Removal [08/2016 - 12/2017]: Procedure

REMOVE SERVICE PLUG GRIP
Refer to REMOVAL [08/2016 - 12/2017]
REMOVE FRONT WHEEL OPENING EXTENSION PAD LH
Refer to PROCEDURE - Step 4
REMOVE NO. 3 ENGINE UNDER COVER
Refer to PROCEDURE - Step 5
DRAIN COOLANT (for Inverter)
See step 3
REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE
Refer to REMOVAL [10/2015 - ]

REMOVE NO. 3 INVERTER BRACKET

Disengage the clamp.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Remove the bolt, nut and No. 3 inverter bracket.

REMOVE NO. 6 INVERTER BRACKET

Remove the bolt, nut and No. 6 inverter bracket.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE INVERTER RESERVE TANK ASSEMBLY

Disconnect the inverter drain hose from the clamp.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	No. 1 Inverter Cooling Hose
*2	Inverter Drain Hose

Slide the 3 clips and disconnect the No. 1 inverter cooling hose and 2 inverter drain hoses from the inverter reserve tank assembly.
NOTE:
Put pieces of cloth into the pipes and disconnected hoses or cover the pipes and hoses with plastic bags to prevent entry of foreign matter.

Remove the bolt, nut and inverter reserve tank assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE NO. 1 INVERTER RESERVE TANK BRACKET

Remove the 2 bolts and No. 1 inverter reserve tank bracket from the inverter with converter assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE INVERTER TERMINAL COVER

WARNING:

Wear insulated gloves.

Remove the 11 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 inverter terminal cover.
Do not touch the inverter terminal cover waterproof seal.
Do not allow any foreign matter or water to enter the inverter with converter assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Interlock
*b	Waterproof Seal

CHECK TERMINAL VOLTAGE

WARNING:

Wear insulated gloves.

NOTE:

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

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

Standard Voltage

0 V

HINT:

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

DISCONNECT HV AIR CONDITIONING WIRE

WARNING:

Wear insulated gloves.

Using an insulated tool, remove the 5 bolts and disconnect the HV air conditioning wire from the inverter with converter assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Waterproof Seal

NOTE:

Do not allow any foreign matter or water to enter the inverter with converter assembly.
Do not touch the waterproof seal or terminals of the connector.
Do not damage the terminals, connector housing 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.

DISCONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR

WARNING:

Wear insulated gloves.

Using an insulated tool, remove the 5 bolts and disconnect the high voltage cable of front motor (for Generator (MG1)) 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 waterproof seal or terminals of the connector.
Do not damage the terminals, connector housing 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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using an insulated tool, remove the 5 bolts and disconnect the high voltage cable of front motor (for Motor (MG2)) 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 waterproof seal or terminals of the connector.
Do not damage the terminals, connector housing 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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

DISCONNECT HV FLOOR UNDER WIRE

WARNING:

Wear insulated gloves.

Using an insulated tool, remove the 5 bolts and disconnect the HV floor under wire (for Rear Motor (MGR)) 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 waterproof seal or terminals of the connector.
Do not damage the terminals, connector housing 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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Waterproof Seal

Disengage the clamp.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using an insulated tool, remove the 4 bolts and disconnect the HV floor under wire (for HV Battery) 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 waterproof seal or terminals of the connector.
Do not damage the terminals, connector housing 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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Interlock
*b	Waterproof Seal

Disengage the 3 clamps.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEMPORARILY INSTALL INVERTER TERMINAL COVER

WARNING:

Wear insulated gloves.

Temporarily install the inverter terminal cover with the 11 bolts to prevent any foreign matter or water from entering the inverter with converter assembly.

NOTE:

Visually confirm that the inverter terminal cover waterproof seal is securely installed before installing the inverter terminal cover.
Do not touch the inverter terminal cover waterproof seal.
Make sure that the interlock is fully engaged.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

DISCONNECT LOW VOLTAGE CONNECTOR

WARNING:

Wear insulated gloves.

NOTE:

Insulate the disconnected connectors with insulating tape.
Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.

Move the lock lever as shown in the illustration and disconnect the low voltage connector.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Disconnect the low voltage connector.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

DISCONNECT WATER HOSE

Disengage the clamp.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Inlet No. 1 Inverter Cooling Hose
*2	Outlet No. 2 Inverter Cooling Hose

Slide the 2 clips and disconnect the inlet No. 1 inverter cooling hose and outlet No. 2 inverter cooling hose from the inverter with converter assembly.
NOTE:
Put pieces of cloth into the pipes and disconnected hoses or cover the pipes and hoses with plastic bags to prevent entry of foreign matter.

Release the retainer and disconnect the outlet No. 1 inverter cooling hose from the inverter with converter assembly as shown in the illustration.

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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Retainer

DISCONNECT NO. 2 ENGINE ROOM RELAY BLOCK

Disengage the clamp and disconnect the No. 2 engine room relay block.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

DISCONNECT NO. 5 ENGINE ROOM WIRE

Remove the No. 1 relay block cover from the No. 1 relay block cover.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Disengage the 3 claws and remove the No. 1 relay block cover from the engine room relay block and junction block assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Remove the nut.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Disengage the claw and disconnect the No. 5 engine room wire from the engine room relay block and junction block assembly.

REMOVE INVERTER WITH CONVERTER ASSEMBLY

WARNING:

Wear insulated gloves.

Remove the 2 bolts, nut and inverter with converter assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Since the inverter with converter assembly is very heavy, 2 people are needed to remove it. When removing the inverter with converter assembly, be careful not to damage the parts around it.
To prevent damage, do not hold the inverter with converter assembly by the connectors, brackets or pipes.
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 with converter assembly so that coolant does not spill out.

REMOVE INVERTER DRAIN HOSE

Slide the clip and remove the inverter drain hose from the inverter with converter 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.

REMOVE INVERTER COOLING PIPE

Slide the clip and disconnect the inlet No. 2 inverter cooling hose from the inverter with converter 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.

Remove the 2 bolts and inverter cooling pipe from the inverter with converter assembly.

REMOVE HIGH VOLTAGE FUSE

WARNING:

Wear insulated gloves.

HINT:

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

Remove the 11 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 inverter terminal cover.
Do not touch the inverter terminal cover waterproof seal.
Do not allow any foreign matter or water to enter the inverter with converter assembly.

Remove the 2 nuts and holder from the inverter with converter assembly.

NOTE:

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

Temporarily install the inverter terminal cover with the 11 bolts to prevent any foreign matter or water from entering the inverter with converter assembly.

NOTE:

Visually confirm that the inverter terminal cover waterproof seal is securely installed before installing the inverter terminal cover.
Do not touch the inverter terminal cover waterproof seal.
Make sure that the interlock is fully engaged.

Place the holder as shown in the illustration.

HINT:

Use either the location shown in the illustration or another method to hold the holder for the subsequent step.

Remove the 2 nuts and high voltage fuse from the holder.

REMOVE WIRE HARNESS CLAMP BRACKET

HINT:

Perform this procedure only when replacement of a wire harness clamp bracket is necessary.

Remove the bolt and wire harness clamp bracket from the inverter with converter assembly.

Disengage each clamp and remove the 2 clamps from the wire harness clamp bracket.

Remove the bolt and wire harness clamp bracket from the inverter with converter assembly.

REMOVE NO. 5 ENGINE ROOM WIRE

HINT:

Perform this procedure only when replacement of the No. 5 engine room wire is necessary.

Open the terminal cover.

*a	Terminal Cover

Remove the nut and No. 5 engine room wire from the inverter with converter assembly.