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Converter & Inverter Assembly Removal

WARNING: This page is about a different car, the 2002 Toyota Prius. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove service plug  . See PRECAUTION .
  2. Drain HV coolant  . See Step 2)  in Replace Coolant in HYBRID TRANSAXLE ON-VEHICLE REPAIR .
  3. Remove COWL TOP PANEL .
  4. Verify "ZERO" V  .
    CAUTION:
    • Before starting step ( a), 5 minutes or more should be passed after removing the service plug.
    • Be careful to prevent foreign matter from entering the inside of connector cover.
    1. Disconnect the connector of the battery power cable and insulate it with packaging tape.
    2. Using a torx socket wrench (T30), remove the 4 screws and inverter terminal cover.
      3. NOTE: Slide the connector cover to disconnect the circuit breaker sensor connector.
    3. Using a torx socket wrench (T40), remove the 2 screws, circuit breaker sensor and connector cover.
    4. Using a voltmeter, measure the voltage between terminals of 3 phases (U-V, V-W, U-W) and each terminal and body ground to verify them to be approximately 0 V.
      Fig 1: Identifying Converter & Inverter Assembly
      G01066164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Remove converter & inverter assembly  :
      CAUTION: Be careful to prevent foreign matter from entering the inside of connector cover.
      Fig 2: Identifying MG2 Power Cable Securing & Terminal Bolts
      G01066165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 6 bolts and 3 power cables for MG2.
      2. CAUTION:
      • Remove the power cables for MG1 together with converter & inverter assembly.
      • Be careful to prevent foreign matter from entering the inside of connector cover.
      Fig 3: Identifying MG1 Power Cable Terminal Bolts
      G01066166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and power cables for MG1.
    3. Remove the bolt and ground cable.
    4. Disconnect the 3 water hoses from the converter & inverter assembly.
    5. Remove the 4 bolts and converter & inverter assembly.
      Fig 4: Locating Converter & Inverter Assembly Mounting Bolts & Water Hose Connections
      G01066167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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