Lexus ES manuals

Lexus ES: Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during HV battery removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedure

Effect/Inoperative Function when Necessary Procedure not Performed

Link

*: When performing learning using the Techstream.

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Auxiliary battery terminal is disconnected/reconnected

Perform steering sensor zero point calibration

Lane Control System

Pre-collision System

Parking Support Brake System*

Lighting System

Memorize steering angle neutral point

Parking assist monitor system

Panoramic view monitor system

Initialize power trunk lid system

Power Trunk Lid System

Replacement of HV battery

Battery status info update

HV battery status information cannot be updated

Replacement of hybrid battery terminal block

Perform high voltage fuse accumulated load history reset

DTCs are stored

CAUTION:

  • Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.

    Click here

  • To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.

NOTICE:

  • When the cable is disconnected from the negative (-) auxiliary battery terminal, some systems need to be initialized after the cable is reconnected.

    Click here

  • If the HV battery has been struck or dropped, replace it.
  • When connecting a connector to the HV battery, confirm that the connector is securely connected through the following:

    - Push the connector until a click sound is heard.

    - Visually check and confirm that the connector is securely connected by pulling on it.

  • Make sure to insulate the high-voltage connectors and terminals of the HV battery with insulating tape after removing it.

    If the HV battery is stored without insulating the connectors and terminals, electric shock or fire may result.

  • When performing repairs around the HV battery, such as using a tap, do not allow metal shavings to enter the HV battery.
  • Do not touch any high voltage wire harnesses, connectors or parts with bare hands.
  • Hold the areas shown in the illustration and lift the HV battery.
  • Do not allow foreign matter, such as grease or oil, to adhere to the bolts or nuts of the HV battery.
  • Do not put your hands into the openings of the HV battery.

    *a

    Opening

  • When removing/installing/moving the HV battery, make sure not to tilt it more than 80°.
  • Do not climb on top of or stand on the HV battery.
  • Do not allow any foreign matter or water to enter the HV battery.
  • If any bolts, nuts or clips are dropped into the HV battery, make sure to remove them.
  • After the power switch is turned off, the radio receiver assembly records various types of memory and settings. As a result, after turning the power switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal. (for Audio and Visual System)
  • After the power switch is turned off, the radio receiver assembly records various types of memory and settings. As a result, after turning the power switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal. (for Navigation System)

HINT:

When disposing of an HV battery, make sure to return it through an authorized collection agent who is capable of handling it safely. If the HV battery is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.

PROCEDURE

1. PRECAUTION

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2. REMOVE SERVICE PLUG GRIP

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3. DISCONNECT ENGINE ROOM MAIN WIRE

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4. REMOVE CONNECTOR COVER ASSEMBLY

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5. CHECK TERMINAL VOLTAGE

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6. INSTALL CONNECTOR COVER ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Using a T25 "TORX" socket wrench, install the connector cover assembly to the inverter with converter assembly with the bolt (A).

Torque:

4.5 N·m {46 kgf·cm, 40 in·lbf}

NOTICE:

Do not touch the waterproof seal of the connector cover assembly.

*a

Bolt (A)

*b

Bolt (B)

(b) Install the bolt (B).

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

7. CONNECT ENGINE ROOM MAIN WIRE

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8. REMOVE BATTERY COOLING BLOWER ASSEMBLY

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9. REMOVE NO. 1 HV BATTERY COVER PANEL RH

CAUTION:

Be sure to wear insulated gloves.

(a) Using the service plug grip, remove the battery cover lock striker.

HINT:

Insert the projection of the service plug grip and turn the button of the battery cover lock striker counterclockwise to release the lock.

*1

Service Plug Grip

*2

Battery Cover Lock Striker

*a

Projection

*b

Turn

*c

Button

(b) Remove the 3 bolts, 3 nuts and No. 1 HV battery cover panel RH from the HV battery.

10. DISCONNECT HV FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Disconnect the 2 HV battery junction block assembly connectors.

NOTICE:

Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

*a

Shield Ground

(b) Disconnect the shield ground from the HV battery.

(c) Disconnect the floor wire connector.

11. DISCONNECT FLOOR WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Disengage the clamp.

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

(c) Disconnect the HV battery junction block assembly connector.

12. REMOVE NO. 2 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY

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13. DISCONNECT FLOOR WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Disengage the 2 clamps to disconnect the floor wire.

14. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the clip.

(b) Disengage the claw to remove the No. 1 hybrid battery exhaust duct from the HV battery.

15. DISCONNECT FLOOR WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Disengage the clamp.

(b) Disconnect the battery voltage sensor connector.

16. REMOVE HV BATTERY

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the 5 bolts and HV battery from the vehicle body.

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 remove it. When removing the HV battery, be careful not to damage the parts around it.
  • When removing the HV battery from the vehicle, do not allow it to contact the vehicle.
  • When removing/installing/moving the HV battery, make sure not to tilt it more than 80°.
  • Insulate the disconnected terminals or connectors with insulating tape.
  • If the HV battery has been struck or dropped, replace it.

17. REMOVE NO. 4 HV BATTERY SHIELD SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the 4 nuts and No. 4 HV battery shield sub-assembly from the HV battery.

18. REMOVE NO. 3 HV BATTERY SHIELD SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the 4 nuts and No. 3 HV battery shield sub-assembly from the HV battery.

19. REMOVE NO. 4 HV BATTERY END PLATE SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the 2 bolts, 2 nuts and No. 4 HV battery end plate sub-assembly from the HV battery.

*a

Bolt

*b

Nut

20. REMOVE NO. 5 HV BATTERY END PLATE SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the 12 nuts and No. 5 HV battery end plate sub-assembly from the HV battery.

21. REMOVE UPPER HV BATTERY COVER SUB-ASSEMBLY

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22. REMOVE NO. 1 HV BATTERY SHIELD PANEL

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23. REMOVE BATTERY VOLTAGE SENSOR

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24. REMOVE HYBRID BATTERY TERMINAL BLOCK

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25. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY

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26. REMOVE NO. 2 HYBRID BATTERY SHIELD SUB-ASSEMBLY

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27. REMOVE NO. 1 HV BATTERY INTAKE DUCT LH

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READ NEXT:

 Installation

INSTALLATION PROCEDURE 1. INSTALL NO. 1 HV BATTERY INTAKE DUCT LH Click here 2. INSTALL NO. 2 HYBRID BATTERY SHIELD SUB-ASSEMBLY Click here 3. INSTALL HV BATTERY JUNCTION BLOCK ASSEMBLY Click here

 Charging

CHARGING CAUTION / NOTICE / HINT The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced when charg

 Hv Battery Stack (for Lithium-ion Battery)

SEE MORE:

 Reassembly

REASSEMBLY PROCEDURE 1. INSTALL OIL PUMP REGULATOR RING (a) Install the oil pump regulator ring to the oil pump body. *1 Oil Pump Regulator Vane *2 Oil Pump Regulator Ring *3 Oil Pump Relief Valve Spring *4 Vane Spring (b) Install the 2 oil pump regulator

 Parking Brake System

PrecautionPRECAUTION NOTICE: If the battery is connected, the parking brake will operate when the electric parking brake switch assembly is pulled to the lock side even if the engine switch (for Gasoline Model) or power switch (for HV Model) is off. Do not operate the electric parking brake swit

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