Lexus IS300h User manual

IS300h
Gasoline-Electric
Hybrid Synergy Drive
AVE30 Series

ii
Foreword
This guide was developed to educate and assist dismantlers in the safe handling of Lexus IS300h
gasoline-electric hybrid vehicles. IS300h 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
IS300h, as they may not be familiar to dismantlers.
High voltage electricity powers the A/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 IS300h to help ensure the high voltage, approximately 230.4 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 IS300h identification.
• Major hybrid component locations and descriptions.
By following the information in this guide, dismantlers will be able to handle IS300h
hybrid-electric vehicles as safely as the dismantling of a conventional gasoline engine automobile.
©2013 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.

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Table of Contents
IS300h Identification....................................................................................................................................2
Exterior .........................................................................................................................................................3
Interior...........................................................................................................................................................4
Engine Compartment....................................................................................................................................6
Hybrid Component Locations & Descriptions...........................................................................................7
Specifications................................................................................................................................................8
Lexus Hybrid Drive Operation....................................................................................................................9
Vehicle Operation..........................................................................................................................................9
Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery......................................................................10
HV Battery Pack..........................................................................................................................................10
Components Powered by the HV Battery Pack...........................................................................................10
HV Battery Pack Recycling.........................................................................................................................11
Auxiliary Battery..........................................................................................................................................11
High Voltage Safety ....................................................................................................................................12
High Voltage Safety System........................................................................................................................12
High Voltage Safety (Continued)...............................................................................................................13
Service Plug Grip........................................................................................................................................13
Precaution to be observed when dismantling the vehicle........................................................................14
Necessary Items.........................................................................................................................................14
Spills.............................................................................................................................................................15
Dismantling the vehicle..............................................................................................................................16
Removal of HV battery ..............................................................................................................................20
HV Battery Caution Label.........................................................................................................................36

About the IS300h
The IS300h 4-door sedan joins the 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 IS300h 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 IS300h operates in various driving modes.
During light acceleration at low speeds, the vehicle is powered by the electric motor.
The gasoline engine is shut off.
During 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.
 During full acceleration, such as climbing a hill, both the gasoline engine and the electric
motor power the vehicle.
During deceleration, such as when braking, the vehicle regenerates kinetic energy from
the rear wheels to produce electricity that recharges the battery pack.
While the vehicle is stopped, the gasoline engine and electric motor are off, however the
vehicle remains on and operational.
Stopping
Normal Driving
Starting 
Acceleration  Deceleration
Electricity Electricity and gasoline
Electricity and gasoline
(additional electricity
extracted from batteries)
Charging batteries
Engine automaticall
y
stopped
1

IS300h Identification
In appearance, the 2014 model year IS300h is nearly identical to the conventional, non-hybrid
Lexus IS350/250. The IS300h 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: JTHBH1D22000101 (with Rear Seat Side Airbag)
JTHBH5D22000101 (without Rear Seat Side Airbag)
An IS300h is identified by the first 8 alphanumeric characters JTHBH1D2 or JTHBH5D2.
This illustration is for an LHD model
Left Side Windshield Cowl, Left Side B Pillar, and Engine Compartment Cowl
2

IS300h Identification (Continued)
Exterior
IS300h logo on the trunk.
logos on the rocker moldings.
Gasoline fuel filler door located on the left side rear quarter panel.
Exterior Front and Driver Side View
Exterior Rear and Driver Side View





3

IS300h Identification (Continued)
Interior
The instrument cluster (READY indicator and warning lights) located in the dash behind the
steering wheel, is different than the one on the conventional, non-hybrid IS350/250.
Hint:
If the vehicle is shut off, the instrument cluster gauges will be “blacked out”, not illuminated.
Interior View
Instrument Cluster View


READY Indicator
Exce
p
t F SPORT
READY Indicator
F SPORT
4

IS300h Identification (Continued)
A switchable gauge in the instrument cluster showing either a hybrid system indicator or a
tachometer depending on driving mode.
Instrument Cluster View

Exce
p
t F SPORT
Hybrid System Indicator Tachometer
F SPORT
Tachometer
Hybrid System Indicator
5

IS300h Identification (Continued)
Engine Compartment
 2.5-liter aluminum alloy gasoline engine.
 Logo on the plastic engine cover.
 Orange colored high voltage power cables.
Engine Compartment View
Power Cables



6

7
Hybrid Component Locations & Descriptions
Component Location Description
12 Volt Auxiliary
Battery Left Side of Trunk A lead-acid battery that supplies power to the low voltage devices.
Hybrid Vehicle
(HV) Battery
Pack 
Trunk Area,
Mounted to Spare
Tire Area
230.4 Volt Nickel Metal Hydride (NiMH) battery pack
consisting of 32 low voltage (7.2 Volt) modules connected
in series.
Power Cables Undercarriage
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 Engine Compartment Boosts and inverts the high voltage electricity from the HV battery pack to 3-phase AC electricity that drives the
electric motor. The inverter/converter also converts AC
electricity from the electric generator and electric motor
(regenerative braking) to DC that recharges the HV battery
pack.
DC-DC
Converter
for 12 Volt
Auxiliary
Battery 
Inverter/
Converter Converts 230.4 Volts from the HV battery pack to 12 Volts for low voltage vehicle power.
Gasoline
Engine Engine Compartment Provides two functions: 1) Powers the vehicle.
2) Powers the generator to recharge the HV battery pack.
The engine is started and stopped under control of the
vehicle computer.
Electric
Motor Transmission 3-phase high voltageAC permanent magnet electric motor contained in the transmission and drives the rear wheels
through the propeller shaft.
Electric Generator
Transmission 3-phase high voltage AC generator that is contained in the
transmission and recharges the HV battery pack.
A/C Compressor
(with Inverter) Engine Compartment 3-phase high voltage AC electrically driven motor compressor.
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.

Hybrid Component Locations & Descriptions (Continued)
Specifications
Gasoline Engine: 178 hp (133 kW), 2.5-liter Aluminum Alloy Engine
Electric Motor: 141 hp (105 kW), Permanent Magnet Motor
Transmission: Automatic Only
HV Battery: 230.4 Volt Sealed NiMH Battery
Curb Weight: 3,571 - 3,792 lbs/1,620 - 1,720 kg
Fuel Tank: 17 gals/66 liters
Frame Material: Steel Unibody
Body Material: Steel Panels except for Aluminum Engine Hood
Seating Capacity: 5 passenger
8

















LHD Models
RHD Models


LHD Models
RHD Models




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. When illuminated, it informs the driver that the vehicle is on and
operational even though the gasoline engine may be off and the engine compartment is silent.
Vehicle Operation
• With the IS300h, the gasoline engine may stop and start at any time while the READY indicator is
on.
• Never assume that the vehicle is shut off just because the engine is off. Always look for the
READY indicator status. The vehicle is shut off when the READY indicator is off.
• The vehicle may be powered by:
1. The electric motor only.
2. A combination of both the electric motor and the gasoline engine.
Instrument Cluster READY Indicator
Except F SPORT
F SPORT
9

Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery
The IS300h 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 spare tire area.
The metal case is isolated from high voltage and concealed by fabric covers in the trunk.
• The HV battery pack consists of 32 low voltage (7.2 Volt) NiMH battery modules connected in
series to produce approximately 230.4 Volts. Each NiMH battery module is non-spillable and
sealed in a metal case.
• The electrolyte used in the NiMH battery module is an alkaline mixture of potassium and sodium
hydroxide. The electrolyte is absorbed into the battery cell plates and will not normally leak,
even in a collision.
HV Battery Pack
Battery pack voltage 230.4 V
Number of NiMH battery modules in the pack 32
NiMH battery module voltage 7.2 V
NiMH battery module dimensions
(Width x Length x Height) 10.9 x 0.8 x 4.2 in (276 x 20 x 106 mm)
NiMH module weight 2.3 lbs (1.0 kg)
NiMH battery pack dimensions
(Width x Length x Height) 29.4 x 21.3 x 9.1 in (748 x 540 x 231.5 mm)
NiMH battery pack weight 109 lbs (49.5 kg)
Note: Values in inches have been rounded
Components Powered by the HV Battery Pack
• Electric Motor • Power Cables
• Electric Generator • A/C Compressor
• Inverter/Converter
- DC-DC Converter for 12 Volt Auxiliary Battery
10

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 36) or the nearest Lexus dealer.
Auxiliary Battery
• The IS300h contains a sealed lead-acid 12 Volt battery. This 12 Volt auxiliary battery powers the
vehicle electrical system similar to a conventional vehicle. As with other conventional vehicles,
the negative terminal of the auxiliary battery is grounded to the metal chassis of the vehicle.
• The auxiliary battery is located in the trunk area. It is concealed by a fabric cover on the left side
in the rear quarter panel well.
230.4 Volt HV Battery Pack 12 VoltAuxiliary Battery Mounted in the Trunk
Area
HV Battery Pack (Viewed from the Trunk Area)
11

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, routed along the propeller shaft and transmission tunnel to the
inverter/converter. The inverter/converter contains a circuit that boosts the HV battery
voltage from 230.4 to 650 Volts DC. The inverter/converter creates 3-phase AC to power
the motor. Power cables are routed from the inverter/converter to each high voltage motor
(electric motor, electric generator, and A/C compressor). The following systems are
intended to help keep occupants in the vehicle and emergency responders safe from high
voltage electricity:
High Voltage Safety System
• A high voltage fuse * provides short circuit protection in the HV battery pack.
• Positive and negative high voltage power cables * connected to the HV battery pack are
controlled by 12 Volt normally open relays *. When the vehicle is shut off, the relays stop
electrical flow from leaving the HV battery pack.
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.
• Both positive and negative power cables * are insulated from the metal chassis, so there is no
possibility of electric shock when touching the metal chassis.
• A ground-fault monitor * continuously monitors for high voltage leakage to the metal chassis
while the vehicle is running. If a malfunction is detected, the hybrid vehicle computer * will
illuminate the master warning light in the instrument cluster and indicate “Check Hybrid
System” on the multi-information display.
• The HV battery pack relays will automatically open to stop electricity flow in a collision sufficient
to activate the SRS.
*Numbers apply to the illustration on the following page.
12

High Voltage Safety (Continued)
Service Plug Grip
• The high-voltage circuit is cut by removing the service plug grip (see page 16).
High Voltage Safety System – Vehicle Shut Off (READY-OFF)
High Voltage Safety System – Vehicle On and Operational (READY-ON)
HV Battery Assembly
0 Volts AC
3-Phase
A
/C
Compressor
Electric
Generator
Electric
Motor
Inverter/
Converter
V
olt DC
V
olt DC
00
Hybrid Vehicle Computer
00
12 Volt Auxiliary
Battery
HV Battery Assembly
650 Volts
A
C Max.
3-Phase
Inverter/
Converter
V
olt DC
V
olt DC
230.4
Hybrid Vehicle Computer
230.4
A
/C
Compressor
Electric
Generator
Electric
Motor
12 Volt Auxiliary
Battery
13

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.
Necessary Items
• Protective clothing such as insulated gloves (electrically insulated), rubber gloves, safety goggles,
and safety shoes.
• Insulating tape such as electrical tape that has a suitable electrical insulation rating.
• Before wearing insulated gloves, make sure that they are not cracked, ruptured, torn, or damaged in
any way. Do not wear wet insulated gloves.
• An electrical tester that is capable of measuring DC 750 Volts or more.
14

15
Spills
The IS300h 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. A catastrophic crash that would breach both the metal battery
pack case and a metal battery module would be a rare occurrence.
A caustic alkaline is at the opposite end of the pH scale from a strong acid. A safe (neutral)
substance is approximately in the middle of this scale. Adding a weak acidic mixture, such as
a dilute boric acid solution or vinegar, to the caustic alkaline electrolyte will cause the
electrolyte to be neutralized. This is similar but opposite to the use of baking soda to
neutralize a lead-acid battery electrolyte spill.
A Lexus Product Safety Data Sheets (PSDS) is attached to this document.
• Handle NiMH electrolyte spills using the following Personal Protective Equipment (PPE):
• Splash shield or safety goggles. A fold down face shield is not acceptable for acid
or electrolyte spills.
• Rubber, latex or nitrile gloves.
• Apron suitable for alkaline.
• Rubber boots.
• Neutralize NiMH electrolyte.
• Use a boric acid solution or vinegar.
• Boric acid solution - 800 grams boric acid to 20 liters water or 5.5 ounces boric
acid to 1 gallon of water.

Dismantling the vehicle
The following 3 pages contain general instructions for use when working on an IS300h. Read these
instructions before proceeding to the HV battery removal instructions on page 20.
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 any high voltage component.
1. Shut off the ignition (READY indicator is off).
Then disconnect the cable from the auxiliary
battery negative (-) terminal.
(1) Remove the luggage trim service hole cover.
(2) Disconnect the battery negative terminal.
2. Remove the luggage compartment floor mat.
3. Remove the luggage compartment trim box.
(1) Remove the 6 clips.
(2) Disengage the 3 guides and remove the
luggage compartment trim box.
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