LEMON Manuals: Even more car manuals for everyone
Home >> Lexus >> 2020 >> LS 500h AWD >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Electric Motor Systems >> Hybrid Battery Control System - Service Information (1 Of 5) >> Inverter With Converter >> Removal [10/2020 - 11/2021] >> Procedure

Removal [10/2020 - 11/2021]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    Refer to PRECAUTION [10/2020 - 11/2021]

  2. AIR SUSPENSION CONTROL PROHIBITED (w/ Air Suspension) 

    Refer to PRECAUTION [10/2017 - ]

  3. REMOVE LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 25

  4. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to REMOVAL [10/2020 - 11/2021]

  5. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [10/2020 - 11/2021]

  6. REMOVE UPPER RADIATOR SUPPORT SEAL 

    Refer to PROCEDURE - Step 2

  7. REMOVE RADIATOR COVER PLATE 

    Refer to PROCEDURE - Step 3

  8. REMOVE LOWER RADIATOR AIR DEFLECTOR 

    Refer to PROCEDURE - Step 4

  9. REMOVE INVERTER COVER ASSEMBLY RH 
    1. Disengage the 2 claws and clip to remove the inverter cover assembly RH.
      GTY815204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. DRAIN COOLANT (for Inverter) 
    WARNING:
    • To avoid the danger of being burned, do not remove the reserve tank cap or drain cock plug while the coolant (for inverter) is still hot.
    • Pressurized, hot coolant (for inverter) and steam may be released and cause serious burns.
    GTY798827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *1 Inverter Reserve Tank Cap *2 Drain Cock Plug
    1. Remove the oil pan protector.
    2. Drain the coolant.

      Refer to PROCEDURE - Step 6

  11. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 

    Refer to REMOVAL [10/2020 - ]

  12. REMOVE CONNECTOR COVER ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. Remove the 2 bolts and connector cover assembly.
      NOTE:
      • Make sure to pull the connector cover assembly straight up, as a connector is connected to the bottom of the cover.
      • Do not touch the connector cover assembly waterproofing rubber.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      GTY814815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. CHECK TERMINAL VOLTAGE 
    WARNING:

    Wear insulated gloves.

    1. Using a voltmeter, measure the voltage between the terminals of the 2 phase connectors.

      Standard Voltage

      0 V

      NOTE:

      Do not allow any foreign matter or water to enter the inverter with converter assembly.

      HINT: 

      Use a measuring range of DC 750 V or more on the voltmeter.

      GTY814820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. Temporarily install the connector cover assembly with the 2 bolts to prevent any foreign matter or water from entering the inverter with converter assembly.
      NOTE:
      • Visually confirm that the connector cover assembly waterproofing rubber is securely installed before installing the connector cover assembly.
      • Do not touch the connector cover assembly waterproofing rubber.
      • Make sure that the interlock is fully engaged.
      GTY814815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE INVERTER TERMINAL COVER 
    WARNING:

    Wear insulated gloves.

    1. Remove the 3 bolts and inverter terminal cover from the inverter with converter assembly.
      NOTE:
      • Make sure to pull the inverter terminal cover straight up, as a connector is connected to the bottom of the cover.
      • Do not touch the inverter terminal cover waterproofing rubber.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      GTY814819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. DISCONNECT GENERATOR CABLE 
    WARNING:

    Wear insulated gloves.

    1. Using an insulated tool, remove the 3 bolts (A).
      GTY781060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an insulated tool, remove the 2 bolts (B), and disconnect the generator cable from the inverter with converter assembly.
      NOTE:
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Do not touch the connector waterproofing rubber or terminals.
      • Do not damage the terminals, connector housings or inverter with converter assembly during disconnection.
      • Insulate the disconnected terminals with insulating tape.
      • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
  17. DISCONNECT MOTOR CABLE 
    WARNING:

    Wear insulated gloves.

    1. Using an insulated tool, remove the 3 bolts (A).
      GTY787915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an insulated tool, remove the 2 bolts (B), and disconnect the motor cable from the inverter with converter assembly.
      NOTE:
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Do not touch the connector waterproofing rubber or terminals.
      • Do not damage the terminals, connector housings or inverter with converter assembly during disconnection.
      • Insulate the disconnected terminals with insulating tape.
      • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
  18. REMOVE INVERTER MOTOR CABLE BRACKET ASSEMBLY 
    1. Detach the 3 clamps from the inverter motor cable bracket assembly.
      GTY814810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and inverter motor cable bracket from the inverter with converter assembly.
  19. REMOVE FENDER APRON BRACE SUB-ASSEMBLY RH 
    1. GTY814814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Detach the clamp from the fender apron brace sub-assembly RH.

    2. Remove the 2 bolts and fender apron brace sub-assembly RH.
  20. DISCONNECT NO. 5 INVERTER COOLING HOSE 
    1. Release the retainer and disconnect the No. 5 inverter cooling hose from the inverter with converter assembly as shown in the illustration.
      NOTE:

      Apply insulating tape to the pipes and in the disconnected hoses, or cover the pipes and hoses with plastic bags to prevent foreign matter from entering the cooling system and to prevent coolant from spilling near the inverter with converter assembly.

      GTY814801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      GTY835984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. DISCONNECT NO. 4 INVERTER COOLING HOSE 
    1. Slide the hose clip and disconnect the No. 4 inverter cooling hose from the inverter with converter assembly.
      NOTE:

      Apply insulating tape to the pipes and in the disconnected hoses, or cover the pipes and hoses with plastic bags to prevent foreign matter from entering the cooling system and to prevent coolant from spilling near the inverter with converter assembly.

      GTY814801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      GTY814803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT ENGINE ROOM MAIN WIRE 
    WARNING:

    Wear insulated gloves.

    1. Raise the lock lever and disconnect the engine room main wire (inverter with converter assembly connector) from the inverter with converter assembly as shown in the illustration.
      NOTE:
      • Insulate the disconnected connector with insulating tape.
      • Cover the hole where the connector was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
      GTY814805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 nuts and wiring harness clamp bracket.
      GTY814795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the connector cover assembly.

      See step  12

    4. Disconnect the engine room main wire (HV air conditioning wire) from the inverter with converter assembly.
      NOTE:
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Do not touch the connector waterproofing rubber or terminals.
      • Do not damage the connectors, connector housings or inverter with converter assembly during disconnection.
      • Insulate the disconnected terminals with insulating tape.
      • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
      GTY814792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Temporarily install the connector cover assembly.

      See step  14

  23. DISCONNECT FLOOR UNDER WIRE 
    WARNING:

    Wear insulated gloves.

    1. Remove the connector cover assembly.

      See step  12

    2. Remove the bolt, and disconnect the HV floor under wire from the inverter with converter assembly.
      NOTE:
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Do not touch the connector waterproofing rubber or terminals.
      • Do not damage the connectors, connector housings or inverter with converter assembly during disconnection.
      • Insulate the disconnected terminals with insulating tape.
      • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
      GTY835979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Temporarily install the connector cover assembly.

      See step  14

  24. REMOVE INVERTER WITH CONVERTER ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. Open the inverter bus-bar plate sub-assembly cover.
      GTY814788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut and disconnect the inverter bus-bar plate sub-assembly.
    3. Disconnect the connector.
    4. GTY814797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Detach the clamp from the No. 6 inverter bracket.

    5. Remove the 6 bolts, No. 6 inverter bracket and inverter with converter assembly.
      NOTE:
      • Since the inverter with converter assembly is very heavy, 2 people are needed to remove the inverter with converter assembly. When removing the inverter with converter assembly, do not damage the parts around it.
      • To prevent damage, do not hold the inverter with converter assembly by the connectors.
      • To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.
      • Cover the connectors with insulating tape to prevent foreign matter or water from entering.

      HINT: 

      Even after the coolant is drained, coolant remains in the inverter due to its internal structure. Therefore, seal or cover the pipes when removing the inverter so that coolant does not spill out.

    6. When removing and storing the inverter with converter assembly, make sure to install the inverter terminal cover and place a cushion under the inverter with converter assembly to protect it.
      GTY786809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Cushion
      NOTE:

      Do not place the inverter with converter assembly upside down.

  25. REMOVE NO. 4 INVERTER BRACKET 
    1. Remove the 2 bolts and No. 4 inverter bracket.
      GTY790298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE INVERTER BUS-BAR PLATE SUB-ASSEMBLY 
    1. Detach the clamp and remove the bolt.
      GTY830595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt from the inverter bus-bar plate sub-assembly.
    3. Open the terminal cover.
      GTY790292Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the nut.
      NOTE:

      If the stud bolt becomes loose when removing the nut, tighten the stud bolt to a torque of 10 N.m (102 kgf/cm 7 ft.lbf).

    5. Remove the inverter bus-bar plate sub-assembly.
      NOTE:

      If the inverter bus-bar plate sub-assembly is dropped or deformed, replace it with a new one.

  27. REMOVE NO. 1 INVERTER COOLING HOSE 

    HINT: 

    Perform this procedure only when replacement of the No. 1 inverter cooling hose is necessary.

    1. Slide the 2 hose clips and remove the No. 1 inverter cooling hose from the inverter with converter assembly.
      NOTE:

      Put pieces of cloth into the pipes or cover the pipes with plastic bags to prevent entry of foreign matter.

      GTY790294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE HIGH VOLTAGE FUSE 
    WARNING:

    Wear insulated gloves.

    HINT: 

    Perform this procedure only when replacement of the high voltage fuse is necessary.

    1. Remove the connector cover assembly.

      See step  12

    2. Remove the 2 nuts and high voltage fuse.
      NOTE:

      Do not allow any foreign matter or water to enter the inverter with converter assembly.

      GTY790293Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Temporarily install the connector cover assembly.

      See step  14

scientia non olet · About LEMON Manuals