Lexus LS600L Dismantling Manual
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Lexus LS600L Dismantling Manual

Lexus LS600L Dismantling Manual

Gasoline-electric lexus hybrid drive
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Gasoline-Electric
Lexus Hybrid Drive
UVF45/46 Series

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Summary of Contents for Lexus LS600L

  • Page 1 Gasoline-Electric Lexus Hybrid Drive UVF45/46 Series...
  • Page 2 By following the information in this guide, dismantlers will be able to handle the LS600h/LS600hL hybrid-electric vehicles as safely as the dismantling of a conventional non-hybrid automobile. ¤ 2007 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.

  • Page 3: Table Of Contents

    Table of Contents About the LS600h/LS600hL ........................1 LS600h/LS600hL Identification ........................ 2 Exterior ................................. 3 LS600h/LS600hL Identification (Continued)................... 4 Interior ................................4 Engine Compartment............................ 5 Hybrid Component Locations & Descriptions ..................6 Specifications..............................7 Lexus Synergy Drive Operation........................ 8 Vehicle Operation ............................8 Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery ..............

  • Page 5: About The Ls600H/Ls600Hl

    About the LS600h/LS600hL The LS600h/LS600hL sedan joins the RX400h and GS450h 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: Gasoline stored in the fuel tank for the gasoline engine.

  • Page 6: Ls600H/Ls600Hl Identification

    LS600h/LS600hL Identification In appearance, the 2008 model year/2007 calendar year LS600h/LS600hL is nearly identical to the conventional, non-hybrid Lexus LS460/LS460L. The LS600h/LS600hL is a 4-door sedan and the suffix “L” indicates a long wheelbase. 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, driver door pillar, and engine compartment.

  • Page 7: Exterior

    Exterior n LS600h or LS600hL logos on the trunk. o HYBRID logos on the rear door moldings. p Lexus logos that have blue in the background. n LS600h or LS600hL Exterior Rear and Left Side View Exterior Left Side View Exterior Front View...

  • Page 8: Ls600H/Ls600Hl Identification (Continued)

    LS600h/LS600hL Identification (Continued) Interior q The instrument cluster (speedometer, fuel gauge, warning lights) located in the dash behind the steering wheel, is different than the one on the conventional, non-hybrid LS460/LS460L. r The hybrid system indicator (power meter) is located next to the tachometer. Hint: If the vehicle is shut off, the instrument cluster gauges will be “blacked out”, not illuminated.

  • Page 9: Engine Compartment

    Engine Compartment s 5.0-liter aluminum alloy gasoline engine. t Logo on the plastic engine cover. u Orange colored high voltage power cables. LEXUS HYBRID DRIVE Logo on Engine cover Engine Compartment Power Cables...

  • Page 10: Hybrid Component Locations & Descriptions

    Hybrid Component Locations & Descriptions Component* Location Description 12 Volt n Trunk, Driver Side A lead-acid battery that supplies power to the low voltage devices. Auxiliary Battery Hybrid o Trunk Area, Mounted 288 Volt Nickel Metal Hydride (NiMH) battery pack consisting of Vehicle (HV) to Cross Member and 20 low voltage (14.4 Volt) modules connected in series.

  • Page 11: Specifications

    Specifications Gasoline Engine: 390 hp (290 kW), 5.0-liter Aluminum Alloy Engine Electric Motor: 221 hp (165 kW), Permanent Magnet Motor Transmission: Automatic Only HV Battery: 288 Volt Sealed NiMH Battery Curb Weight: 5,004-5,357 lbs/2,270-2,430 kg Fuel Tank: 18.5 Imp gals, 22.1 US gals/84 liter Frame Material: Steel Unibody, Steel Panels and Aluminum Engine Hood This illustration is for an LHD model.

  • Page 12: Lexus Synergy Drive Operation

    Lexus Synergy 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.

  • Page 13: Hybrid Vehicle (Hv) Battery Pack And Auxiliary Battery

    Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery The LS600h/LS600hL 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 securely mounted in the trunk area behind the rear seat.

  • Page 14: Hv Battery Pack Recycling

    HV Battery Pack Recycling The HV battery pack is recyclable. Contact your Lexus Distributor as mentioned on HV battery Caution Label (see page 36) or the nearest Lexus dealer. Auxiliary Battery The LS600h/LS600hL also contains a lead-acid 12 Volt battery. This 12 Volt auxiliary battery powers the vehicle electrical system similar to a conventional vehicle.

  • Page 15: High Voltage Safety

    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, along the propeller shaft and transmission tunnel to the power control unit. The power control unit contains a circuit that boosts the HV battery voltage from 288 to 650 Volts DC.

  • Page 16: Service Plug Grip

    Service Plug Grip The high-voltage circuit is cut by removing the service plug grip (see page 15). High Voltage Safety System – Vehicle Shut Off (READY OFF) High Voltage Safety System – Vehicle On and Operational (READY ON)

  • Page 17: Precaution To Be Observed When Dismantling The Vehicle

    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.

  • Page 18: Spills

    Spills The LS600h/LS600hL contains the same common automotive fluids used in other non-hybrid Lexus vehicles, with the exception of 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.

  • Page 19: Dismantling A Vehicle

    Dismantling a vehicle The following 2 pages contain general instructions for use when working on an LS600h/LS600hL. Read these instructions before proceeding to the HV battery removal instructions on page 18. WARNING: ・ The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled.
  • Page 20 3. Carry the removed service plug grip in your pocket to prevent other staff from accidentally reinstalling it while you are dismantling the vehicle. 4. Make other staff aware that a high-voltage system is being dismantled by using the following sign: CAUTION: HIGH-VOLTAGE.

  • Page 22: Removal Of Hv Battery

    Removal of HV battery WARNING: ・ Be sure to wear insulated gloves when handling high-voltage parts. ・ Even if the vehicle is shut off and the relays are off, be sure to remove the service plug grip before performing any further work.
  • Page 23 6. Remove the service plug grip. Service Plug Grip (1) Pull the edge of the battery service hole cover outward. HV battery (2) Slide the cover to the left to remove Caution: Wear insulated gloves for the following 4 steps. (3) Slide the handle of the service plug grip to the left.
  • Page 24 8. Remove the 2 clips and motor cable cover. For LHD For RHD 9. Remove the 2 clips and inverter cover assembly. For LHD For RHD 10. Remove the 2 bolts and connector cover assembly 10 minutes or more after removal of the service plug grip.
  • Page 25 11. Check the voltage at the terminals in the inspection point in the power control unit. Caution: Wear insulated gloves. To prevent serious injury or death, do not proceed with dismantling of the HV system until the voltage at the terminals in the inspection point is 0 V. Standard voltage: 0 V Hint: Set the tester to DC 750 Volts measure the voltage.
  • Page 26 12. Remove the rear seat assembly (Power Seat Type). (1) Remove the seat cushion assemblies LH and RH. (2) Remove the center seat cushion assembly. (3) Cut the seat belts LH and RH. (4) Remove the rear seatback assemblies LH and RH. (5) Remove the center seatback assembly.
  • Page 27 13. Remove the rear seat assembly (Ottoman Power Seat Type). (1) Remove the seat cushion assemblies LH and RH. (2) Cut the seat belts LH and RH. (3) Remove the center console box assembly. (4) Remove the rear seatback assemblies LH and RH. (5) Remove the rear seatback adjuster assemblies LH and RH.
  • Page 28 14. Remove the rear seat assembly (Fixed Seat Type). (1) Remove the rear seat cushion assembly. (2) Cut the seat belts LH and RH. (3) Remove the rear seatback assembly.
  • Page 29 15. Remove the 3 clips and No. 1 center floor to brace extension. 16. Remove the 3 clips and No. 2 center floor to brace extension. 17. Remove the 2 hole plugs. 18. Remove the No. 2 HV battery shield sub-assembly.
  • Page 30 19. Disconnect the frame wire. (1) Remove the 2 nuts and disconnect the ends of the frame wire from the HV battery. Caution: Wear insulated gloves. Notice: Insulate the terminals of the removed frame wire with insulating tape. (2) Remove the battery shield contact Battery Shield Contact from the HV battery.
  • Page 31 23. Remove the 4 upper rope hooks by pushing the claws in the direction of the arrows shown in the illustration. 24. Remove the 4 bolts and 4 lower rope hooks. 25. Remove the clip and deck trim side board.
  • Page 32 26. Remove the No. 1 luggage compartment light assembly. (1) Using a screwdriver, disengage the 2 claws and remove the light assembly. (2) Disconnect the connector. 27. Remove the front luggage compartment trim cover. (1) Remove the 4 claws, 3 clips and front luggage trim cover (w/o rear air conditioning).
  • Page 33 30. Remove the clip and No. 3 HV No. 3 HV Battery Intake Duct battery intake duct. 31. Remove the No. 2 HV battery intake No. 2 HV Battery Intake Duct duct. 32. Disconnect the 2 connectors and remove the 3 nuts, clip and battery cooling blower assembly.
  • Page 34 Moving the HV battery. Caution: Wear insulated gloves. (1) Remove the 2 nuts, clamp and wire harness protector. (2) Release the claw and remove the 2 nuts and separate the frame wire from the luggage room junction block. (3) Disconnect the connector, disengage the 4 clamps and move the frame wire.
  • Page 35 (4) Disconnect the connector and disengage the 3 clamps. (5) Remove the nut and disconnect the AMD terminal. Notice: Insulate the terminal of the removed AMD wire with insulating tape to prevent a short to body ground. AMD terminal (6) Disconnect the connector clamp. (7) Remove the 4 screws, 2 bolts and 2 rear air conditioning brackets.
  • Page 36 (10) Disconnect the battery pack wire connector. (11) Remove the 2 clips, 4 nuts, 2 bolts and 2 HV battery brackets. (12) Remove the 3 bolts for the front part of the HV battery from the cabin side. (13) Install the luggage compartment floor mat upside down.
  • Page 37 (14) Pull out the HV battery onto the luggage compartment floor mat. Notice: When pulling out the HV battery, 2 people are needed. One should work Pull from the luggage compartment side and the other from the cabin side. Do not allow water in the rear air conditioning drain hose to spill out.
  • Page 38 37. Remove the HV battery. Caution: Wear insulated gloves. (1) Install the HV battery bracket LH to the position shown in the illustration. (2) Using an engine sling device, remove the HV battery from vehicle. Notice: Use cardboard or other similar material to protect the HV battery and vehicle body from damage.
  • Page 39 38. Remove the 2 nuts and No. 1 HV battery shield sub-assembly from the upper HV battery cover. Caution: Wear insulated gloves. 39. Remove the nut, disengage the 4 clamps and disconnect the power steering converter wire from the HV battery.

  • Page 40: Hv Battery Caution Label

    HV Battery Caution Label For U.S.A. For CANADA...
  • Page 41 For EUROPE and others For China...

This manual is also suitable for:

Ls600hlLs600hl

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