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Removal [07/2022 - ]: Procedure

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  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 [07/2022 - ]

  2. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [07/2022 - ]

  3. REMOVE REAR ENGINE UNDER COVER LH 

    Refer to PROCEDURE - Step 1

  4. DRAIN COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 2

  5. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 4

  6. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  7. REMOVE AIR CLEANER CASE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 16

  8. REMOVE ECM 

    Refer to REMOVAL [07/2022 - ]

  9. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  10. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Remove the bolt.
      GTY787004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 clamps to separate the transmission control cable assembly.
  11. DISCONNECT ENGINE WIRE 
    WARNING:

    Wear insulated gloves.

    NOTE:

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

    1. Disconnect the 3 No. 1 engine room relay block connectors.
      GTY837115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 claws to separate the engine wire from the No. 1 engine room relay block.
    3. Remove the nut.
      GTY819950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the 2 claws to separate the engine wire from the No. 1 engine room relay block.
    5. Move each lock lever as shown in the illustration and disconnect the 2 inverter with converter assembly connectors.
      NOTE:
      • 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.
      • 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 inverter with converter assembly.
      • Insulate the disconnected terminals with insulating tape.
      GTY786997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 2 nuts.
      GTY829886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Disengage the clamp and disconnect the engine wire.
  12. REMOVE CONNECTOR COVER ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. Remove the bolt (B).
      GTY831098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt (A)
      *b Bolt (B)
    2. Using a T25 "TORX" socket wrench, remove the bolt (A) and connector cover assembly from the inverter with converter assembly.
      NOTE:
      • Do not touch the connector cover assembly waterproof seal.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
  13. CHECK TERMINAL VOLTAGE 
    WARNING:

    Wear insulated gloves.

    NOTE:

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

    1. 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 more on the voltmeter.

      GTY541774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. Temporarily install the connector cover assembly to the inverter with converter assembly.
      GTY787035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a T25 "TORX" socket wrench, install the bolt.

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

      NOTE:

      Do not touch the waterproof seal of the connector cover assembly.

  15. DISCONNECT FLOOR UNDER WIRE 
    WARNING:

    Wear insulated gloves.

    NOTE:

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

    1. Remove the bolt and disconnect the HV floor under wire from the inverter with converter assembly.
      GTY805341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
      NOTE:
      • 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.
      • 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 inverter with converter assembly.
      • Insulate the disconnected terminals with insulating tape.
    2. Disengage the 2 clamps.
  16. DISCONNECT HV AIR CONDITIONING WIRE 
    WARNING:

    Wear insulated gloves.

    1. Remove the 2 bolts and disconnect the HV air conditioning wire from the inverter with converter assembly.
      GTY799973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
      NOTE:
      • 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.
      • 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 inverter with converter assembly.
      • Insulate the disconnected terminals with insulating tape.
    2. Disengage the clamp.
  17. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. Remove the nut and wire harness clamp bracket.
      GTY787038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DISCONNECT NO. 6 ENGINE WIRE 
    WARNING:

    Wear insulated gloves.

    1. Remove the bolt and disconnect the engine wire from the inverter with converter assembly.
      GTY787039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and disconnect the engine wire from the inverter with converter assembly.
      GTY787031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the claws and open the engine wire terminal cover.
      GTY787022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the nut.
      GTY787024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disengage the clamp and disconnect the engine wire from the inverter with converter assembly.
  19. DISCONNECT NO. 1 INVERTER COOLING HOSE ASSEMBLY 
    1. Slide the clip and disconnect the outlet No. 1 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.

      GTY787052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. DISCONNECT INLET NO. 1 INVERTER COOLING HOSE 
    1. Slide the clip and disconnect the inlet No. 1 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.

      GTY787053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE AIR CLEANER BRACKET 
    1. Disengage the clamp.
      GTY964830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and air cleaner bracket.
  22. REMOVE INVERTER COVER 
    WARNING:

    Wear insulated gloves.

    1. Remove the 2 bolts and inverter cover from the inverter with converter 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 inverter with converter 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.
        GTY596587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Inverter Cover
        *a Screw
      • Although the inverter cover may feel loose, this is not due to a malfunction.

      HINT: 

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

      GTY779586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      GTY785230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Interlock
      *b Waterproof Seal
  23. DISCONNECT MOTOR CABLE 
    WARNING:

    Wear insulated gloves.

    1. Using an insulated tool, remove the 6 bolts.
      GTY542955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
    2. Remove the 4 bolts and disconnect the motor cable from the inverter with converter assembly.
      GTY793085Courtesy 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.
      • To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.
        GTY787057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE INVERTER WITH CONVERTER ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. Remove the 5 bolts, 2 nuts and inverter with converter assembly.
      GTY829892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • 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 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 inverter with converter assembly so that coolant does not spill out.

  25. REMOVE NO. 1 INVERTER BRACKET 
    1. Set the inverter with converter assembly on wooden blocks.
      GTY781435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
      NOTE:

      Make sure to support the inverter with converter assembly at the positions shown in the illustration, otherwise it may be damaged.

      GTY829888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE NO. 2 INVERTER BRACKET 
    1. Remove the 2 bolts and No. 2 inverter bracket from the inverter with converter assembly.
      GTY795282Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
  27. REMOVE TRANSMISSION CONTROL CABLE SUPPORT 
    1. Remove the bolt and transmission control cable support from the inverter with converter assembly.
      GTY829895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. Remove the 2 bolts and wire harness clamp bracket from the inverter with converter assembly.
      GTY787072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and wire harness clamp bracket from the inverter with converter assembly.
      GTY787073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and wire harness clamp bracket from the inverter with converter assembly.
      GTY787074Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE INVERTER PROTECTOR 
    1. Remove the bolt and inverter protector from the inverter with converter assembly.
      GTY964825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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