Lexus ES: Removal

Lexus ES (XZ10) Service Manual / Engine & Hybrid System / Hybrid / Battery Control / Hv Battery (for Nickel Metal Hydride Battery) / 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
*: When performing learning using the Techstream. Click here
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
	Memorize steering angle neutral point	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.
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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.
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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.

11. DISCONNECT FLOOR WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Disengage the clamp.

(b) Disconnect the electric vehicle battery plug 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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SEE MORE:

Reassembly

REASSEMBLY PROCEDURE 1. BEARING POSITION Check bearing position and installation direction. Thrust Needle Roller Bearing and Bearing Race Diameter: Mark Front Side Thrust Bearing Race Diameter Inside / Outside mm (in.) Thrust Bearing Diameter Inside / Outside mm (in.) Rear Side Thrust Be

Dtc Check / Clear

DTC CHECK / CLEAR CHECK FOR DTC (MAIN BODY) (a) Connect the Techstream to the DLC3. (b) Turn the engine switch on (IG). (c) Turn the Techstream on. (d) Enter the following menus: Body Electrical / Main Body / Trouble Codes. Body Electrical > Main Body > Trouble Codes (e) Check for DTCs. CHECK

Lexus ES: Removal

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Installation

Charging

Hv Battery Stack (for Lithium-ion Battery)

SEE MORE:

Reassembly

Dtc Check / Clear