Lexus GS 450h User manual

Gasoline-Electric
Hybrid Synergy Drive
GWL10 Series

ii
Foreword
This guide was developed to educate and assist dismantlers in the safe handling of Lexus GS450h
gasoline-electric hybrid vehicles. GS450h 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 GS450h, as they
may not be familiar to dismantlers.
High voltage electricity powers theA/C compressor, electric motor, generator, and inverter/converter.
All other conventional automotive electrical devices such as the head lights, radio, and gauges are
powered from a separate 12 Volt auxiliary battery. Numerous safeguards have been designed into the
GS450h to help ensure the high voltage, approximately 288 Volt, Nickel Metal Hydride (NiMH) Hybrid
Vehicle (HV) battery pack is kept safe and secure in an accident.
The NiMH HV battery pack contains sealed batteries that are similar to rechargeable batteries used in
some battery operated power tools and other consumer products. The electrolyte is absorbed in the cell
plates and will not normally leak out even if the battery is cracked. In the unlikely event the electrolyte
does leak, it can be easily neutralized with a dilute boric acid solution or vinegar.
High voltage cables, identifiable by orange insulation and connectors, are isolated from the metal chassis
of the vehicle.
Additional topics contained in the guide include:
•Lexus GS450h identification.
•Major hybrid component locations and descriptions.
By following the information in this guide, dismantlers will be able to handle GS450h hybrid-electric
vehicles as safely as the dismantling of a conventional gasoline engine automobile.
©2012 Toyota Motor Corporation
All rights reserved. This book may not be reproduced or
copied, in whole or in part, without the written permission
of Toyota Motor Corporation.

iii
Table of Contents
About the GS450h hybrid..........................................................................................................................1
GS450h Identification ................................................................................................................................2
GS450h Identification (Continued)...........................................................................................................3
GS450h Identification (Continued)...........................................................................................................4
GS450h Identification (Continued)...........................................................................................................5
Hybrid Component Locations & Descriptions.........................................................................................6
Hybrid Component Locations & Descriptions (Continued)...................................................................7
Specifications................................................................................................................................................7
Hybrid Component Locations & Descriptions (Continued)...................................................................8
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
Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (Continued)..............................................10
HV Battery Pack Recycling.........................................................................................................................10
Auxiliary Battery..........................................................................................................................................10
High Voltage Safety ..................................................................................................................................11
High Voltage Safety System........................................................................................................................11
High Voltage Safety (Continued).............................................................................................................12
Service Plug Grip........................................................................................................................................12
Precaution to be observed when dismantling the vehicle......................................................................13
Necessary Items.........................................................................................................................................13
Spills ..........................................................................................................................................................14
Dismantling the vehicle............................................................................................................................15
Removal of HV battery............................................................................................................................18
HV Battery Caution Label ...........................................................................................................................29

1
About the GS450h hybrid
The GS450h joins the LS600h L, RX450h, HS250h and CT200h 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:
1. Gasoline stored in the fuel tank for the gasoline engine.
2. Electricity stored in a high voltage Hybrid Vehicle (HV) battery pack for the
electric motor.
The result of combining these two power sources is improved fuel economy and
reduced emissions. The gasoline engine also powers an electric generator to recharge
the battery pack; unlike a pure all electric vehicle, the GS450h never needs to be
recharged from an external electric power source.
Depending on the driving conditions one or both sources are used to power the vehicle.
The following illustration demonstrates how the GS450h operates in various driving
modes.
nDuring light acceleration at low speeds, the vehicle is powered by the electric motor.
The gasoline engine is shut off.
oDuring normal driving, the vehicle is powered mainly by the gasoline engine. The
gasoline engine also powers the generator to recharge the battery pack and to drive
the motor.
pDuring full acceleration, such as climbing a hill, both the gasoline engine and the
electric motor power the vehicle.
qDuring deceleration, such as when braking, the vehicle regenerates the kinetic
energy from the rear wheels to produce electricity that recharges the battery pack.
rWhile the vehicle is stopped, the gasoline engine and electric motor are off, however
the vehicle remains on and operational.
nStarting oNormal Driving pAcceleration qDeceleration rStopping
Electricity Electricity and gasoline Electricity and gasoline
(additional electricity
extracted from batteries)
Charging batteries Engine automatically
stopped

2
GS450h Identification
In appearance, the 2013 model year GS450h is a nearly identical to the conventional,
non-hybrid Lexus GS350. The GS450h 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, engine compartment, and on the left side B pillar.
Example VIN: JTHBS1BL0D5000101
AGS450h is identified by the first 8 alphanumeric characters JTHBS1BL.
Left Side Windshield Cowl, Left Side B Pillar, and Engine Compartment Cowl

3
GS450h Identification (Continued)
Exterior
nlogos on the trunk.
ologos on the rocker moldings.
pGasoline fuel filler door located on left side rear quarter panel.
qLexus logo on the radiator grille.
Exterior Left Side View
Exterior Front and Rear View

Exterior Rear and Left Side View

4
GS450h Identification (Continued)
Interior
rThe instrument cluster (hybrid system indicator, READY indicator and warning
lights) located in the dash behind the steering wheel, is different than the one on the
conventional, non-hybrid GS350.
sA switchable gauge in the instrument cluster showing either a hybrid system
indicator or a tachometer depending on driving mode.
Notice:
If the vehicle is shut off, the instrument cluster gauges will be “blacked out”, not
illuminated.
Interior View
Instrument Cluster View
Tachometer
Hybrid System Indicator
rs
Hybrid System Indicator Tachometer
for Canada
for U.S.A.
rs

5
GS450h Identification (Continued)
Engine Compartment
t3.5-liter aluminum alloy gasoline engine.
uLogo on the plastic engine cover.
vOrange colored high voltage power cables.

Engine Compartment View

Power Cables

6
Hybrid Component Locations & Descriptions
Component Location Description
12 Volt Auxiliary
Battery nLeft Side of Trunk Alead-acid battery that supplies power to the low voltage devices.
Hybrid Vehicle
(HV) Battery Pack
o
Trunk Area,
Mounted behind
Rear Seat
288 Volt Nickel Metal Hydride (NiMH) battery pack
consisting of 40 low voltage (7.2 Volt) modules connected
in series.
Power Cables pUndercarriage and
Engine
Compartment
Orange colored power cables carry high voltage Direct
Current (DC) between the HV battery pack,
inverter/converter, and A/C compressor. These cables also
carry 3-phase Alternating Current (AC) between the
inverter/converter, electric motor, and generator.
Inverter/
Converter qEngine Compartment Boosts and inverts the high voltage electricity from the HV battery pack to 3-phase AC electricity that drives the
electric motors. The inverter/converter also convertsAC
electricity from the electric generator and electric motor
(regenerative braking) to DC that recharges the HV
battery pack.
Gasoline Engine
r
Engine
Compartment Provides two functions: 1) Powers vehicle.
2) Powers generator to recharge the HV battery pack.
The engine is started and stopped under control of the
vehicle computer.
Electric Motor s
Transmission 3-phase high voltage AC permanent magnet electric motor contained in the transmission and drives the rear wheels
through the propeller shaft.
Electric Generator
tTransmission 3-phase high voltageAC generator that is contained in the
transmission and recharges the HV battery pack.
A/C Compressor
(with inverter)uEngine Compartment 3-phase high voltage AC electrically driven motor compressor.
DC-DC Converter
vfor 12 Volt
Auxiliary Battery
Engine
Compartment Converts 288 Volts from the HV battery pack to 12 Volts for low voltage vehicle power.
DC-DC Converter
wfor EPS On HV Battery Pack Converts 288 Volts from the HV battery pack to 46 Volts for EPS.Dull yellow colored sheathing identifies 46
Volts wires that are routed under the vehicle body to
power the EPS.
Fuel Tank and Fuel
Line Undercarriage,
Left Side and
Center
The fuel tank provides gasoline via a fuel line to the
engine. The fuel line is routed along the left side and
center tunnel under the floor pan.
*Numbers in the component column apply to the illustrations on the following page.