Lexus ES: Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during motor generator control ECU kit removal/installation are shown below.

PROCEDURE

1. REMOVE INVERTER WITH CONVERTER ASSEMBLY

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2. REMOVE WIRE HARNESS CLAMP BRACKET

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3. REMOVE INVERTER PROTECTOR

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4. VERIFY THAT VOLTAGE OF INVERTER WITH CONVERTER IS 0 V

CAUTION:

Wear insulating gloves.

NOTICE:

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

(a) Remove the protective tape from the HV floor under wire opening.

*a Tape

(b) Using a voltmeter, measure the voltage between the high voltage cable connector terminals. Standard voltage: 0V HINT: Use measuring range of DC 750 V or more on the voltmeter. If it is confirmed that high-voltage is not being applied to the inverter with converter assembly, the following procedures can be performed without using insulated tools or gloves.

*a Voltage Measurement Position

(c) Apply protective tape to the area that was exposed.

NOTICE:

Use non-residue type tape.

5. CLEAN INVERTER WITH CONVERTER ASSEMBLY

(a) Using a piece of cloth, clean the outside of the inverter with converter assembly and around the bolts.

NOTICE:

To prevent foreign matter from entering the inverter with converter assembly, make sure that the protective tape is not partially removed.

6. HOW TO PREVENT STATIC ELECTRICITY

SST: 09890-47010

(a) Wear an antistatic wrist strap.

(b) Connect the ground clip of the antistatic mat securely to a ground point provided in the workshop or on a workbench (anchor bolt).

HINT:

If the ground clip cable is too short, use an extension cable.

(c) Connect the ground clip of the antistatic wrist strap securely to the specified point of the antistatic mat.

(d) When handling internal components of the inverter with converter assembly, use only antistatic gloves or bare hands to prevent damage from static electricity or the entry of foreign matter.

7. REMOVE INVERTER UPPER COVER

(a) Remove the 10 bolts.

(b) Using a screwdriver with its tip wrapped with protective tape, remove the inverter upper cover from the inverter with converter assembly.

(c) Using a screwdriver with its tip wrapped with protective tape, remove the inverter upper cover from the inverter with converter assembly.

HINT:

I f the upper inverter panel is difficult to remove, place a screwdriver in a gap under the upper inverter cover and remove.

8. REMOVE SEAL PACKING FROM INVERTER WITH CONVERTER ASSEMBLY

(a) Using a finger, remove any seal packing that has seeped into the inverter with converter assembly.

HINT:

Make sure to remove any seal packing which has seeped toward the inside of inverter with converter assembly before installing the seal packing removal cover, otherwise the seal packing may be pushed into the inverter with converter assembly.

(b) Break off the seal packing removal cover and scraper at each break off line.

(c) Set the seal packing removal cover on the inverter with converter assembly and secure it by lightly pressing it at the 2 areas shown in the illustration.

*a	A-A Cross Section	*b	B-B Cross Section
	Push	-	-

NOTICE:

Make sure that the seal packing removal cover is in secure contact with the inside surface of the inverter with converter assembly without any gaps.

(d) Place the inverter with converter assembly on its side on an antistatic mat as shown in the illustration. NOTICE: Make sure that the MG connector opening in the inverter with converter assembly is facing upward. Make sure that the inverter with converter assembly is oriented correctly, otherwise seal packing may enter the inverter with converter assembly.

*a MG Connector Opening

(e) Using a scraper, remove any remaining seal packing from the inverter with converter assembly.

HINT:

Use the small end of the scraper to remove seal packing from small areas such as bolt holes.

(f) Using a clean piece of cloth, clean the sealing surfaces of the inverter with converter assembly.

(g) Remove the seal packing removal cover. NOTICE: Make sure that the inverter with converter assembly is oriented correctly, otherwise seal packing may enter the inverter with converter assembly when removing the seal packing removal cover.

(h) Check for and remove any foreign matter which has entered the inverter with converter assembly.

(i) Set the inverter with converter assembly upright.

(j) Clean the seal packing removal cover.

HINT:

As the seal packing removal cover will be reused, it is necessary to clean it to prevent foreign matter from entering the inverter with converter assembly and prevent damage.

9. REMOVE MOTOR GENERATOR CONTROL ECU KIT

CAUTION:

To prevent foreign matter from entering the inverter with converter assembly, once the seal packing removal cover has been removed, work cannot be suspended until the motor generator control ECU kit is reinstalled.

(a) Install the seal packing removal cover to the inverter with converter assembly.

HINT:

The seal packing removal cover is installed to help prevent the motor generator control computer kit from being damaged if a part or tool is dropped on it.

(b) Install the 2 guide pins by hand at the positions shown in the illustration. NOTICE: Make sure that the guide pins are tightened securely.

(c) Remove the seal packing removal cover.

(d) Check that the 4 screws of the circuit board replacement jig are unlocked, and then while holding the circuit board replacement jig by the ribs, align it with the guide pins and set it on the inverter with converter assembly.

HINT:

Make sure that circuit board replacement jig is perfectly level with the sealing surface.

	Unlock
	Rib

(e) Secure the circuit board replacement jig with the 2 bolts supplied with the circuit board replacement jig.

*a	Locked
*b	Knob
	Bolt
	Lock

NOTICE:

Tighten the bolt by hand until the head contacts the jig.

(f) Lock the 4 screws as shown in the illustration to secure the circuit board replacement jig to the circuit board.

NOTICE:

When locking the screws of the circuit board replacement jig, do not apply excessive force to the screws, otherwise the circuit board replacement jig may be damaged.

HINT:

Make sure that the screws of the circuit board replacement jig are securely locked.

(g) Turn the 4 knobs of the circuit board replacement jig clockwise and secure the 4 screws of the circuit board replacement jig.

(h) Using SST, release the lock of each vibration dampening connector and raise the 28 vibration dampening connectors until they reach the stopper of the circuit board replacement jig.

SST: 09905-00040

NOTICE:

When disconnecting the vibration dampening connectors, release the lock of each connector with SST and then carefully lift the connector the specified amount.

(i) Using the screwdriver supplied with the circuit board replacement jig, remove the 3 bolts (A).

HINT:

If the bolts are difficult to remove from the circuit board replacement jig, use a magnet hand.

	Bolt (A)
	Bolt (B)

(j) Using the screwdriver supplied with the circuit board replacement jig, remove the 13 bolts (B).

HINT:

If the bolts are difficult to remove from the circuit board replacement jig, use a magnet hand.

(k) Remove the 2 inverter upper cover installation bolts.

(l) While holding the circuit board replacement jig by the ribs, evenly lift the circuit board replacement jig and circuit board straight up and remove it.

Rib

(m) Place the circuit board replacement jig upside down on a clean workbench.

(n) Check that the terminals of the inverter with converter assembly are not bent or damaged and that it is free of foreign matter.

(o) Turn the 4 knobs of the circuit board replacement jig counterclockwise and release the 4 screws of the circuit board replacement jig.

*a	Hold here	*b	Do not hold here
*c	Circuit Board	*d	Circuit Board Replacement Jig
*e	Knob	-	-
	Unlock	-	-

(p) Unlock the 4 circuit board replacement jig screws, and then while holding the sides of the circuit board or the top and bottom of the circuit board at the areas shown in the illustration, lift the circuit board to remove it from the circuit board replacement jig.

NOTICE:

Be careful not to touch any part of the circuit board other than the specified areas.

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