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Removal [11/2021 - ]: Procedure

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  1. REMOVE INVERTER WITH CONVERTER ASSEMBLY 

    Refer to REMOVAL [11/2021 - ] 

  2. REMOVE NO. 1 INVERTER BRACKET 
    See step  23
  3. REMOVE NO. 2 INVERTER BRACKET 

    See step  24

  4. REMOVE WIRE HARNESS CLAMP BRACKET 

    See step  25

  5. REMOVE WIRE HARNESS CLAMP BRACKET 

    See step  26

  6. REMOVE WIRE HARNESS CLAMP BRACKET 

    See step  27

  7. REMOVE HYBRID INVERTER PROTECTOR ASSEMBLY 

    See step  28

  8. VERIFY THAT VOLTAGE OF INVERTER WITH CONVERTER IS 0 V 
    WARNING:

    Be sure to wear insulated gloves.

    NOTE:

    Do not allow any foreign matter or water to enter the inverter with converter assembly.
    1. GTY1203724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the protective tape from the HV floor under wire opening.
    2. GTY1204052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Voltage Measurement Position - -
      1. Using a voltmeter, measure the voltage between the high voltage cable connector terminals.

        Standard voltage

        0 V

        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.
    3. GTY1203724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Apply protective tape to the area that was exposed.
        NOTE:

        Use non-residue type tape.

  9. CLEAN INVERTER WITH CONVERTER ASSEMBLY 
    NOTE:

    To prevent foreign matter from entering the inverter with converter assembly, make sure that the protective tape is not partially removed.
    1. GTY1204643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a piece of cloth, clean the outside of the inverter with converter assembly and around the bolts.
  10. HOW TO PREVENT STATIC ELECTRICITY 
    NOTE:
    • Static electricity should be eliminated when removing/installing the inverter with converter assembly.
    • Do not touch the electronic components of a circuit board.
    • Keep clothes away from electronic components.
    • Place the inverter with converter assembly and any removed electronic components on SST (antistatic mat).
    1. GTY1204809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Wear an antistatic wrist strap.
        • SST: 09890-47010 
      2. Connect the ground clip of the antistatic mat securely to a ground point provided in the workshop or on a workbench (anchor bolt).
      3. Connect the ground clip of the antistatic wrist strap securely to the specified point of the antistatic mat.
      4. If the ground clip cable is too short, use an extension cable.
      5. 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.
  11. DRAIN COOLANT (for Inverter) 
    1. GTY1204158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Place the inverter with converter assembly on a stand as shown in the illustration.
        NOTE:
        • Make sure to use the stand, otherwise the low voltage connectors or inverter upper cover may be damaged.
        • Make sure to place the inverter with converter assembly on the stand so that the coolant pipes are positioned downward.
      2. Connect the ground clip of the antistatic wrist strap securely to the inverter with converter assembly.
      3. Remove the 2 caps from the coolant pipes and drain the coolant (for inverter).
    2. GTY1205311Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Blow compressed air into the inverter with converter assembly until most all of the coolant (for inverter) is blown out.
        NOTE:
        • Do not damage the coolant pipes.
        • Apply compressed air to the silver colored coolant pipe.
      2. Use a piece of cloth as shown in the illustration to prevent the coolant (for inverter) from spraying.
      3. Cover the air inlet port with a piece of cloth to minimize air leakage.
      4. Install the 2 caps to the coolant pipes.
  12. REMOVE CONVERTER COVER 
    1. GTY1204063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. GTY1203864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a screwdriver with its tip wrapped with protective tape, remove the converter cover from the inverter with converter assembly.
        NOTE:
        • Do not damage the sealing surfaces of the inverter with converter assembly.
        • Do not touch or allow grease or oil to contact the sealing surfaces of the inverter with converter assembly.
        • Be careful not to damage the sealing surfaces of the inverter with converter assembly.
        • To prevent internal components of the inverter with converter assembly from being damaged, do not insert the screwdriver excessively.
  13. REMOVE SEAL PACKING FROM INVERTER WITH CONVERTER ASSEMBLY 
    NOTE:
    • Do not allow any removed seal packing to enter the inverter with converter assembly.
    • Do not touch the circuit board.
    • Do not allow any moisture to come into contact.
    1. GTY1205929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a finger, remove any seal packing that has seeped into the inverter with converter assembly.
        NOTE:

        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.

      2. Break off the seal packing removal cover and scraper at each break off line.
      3. Set the seal packing removal cover on the inverter with converter assembly and secure it with tape.
        NOTE:

        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.

    2. GTY1206110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a MG Connector Opening - -
      1. Place the inverter with converter assembly on its side on an antistatic mat as shown in the illustration.
        NOTE:
        • 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.
      2. Using a scraper, remove any remaining seal packing from the inverter with converter assembly.
        NOTE:
        • It is not necessary to remove small amounts of seal packing which are not easily scraped off.
          GTY686879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
          *a Correct *b Incorrect
          *c Width of Sealing Surface *d Difficult to Remove Seal Packing
          *e Peeled Off Seal Packing *f Seal Packing Remaining on Full Width of Sealing Surface
        • Make sure to use the scraper supplied with the seal packing removal cover.
          GTY731991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Remove the tape used to secure the seal packing removal cover and then remove any seal packing which was under the tape.
      4. Using a clean piece of cloth, clean the sealing surfaces of the inverter with converter assembly.
        NOTE:
        • Do not use compressed air or a vacuum cleaner to clean the sealing surfaces of the inverter with converter assembly.
        • Do not use non-residue solvent to clean the sealing surfaces of the inverter with converter assembly.
    3. GTY1204089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the seal packing removal cover.
        NOTE:

        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.

      2. Make sure that the inverter with converter assembly is free of foreign matter.
  14. REMOVE HV CONVERTER KIT 
    NOTE:
    • Do not touch the circuit board.
    • Do not allow any foreign matter or water to enter the inverter with converter assembly.
    1. GTY1205563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Place the inverter with converter assembly on a stand as shown in the illustration.
        NOTE:

        Make sure that the inverter with converter assembly is oriented correctly.

    2. GTY1203533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the 3 bolts (A) in the order shown in the illustration.
      2. Remove the 10 bolts (B).
    3. GTY1205579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Disengage the guide and disconnect the HV converter kit connector and set it as shown in the illustration.
        NOTE:

        Make sure that the wire harness of the connector is engaged to the filter condenser.

    4. GTY1206165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install 2 HV converter kit installation bolts at the positions shown in the illustration and tighten them in several steps to separate the HV converter kit from the inverter with converter assembly.
        NOTE:
        • Tighten the 2 bolts in several steps.
        • Do not forcibly separate the HV converter kit.
        • In order to prevent any foreign matter from entering the inverter with converter assembly, do not remove the bolts.
    5. GTY1206094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Do Not Allow Coolant (for Inverter) to Enter *b Hold Here
      Remove in this Direction - -
      1. Hold the corners of the HV converter kit and remove it as shown in the illustration.
        WARNING:
        • As there is a coolant passage underneath the HV converter kit, be careful not to spill any coolant (for inverter) into the filter condenser or the holes around the edge of the inverter with converter assembly.
        • If any coolant (for inverter) spills into the filter condenser or the holes around the edge of the inverter with converter assembly, do not reuse the inverter with converter assembly.
        • If any coolant (for inverter) spills onto any area other than the specified areas, remove it with a clean piece of cloth.
    6. GTY1204317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt Contacting Surface *b Bolt Hole
      1. Remove any metal shavings from the areas around the bolt holes and 2 positions where bolts were installed to separate the HV converter kit, using tape or equivalent.
    7. GTY1204767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a clean scraper, lift the O-ring at the position shown in the illustration and then remove it.
        WARNING:
        • When removing the O-ring, be careful not to spill any coolant (for inverter) into the filter condenser or the holes around the edge of the inverter with converter assembly.
        • If any coolant (for inverter) spills into the filter condenser or the holes around the edge of the inverter with converter assembly, do not reuse the inverter with converter assembly.
        • If any coolant (for inverter) spills onto any area other than the filter condenser or the holes around the edge of the inverter with converter assembly, remove it with a clean piece of cloth.
      2. Clean the O-ring groove of the inverter with converter assembly.
        NOTE:

        Make sure that the O-ring groove and coolant passage of the inverter with converter assembly are free of foreign matter.

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