No. 4 HV battery intake duct. WARNING: Wear insulated gloves. NOTE: Be sure to engage the duct claws securely. Install the 2 nuts and connector. WARNING: Wear insulated gloves. Torque: 8.0 N*m ( 82 kgf*cm, 71 in.*lbf)
  2. INSTALL NO. 6 HV BATTERY INTAKE DUCT Install the No. 6 HV battery intake duct with the clip. WARNING: Wear insulated gloves.
  3. INSTALL NO. 2 HV BATTERY INTAKE DUCT Install the No. 2 HV battery intake duct with the 2 clips. WARNING: Wear insulated gloves.
  4. INSTALL LUGGAGE COMPARTMENT FRONT TRIM COVER . Refer to «INSTALLATION - Step 4»(ref-387104-S11194699402011022400000)
  5. INSTALL ROPE HOOK ASSEMBLY See step 30
  6. INSTALL TOOL BOX
  7. INSTALL LUGGAGE COMPARTMENT INNER TRIM COVER RH
  8. INSTALL BATTERY SERVICE HOLE COVER LH See step 35
  9. INSTALL LUGGAGE COMPARTMENT FLOOR MAT

Scheme 225

Scheme 225: ILLUSTRATION
Scheme 225: ILLUSTRATION

Scheme 226

Scheme 226: REMOVAL
Scheme 226: REMOVAL

Scheme 227

Scheme 227
Scheme 227
  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 «REMOVAL - Step 20»(ref-387078-S30394130242011022400000)
  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 HYBRID VEHICLE CONVERTER Disconnect the 3 connectors and 3 clamps. WARNING: Wear insulated gloves. NOTE: Insulate the removed terminals with insulating tape. Remove the 4 bolts and hold up the hybrid vehicle converter. WARNING: Wear insulated gloves. Remove the connector and hybrid vehicle converter from the battery carrier. WARNING: Wear insulated gloves.
  1. INSTALL HYBRID VEHICLE CONVERTER Connect the connector to the hybrid vehicle converter. WARNING: Wear insulated gloves. Install the hybrid vehicle converter to the battery carrier with the 4 bolts. Torque: 8.0 N*m ( 82 kgf*cm, 71 in.*lbf) WARNING: Wear insulated gloves. Connect the 3 connectors and 3 clamps. WARNING: Wear insulated gloves.
  2. INSTALL NO. 6 BATTERY CARRIER PANEL See step 20
  3. INSTALL BATTERY CARRIER SUB-ASSEMBLY See step 21
  4. INSTALL BATTERY BRACKET SUB-ASSEMBLY See step 22
  5. CONNECT FRAME WIRE See step 23
  6. INSTALL NO. 3 HV BATTERY EXHAUST DUCT See step 24
  7. REMOVE TOOL BOX
  8. INSTALL LUGGAGE COMPARTMENT FRONT TRIM COVER . Refer to «INSTALLATION - Step 4»(ref-387104-S11194699402011022400000)
  9. INSTALL ROPE HOOK ASSEMBLY See step 30
  10. INSTALL TOOL BOX
  11. INSTALL LUGGAGE COMPARTMENT TRIM SIDE COVER RH
  12. INSTALL SERVICE PLUG GRIP See step 33
  13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
  14. INSTALL BATTERY SERVICE HOLE COVER LH See step 35
  15. INSTALL LUGGAGE COMPARTMENT FLOOR MAT
  16. 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.

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