LEMON Manuals: Even more car manuals for everyone
Home >> Lexus >> 2024 >> RX 500h >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Testing and Diagnosis >> Hybrid Battery Control System - Service Information (1 Of 4) >> INVERTER WITH CONVERTER (for THS-HEV Model) >> Removal [10/2022 - ] >> Procedure

Removal [10/2022 - ]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal.

    Refer to BEFORE DISCONNECTING BATTERY [10/2022 - ]

    Refer to PRECAUTION [10/2022 - ]

  2. REMOVE SERVICE PLUG GRIP 

    Refer to PROCEDURE - Step 5

  3. DRAIN COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 1

  4. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 19 [10/2022 - 10/2024] , or refer to PROCEDURE - Step 19 [10/2024 - ]
  5. DISCONNECT NO. 2 VENTILATION HOSE 

    Refer to PROCEDURE - Step 5 [10/2022 - 08/2023] , or refer to PROCEDURE - Step 5 [08/2023 - ]

  6. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 6 [10/2022 - 08/2023] , or refer to PROCEDURE - Step 6 [08/2023 - ]

  7. REMOVE ECM 

    Refer to PROCEDURE - Step 4 [10/2022 - 08/2023] , or refer to PROCEDURE - Step 4 [08/2023 - ]

  8. REMOVE NO. 2 INVERTER PROTECTOR 
    1. GTY1078047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. DISCONNECT ENGINE ROOM MAIN WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    NOTE:

    Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
    1. GTY1078184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Move the lock lever as shown in the illustration and disconnect the hybrid motor control inverter assembly connector.
        NOTE:
        • Do not touch the waterproof seal or terminals of the connector.
        • Do not damage the terminals, connector housing or hybrid motor control inverter assembly during disconnection.
        • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
        • Insulate the disconnected terminals with insulating tape.
      2. Remove the bolt.
      3. Disengage the clamp and disconnect the engine room main wire.
  10. REMOVE CONNECTOR COVER ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.
    1. GTY1078470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the bolt (A).
      2. Using a T20 "TORX" socket wrench, remove the bolt (B) and connector cover assembly from the hybrid motor control inverter assembly.
        NOTE:
        • Do not touch the connector cover assembly waterproof seal.
        • Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
  11. CHECK TERMINAL VOLTAGE 
    WARNING:

    Be sure to wear insulated gloves.
    1. GTY1077971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 hybrid motor control inverter assembly.

        HINT: 

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

  12. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.
    1. GTY1078578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Temporarily install the connector cover assembly to the hybrid motor control inverter assembly.
      2. Using a T20 "TORX" socket wrench, install the bolt.

        Torque: 4.5 N.m (46 kgf/cm, 40 in.lbf) 

        NOTE:
        • Do not touch the connector cover assembly waterproof seal.
        • Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
  13. DISCONNECT FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves.
    1. GTY1078966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal - -
      1. Remove the 2 bolts and disconnect the HV floor under wire from the hybrid motor control inverter assembly.
        NOTE:
        • Do not damage the terminals, interlock connector or hybrid motor control inverter assembly during disconnection.
        • Do not touch the waterproof seal or terminals of the connector.
        • Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
        • Although the connector may feel loose, this is not due to a malfunction.
    2. GTY1078051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. GTY1078020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal - -
      1. Remove the bolt and disconnect the HV floor under wire from the hybrid motor control inverter assembly.
        NOTE:
        • Do not touch the waterproof seal or terminals of the connector.
        • Do not damage the terminals, connector housing or hybrid motor control inverter assembly during disconnection.
        • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
        • Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
        • Insulate the disconnected terminals with insulating tape.
  14. DISCONNECT HV AIR CONDITIONING WIRE 
    WARNING:

    Be sure to wear insulated gloves.
    1. GTY1077736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal - -
      1. Remove the 2 bolts.
      2. Disengage the clamp and disconnect the HV air conditioning wire from the hybrid motor control inverter assembly.
        NOTE:
        • Do not touch the waterproof seal or terminals of the connector.
        • Do not damage the terminals, connector housing or hybrid motor control inverter assembly during disconnection.
        • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
        • Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
        • Insulate the disconnected terminals with insulating tape.
  15. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. GTY1077911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. DISCONNECT ENGINE WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    NOTE:
    • After disconnecting the engine wire, cover the connector of the generator temperature sensor and resolver (transmission fluid temperature sensor) with tape (nonresiduetype) or equivalent to prevent the entryof foreign matter or water.
      GTY1077915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
    1. GTY1078101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Move the lock lever as shown in the illustration and disconnect the hybrid motor control inverter assembly connector.
        NOTE:
        • Do not touch the waterproof seal or terminals of the connector.
        • Do not damage the terminals, connector housing or hybrid motor control inverter assembly during disconnection.
        • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
        • Insulate the disconnected terminals with insulating tape.
    2. GTY1077930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. GTY1077679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Generator Temperature Sensor Connector *b Resolver (Transmission Fluid Temperature Sensor) Connector
    4. GTY1077925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. GTY1078008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Disengage the 2 claws and open the engine wire terminal cover.
    6. GTY1077942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT NO. 1 INVERTER COOLING HOSE 
    1. GTY1078990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Slide the clip and disconnect the No. 1 inverter cooling hose from the hybrid motor control inverter assembly.
        NOTE:

        Put pieces of cloth into the pipe and disconnected hose or cover the pipe and hose with plastic bags to prevent entry of foreign matter.

  18. DISCONNECT NO. 4 INVERTER COOLING HOSE 
    1. GTY1078884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Slide the clip and disconnect the No. 4 inverter cooling hose from the hybrid motor control inverter assembly.
        NOTE:

        Put pieces of cloth into the pipe and disconnected hose or cover the pipe and hose with plastic bags to prevent entry of foreign matter.

  19. REMOVE UPPER INVERTER COVER SUB-ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.
    1. GTY1132755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Interlock *b Waterproof Seal
      1. Loosen the 2 bolts, leaving 2 to 3 threads at the tip of the bolt still engaged.
      2. Using the 2 bolts as guides, remove the upper inverter cover from the hybrid motor control inverter assembly.
        NOTE:
        • Make sure to pull the inverter cover straight out, as a connector is connected to the inside of the inverter cover.
        • Do not touch the waterproof seal of the inverter cover.
        • Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
        • When removing the inverter cover, do not pull the areas (A) as they may deform.
        • Make sure that the interlock is installed to the inverter cover.
        • Do not remove or excessively tighten the screw of the inverter cover.
          GTY1052470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
          *a Screw
        • Although the inverter cover may feel loose, this is not due to a malfunction.
        • Hold the upper inverter cover horizontal while removing it.
          GTY1106305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT: 

        If necessary, use a screwdriver with its tip wrapped with protective tape as shown in the illustration to remove the inverter cover.

        GTY1131950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Remove the 2 bolts.
  20. DISCONNECT MOTOR CABLE 
    WARNING:

    Be sure to wear insulated gloves.
    1. GTY1077684Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an insulated tool, remove the 6 bolts.
        NOTE:
        • Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
        • Do not touch the waterproof seal or terminals of the connector.
    2. GTY1078439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal - -
      1. Remove the 4 bolts and disconnect the motor cable from the hybrid motor control inverter assembly.
        NOTE:
        • Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
        • Do not touch the waterproof seal or terminals of the connector.
        • Do not damage the terminals, connector housing or hybrid motor control inverter assembly during disconnection.
        • Insulate the disconnected terminals with insulating tape.
        • After disconnecting the motor cable, wrap it with a plastic bag or equivalent to protect it.
        • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
        • To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.
          GTY1077889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. GTY1077882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE HYBRID MOTOR CONTROL INVERTER ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.
    1. GTY1077883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the 5 bolts, 2 nuts and hybrid motor control inverter assembly.
        NOTE:
        • When removing the hybrid motor control inverter assembly, be careful not to damage the parts around it.
        • To prevent damage, do not hold the hybrid motor control inverter assembly by the connectors, brackets or cooling pipes.
        • To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.

        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 hybrid motor control inverter assembly so that coolant does not spill out.

  23. REMOVE NO. 1 INVERTER BRACKET 
    NOTE:

    Make sure to support the hybrid motor control inverter assembly at the positions shown in the illustration, otherwise it may be damaged.

    1. *a: Bottom of hybrid motor control inverter assembly

      *b: Support

    GTY1066013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. GTY1078036Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Set the hybrid motor control inverter assembly on wooden blocks.
      2. Remove the 2 bolts and No. 1 inverter bracket from the hybrid motor control inverter assembly.
  24. REMOVE NO. 2 INVERTER BRACKET 
    1. GTY1077890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. GTY1078839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. GTY1078799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. GTY1078795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE HYBRID INVERTER PROTECTOR ASSEMBLY 
    1. GTY1078797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
scientia non olet · About LEMON Manuals