Lexus ES: Installation

INSTALLATION

PROCEDURE

1. INSTALL NO. 1 HV BATTERY INTAKE DUCT LH

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2. INSTALL NO. 2 HYBRID BATTERY SHIELD SUB-ASSEMBLY

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3. INSTALL HV BATTERY JUNCTION BLOCK ASSEMBLY

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4. INSTALL HYBRID BATTERY TERMINAL BLOCK

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5. INSTALL BATTERY VOLTAGE SENSOR

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6. INSTALL NO. 1 HV BATTERY SHIELD PANEL

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7. INSTALL UPPER HV BATTERY COVER SUB-ASSEMBLY

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8. TEMPORARILY INSTALL NO. 4 HV BATTERY END PLATE SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Temporarily install the No. 4 HV battery end plate sub-assembly to the HV battery with the 2 bolts and 2 nuts.

(b) Fully tighten the 2 nuts.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

9. INSTALL NO. 5 HV BATTERY END PLATE SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Install the No. 5 HV battery end plate sub-assembly to the HV battery with the 12 nuts.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

10. INSTALL NO. 4 HV BATTERY SHIELD SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Install the No. 4 HV battery shield sub-assembly to the HV battery with the 4 nuts.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

11. INSTALL NO. 3 HV BATTERY SHIELD SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Install the No. 3 HV battery shield sub-assembly to the HV battery with the 4 nuts.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

12. INSTALL NO. 4 HV BATTERY END PLATE SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Fully tighten the 2 bolts.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

13. INSTALL HV BATTERY

CAUTION:

Be sure to wear insulated gloves.

(a) Install the HV battery to the vehicle body with the 3 bolts (A), bolt (B) and bolt (C). Torque: 19 N·m {194 kgf·cm, 14 ft·lbf} NOTICE: Do not allow foreign matter, such as grease or oil, to adhere to the bolts of the HV battery. To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent. Use cardboard or another similar material to protect the HV battery and vehicle body from damage. Since the HV battery is very heavy, 2 people are needed to install it. When installing the HV battery, be careful not to damage the parts around it. When removing/installing/moving the HV battery, make sure not to tilt it more than 80°. While lowering the HV battery into the vehicle, do not allow it to contact the vehicle. As bolts with 3 different lengths are used, make sure to install each bolt to the correct position. If the HV battery has been struck or dropped, replace it.

*a Bolt (A) (Bolt Length: 25 mm (0.984 in.)) *b Bolt (B) (Bolt Length: 24 mm (0.945 in.)) *c Bolt (C) (Bolt Length: 65 mm (2.559 in.))

14. CONNECT FLOOR WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Connect the battery voltage sensor connector.

(b) Engage the clamp.

15. INSTALL NO. 1 HYBRID BATTERY EXHAUST DUCT

CAUTION:

Be sure to wear insulated gloves.

(a) Engage the claw to install the No. 1 hybrid battery exhaust duct to the HV battery.

(b) Install the clip.

16. CONNECT FLOOR WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Engage the 2 clamps.

17. INSTALL NO. 2 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY

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18. CONNECT FLOOR WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Connect the HV battery junction block assembly connector.

(b) Connect the electric vehicle battery plug assembly connector.

(c) Engage the clamp.

19. CONNECT FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Connect the floor wire connector.

(b) Connect the shield ground to the HV battery.

*a Shield Ground

(c) Connect the 2 HV battery junction block assembly connectors.

NOTICE:

Make sure that the connectors are connected securely.

20. INSTALL NO. 1 HV BATTERY COVER PANEL RH

CAUTION:

Be sure to wear insulated gloves.

(a) Install the No. 1 HV battery cover panel RH to the HV battery with the 3 bolts and 3 nuts. Torque: 7.5 N·m {76 kgf·cm, 66 in·lbf}

*1 Battery Cover Lock Striker *a Button *b Push

(b) Install the battery cover lock striker, then push the button to lock it.

21. INSTALL BATTERY COOLING BLOWER ASSEMBLY

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22. INSTALL SERVICE PLUG GRIP

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23. PERFORM INITIALIZATION

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