Lexus HS 250h Vehicle Dismantling Manual
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Lexus HS 250h Vehicle Dismantling Manual

Anf10 series gasoline-electric hybrid synergy drive
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Summary of Contents for Lexus HS 250h

  • Page 1 Gasoline-Electric Hybrid Synergy Drive ANF10 Series...
  • Page 2 Foreword This guide was developed to educate and assist dismantlers in the safe handling of Lexus HS250h gasoline-electric hybrid vehicles. HS250h dismantling procedures are similar to other non-hybrid Lexus vehicles with the exception of the high voltage electrical system. It is important to recognize and understand the high voltage electrical system features and specifications of the Lexus HS250h, as they may not be familiar to dismantlers.

  • Page 3: Table Of Contents

    HS250h Identification (Continued) ......................4 Interior................................4 Engine Compartment ............................5 Hybrid Component Locations & Descriptions..................6 Specifications ..............................7 Lexus Hybrid Drive Operation.........................8 Vehicle Operation............................8 Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery..............9 HV Battery Pack............................9 Components Powered by the HV Battery Pack.....................9 HV Battery Pack Recycling .........................10 Auxiliary Battery ............................10...

  • Page 5: About The Hs250H

    The HS250h sedan joins the LS 600h L, RX 450h and GS 450h as a hybrid model for Lexus. Lexus Hybrid Drive means that the vehicle contains a gasoline engine and an electric motor for power. The two hybrid power sources are stored on board the vehicle: Gasoline stored in the fuel tank for the gasoline engine.

  • Page 6: Hs250H Identification

    HS250h Identification In appearance, the 2010 model year HS250h is a 4-door sedan. Exterior, interior, and engine compartment illustrations are provided to assist in identification. The alphanumeric 17 character Vehicle Identification Number (VIN) is provided in the front windshield cowl, driver door pillar, and engine compartment. JTHBB1BAA82020211 Example VIN: An HS250h is identified by the first 8 alphanumeric characters...

  • Page 7: Exterior

    HS250h Identification (Continued) Exterior logo on the back door. logo on the rear door moldings. Exterior Driver Side View Exterior Front and Rear View Exterior Rear and Driver Side View...

  • Page 8: Hs250H Identification (Continued)

    HS250h Identification (Continued) Interior Instrument cluster (speedometer, power meter, READY light, shift position indicators, warning lights) located in the dash behind the steering wheel. Hint: If the vehicle is shut off, the instrument cluster gauges will be “blacked out”, not illuminated.

  • Page 9: Engine Compartment

    HS250h Identification (Continued) Engine Compartment 2.4-liter aluminum alloy gasoline engine. LEXUS HYBRID DRIVE logo on the plastic engine cover. Orange colored high voltage power cables. Engine Compartment View Power Cables...

  • Page 10: Hybrid Component Locations & Descriptions

    Hybrid Component Locations & Descriptions Component Location Description 12 Volt Auxiliary Trunk Passenger A lead-acid battery that supplies power to the low Battery Side voltage devices. Trunk Area, 244.8 Volt Nickel Metal Hydride (NiMH) battery pack Mounted to consisting of 34 low voltage (7.2 Volt) modules Hybrid Vehicle Cross Member...

  • Page 11: Specifications

    Hybrid Component Locations & Descriptions (Continued) Specifications Gasoline Engine: 147 hp (110 kW), 2.4-liter Aluminum Alloy Engine Electric Motors 141 hp (105 kW), Permanent Magnet Motor Transmission: Automatic Only (electrically controlled continuously variable transaxle) HV Battery: 244.8 Volt Sealed NiMH Battery Curb Weight: 3,770 lbs/1,710 kg Fuel Tank: 14.5 Us.gals/55.0 liters Frame Material: Steel Unibody...

  • Page 12: Lexus Hybrid Drive Operation

    Lexus Hybrid Drive Operation Once the READY indicator is illuminated in the instrument cluster, the vehicle may be driven. However, the gasoline engine does not idle like a typical automobile and will start and stop automatically. It is important to recognize and understand the READY indicator provided in the instrument cluster.

  • Page 13: Hybrid Vehicle (Hv) Battery Pack And Auxiliary Battery

    Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery The HS250h features a high voltage Hybrid Vehicle (HV) battery pack that contains sealed Nickel Metal Hydride (NiMH) battery modules. HV Battery Pack • The HV battery pack is enclosed in a metal case and is rigidly mounted to the cabin area floor pan cross member under the second row rear seat.

  • Page 14: Hv Battery Pack Recycling

    Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (Continued) HV Battery Pack Recycling • The HV battery pack is recyclable. Contact either your Lexus Distributor as mentioned on HV battery Caution Label (see page 30) or the nearest Lexus dealer. Auxiliary Battery •...

  • Page 15: High Voltage Safety

    High Voltage Safety The HV battery pack powers the high voltage electrical system with DC electricity. Positive and negative orange colored high voltage power cables are routed from the battery pack, under the vehicle floor pan, to the inverter/converter. The inverter/converter contains a circuit that boosts the HV battery voltage from 244.8 to 650 Volts DC.

  • Page 16: Service Plug Grip

    High Voltage Safety (Continued) Service Plug Grip • The high-voltage circuit is cut by removing the service plug grip (see page 15). High Voltage Safety System – Vehicle Shut Off (READY-OFF) High Voltage Safety System – Vehicle On and Operational (READY-ON)

  • Page 17: Precaution To Be Observed When Dismantling The Vehicle

    Precaution to be observed when dismantling the vehicle WARNING: ・ The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled. To prevent serious injury or death from severe burns or electric shock, avoid touching, cutting, or opening any orange high voltage power cable or high voltage component.

  • Page 18: Spills

    Spills The HS250h contains the same common automotive fluids used in other non-hybrid Lexus vehicles, with the exception of the NiMH electrolyte used in the HV battery pack. The NiMH battery electrolyte is a caustic alkaline (pH 13.5) that is damaging to human tissues. The electrolyte, however, is absorbed in the cell plates and will not normally spill or leak out even if a battery module is cracked.

  • Page 19: Dismantling The Vehicle

    Dismantling the vehicle The following 2 pages contain general instructions for use when working on an HS250h. Read these instructions before proceeding to the HV battery removal instructions on page 18. WARNING: ・ The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled.
  • Page 20 Instead, wash the eye(s) with a dilute boric acid solution or a large amount of water and seek medical care. 10. With the exception of the HV battery, remove parts by following procedures which are similar to conventional Lexus vehicles. For the removal of the HV battery, refer to the following pages.

  • Page 22: Removal Of Hv Battery

    Removal of HV battery WARNING: ・ Be sure to wear insulated gloves when handling high-voltage parts. ・ Even if the vehicle is shut off and the relays are off, be sure to remove the service plug grip before performing any further work.
  • Page 23 Remove the service plug grip. HV Battery Disengage the 2 clips and 2 guides, and remove the battery service hole cover. (2) Slide the handle of the service plug grip to the left. Service Plug Grip Caution: Wear insulated gloves for the following 3 steps. (3) Raise the release handle of the service plug grip as shown in the illustration below.
  • Page 24 7. Remove the 2 bolts and connector cover assembly. 8. Check the voltage at the terminals in the inspection point in the power control unit. Caution: Wear insulated gloves. To prevent serious injury or death, do not proceed with dismantling of the HV system until the voltage at the terminals in the inspection point is 0 V.
  • Page 25 10. Disengage the claw to open the 3 caps of the rear seat shoulder belt guide. 11. Remove the rear seatback assembly. (1) Remove the 4 bolts. (2) Disengage the 3 hooks and remove the rear seatback assembly. 12. Remove the tool with stay box sub-assembly from the trunk.
  • Page 26 13. Remove the rear floor finish plate. (1) Remove the 3 clips. Disengage the 4 clips and 2 guides, and remove the rear floor finish plate. 14. Remove the No. 1 luggage compartment light assembly Using a screwdriver, disengage the claw and guide..
  • Page 27 16. Remove the rope hook. 17. Remove the inner luggage compartment trim cover. Remove the 3 clips and inner luggage compartment trim cover.. 18. Remove the auxiliary battery. Loosen the nut and separate the positive (+) battery terminal. Remove the nut and battery clamp.
  • Page 28 19. Remove the battery cooling blower assembly. Remove the 2 clips and No. 1 HV battery intake duct. Remove the clip and No. 4 HV battery intake duct. Remove the clip and No. 2 HV battery intake duct with the No. 3 HV battery intake duct.
  • Page 29 20. Disconnect the frame wire. Disconnect the 2 clamps and frame wire. Clamp 21. Remove the No. 4 hybrid battery shield panel. Caution: Wear insulated gloves for the following 2 steps. (1) Using the service plug grip, remove the battery cover lock striker Hint: Insert the projecting part of the service plug grip and turn the button of the battery cover...
  • Page 30 24. Remove the No. 3 hybrid battery exhaust duct. Disconnect the 2 clips. 25. Remove the No. 2 hybrid battery exhaust duct Remove the clip and No. 2 hybrid battery exhaust duct. 26. Remove the No. 1 hybrid battery exhaust duct.
  • Page 31 Remove the 2 bolts and child restraint seat anchor bracket sub-assembly RH 29. Remove the HV battery Caution: Wear insulated gloves. Notice: Insulate the terminals of the removed frame wire with insulating tape. (1) Disconnect the frame wire clamp. Disconnect the battery room ventilation hose Disconnect the battery pack wire connector and clamp...
  • Page 32 Remove the 4 bolts from the HV battery Turn the luggage compartment floor mat over Use a tire lever from the cabin side to lift the HV battery up over the tabs on the body...
  • Page 33 Using a tire lever to hold up the HV battery, insert a wooden block or equivalent as shown in the illustration Pull the HV battery together with the cardboard toward the rear of the vehicle (10) Disconnect the clamp as shown in the illustration (11) Using a suitable adaptor such as a rope,...

  • Page 34: Hv Battery Caution Label

    HV Battery Caution Label For U.S.A. For CANADA...

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