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W/Converter Inverter ASSY: Replacement

NOTE:
  • When working on the high voltage systems, always wear insulating gloves. 
  • After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 
  • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. 
  • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. 
  1. PRECAUTION (SEE  PRECAUTION   ) 
  2. REMOVE ENGINE UNDER COVER LH 
  3. REMOVE ENGINE UNDER COVER RH 
  4. DRAIN HV COOLANT (See  COOLANT  ) 
  5. REMOVE REAR FLOOR BOARD NO.2 (See  SERVICE PLUG GRIP   ) 
  6. REMOVE DECK FLOOR BOX REAR (See  SERVICE PLUG GRIP   ) 
  7. REMOVE REAR FLOOR BOARD NO.3 (See  SERVICE PLUG GRIP   ) 
  8. DISCONNECT BATTERY NEGATIVE TERMINAL (See  SERVICE PLUG GRIP   ) 
  9. REMOVE SERVICE PLUG GRIP (See  SERVICE PLUG GRIP   ) 
  10. REMOVE FRONT WIPER ARM HEAD CAP (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  11. REMOVE FR WIPER ARM LH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  12. REMOVE FR WIPER ARM RH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  13. REMOVE HOOD TO COWL TOP SEAL (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  14. REMOVE COWL TOP VENTILATOR LOUVER LH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  15. REMOVE COWL TOP VENTILATOR LOUVER RH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  16. REMOVE WINDSHIELD WIPER MOTOR & LINK ASSY (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  17. REMOVE COWL TOP PANEL SUB-ASSY OUTER FRONT (SEE  REPLACEMENT  ) 
  18. REMOVE RADIATOR SUPPORT OPENING COVER 
  19. REMOVE INVERTER COVER 
    1. Using a T30 Torx socket wrench, remove the Torx screw.
    2. Remove the 12 bolts and inverter cover.
      Fig 1: Locating Torx Screw
      G02617189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. VERIFY THAT VOLTAGE OF W/CONVERTER INVERTER ASSY IS 0V 
    NOTE: Wear insulating gloves. 
    1. Using a voltmeter, measure the voltage of the high voltage DC line.

      Standard: 0 V 

      HINT:

      Use measuring range of DC 400 V or more on the voltmeter.

      Fig 2: Measuring Voltage Of High Voltage DC Line Using Voltmeter
      G02617190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using the voltmeter, measure the voltage between the terminals of the three phase connector (U - V, V - W, U - W).

      Standard: 0 V 

      HINT:

      Use measuring range of DC 400 V or more on the voltmeter.

      Fig 3: Measuring Voltage Between Terminals Of Three Phase Connector
      G02617191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. DISCONNECT INVERTER COOLING HOSE NO.2 
    Fig 4: Disconnecting Inverter Cooling Hose No.2
    G02617192Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT INVERTER COOLING HOSE NO.1 
    Fig 5: Disconnecting Inverter Cooling Hose No.1
    G02617193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT INVERTER COOLING HOSE NO.6 
    Fig 6: Disconnecting Inverter Cooling Hose No.6
    G02617194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. SEPARATE CIRCUIT BREAKER SENSOR NO.1 
    1. Move the outer section to the wire harness side as illustrated, then disconnect the circuit breaker sensor No. 1.
      Fig 7: Identifying Outer Section
      G02617195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. DISCONNECT FRAME WIRE 
    NOTE:
    • Wear insulating gloves. 
    • After removing the service plug grip, be sure to wait for at least 5 minutes before performing any work. 
    • Insulate the electrode and connector parts with insulating tape. 
    1. Remove the 2 frame wire connectors from the with converter inverter assembly.
      Fig 8: Removing Frame Wire Connectors From Converter
      G02617196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE W/CONVERTER INVERTER ASSY 
    1. Using a small screwdriver, lift up the lock pin (green) as illustrated to unlock.
      NOTE: Wear insulating gloves. 
    2. Disconnect the connector for the air conditioner inverter.
      NOTE: Wear insulating gloves. 
      Fig 9: Lifting Up Lock Pin Using Screwdriver
      G02617197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the 3 connectors shown in the illustration.
      Fig 10: Disconnecting Connectors
      G02617198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the 3 connectors shown in the illustration and the engine main wire harness.
      Fig 11: Locating Connector
      G02617199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 5 bolts, then disconnect the MG2 power cable.
      NOTE:
      • Wear insulating gloves. 
      • Insulate the connector parts with insulating tape. 
        Fig 12: Disconnecting MG2 Power Cable
        G02617200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 5 bolts, then disconnect the MG1 power cable.
      NOTE:
      • Wear insulating gloves. 
      • Insulate the connector parts with insulating tape. 
        Fig 13: Disconnecting MG1 Power Cable
        G02617201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 3 bolts and the with converter inverter assembly.
      Fig 14: Removing Bolts And Converter Inverter Assembly
      G02617202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Disconnect the connector for the air conditioner inverter from the bracket.
    9. Remove the bolt and connector bracket for the air conditioner inverter.
      Fig 15: Disconnecting Connector For Air Conditioner Inverter
      G02617203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE INVERTER BRACKET NO.1 
    1. Remove the 2 bolts and inverter bracket No. 1.
      Fig 16: Removing Inverter Bracket No.1
      G02617204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE INVERTER BRACKET NO.2 
    1. Remove the 2 bolts and inverter bracket No. 2.
      Fig 17: Removing Inverter Bracket No.2
      G02617205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE CIRCUIT BREAKER SENSOR NO.1 
    1. Remove the 2 bolts and circuit breaker sensor No. 1.
      Fig 18: Removing Circuit Breaker Sensor No.1
      G02617206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL CIRCUIT BREAKER SENSOR NO. 1 
    1. Install the circuit breaker sensor No. 1 with the 2 bolts.

      Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 

      Fig 19: Installing Circuit Breaker Sensor No. 1
      G02617207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL INVERTER BRACKET NO.2 
    1. Install the inverter bracket No. 2 with the 2 bolts.

      Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) 

      Fig 20: Installing Inverter Bracket No.2
      G02617208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL INVERTER BRACKET NO.1 
    1. Install the inverter bracket No. 1 with the 2 bolts.

      Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) 

      Fig 21: Installing Inverter Bracket No.1
      G02617209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL W/CONVERTER INVERTER ASSY 
    1. Install the connector bracket for the air conditioner inverter with the bolt.

      Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 

    2. Install the connector for the air conditioner inverter on the bracket.
      Fig 22: Installing Connector For Air Conditioner
      G02617210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the with converter inverter assembly with the 3 bolts.
      NOTE: Wear insulating gloves. 

      Torque: 21 N.m (214 kgf.cm, 16 ft.lbf) 

      Fig 23: Installing Converter Inverter Assembly
      G02617211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the MG1 power cable to the MG1 power cable terminal with the 5 bolts.
      NOTE: Wear insulating gloves. 

      Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 

      Fig 24: Installing MG1 Power Cable To MG1 Power Cable Terminal
      G02617212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the MG2 power cable to the MG2 power cable terminal with the 3 bolts.
      NOTE: Wear insulating gloves. 

      Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 

      Fig 25: Installing MG2 Power Cable To MG2 Power Cable Terminal
      G02617213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the 3 connectors shown in the illustration.
      NOTE: Wear insulating gloves. 
    7. Insert the grommet of the engine main wire harness into the U-shaped groove of the inverter case.
      NOTE: Wear insulating gloves. 
      Fig 26: Inserting Grommet Of Engine Main Wire Harness Into U-Shaped Groove
      G02617214Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Connect the 3 connectors shown in the illustration.
      NOTE: Wear insulating gloves. 
    9. Connect the connector for the air conditioner inverter, then lock the connector with the lock pin.
      NOTE: Wear insulating gloves. 
      Fig 27: Locating Connector
      G02617215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. CONNECT FRAME WIRE 
    NOTE: Wear insulating gloves. 
  35. CONNECT CIRCUIT BREAKER SENSOR NO.1 
    NOTE: Wear insulating gloves. 
  36. CONNECT INVERTER COOLING HOSE NO.6 
  37. CONNECT INVERTER COOLING HOSE NO.1 
  38. CONNECT INVERTER COOLING HOSE NO.2 
  39. INSTALL INVERTER COVER 
    1. Temporarily fasten the inverter cover with the 12 bolts and Torx screw.
    2. Tighten the 12 bolts.

      Torque: 11 N.m (112 kgf.cm, 8.1 ft.lbf) 

    3. Using a T30 Torx socket wrench, tighten the Torx screw.

      Torque: 11 N.m (112 kgf.cm, 8.1 ft.lbf) 

      Fig 28: Temporarily Fasten Inverter Cover
      G02617216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL RADIATOR SUPPORT OPENING COVER 
  41. INSTALL COWL TOP PANEL SUB-ASSY OUTER FRONT 
  42. INSTALL WINDSHIELD WIPER MOTOR & LINK ASSY 
  43. INSTALL COWL TOP VENTILATOR LOUVER RH 
  44. INSTALL COWL TOP VENTILATOR LOUVER LH 
  45. INSTALL HOOD TO COWL TOP SEAL 
  46. INSTALL FR WIPER ARM RH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  47. INSTALL FR WIPER ARM LH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  48. INSTALL FRONT WIPER ARM HEAD CAP 
  49. INSTALL SERVICE PLUG GRIP (See  SERVICE PLUG GRIP   ) 
    NOTE: Wear insulating gloves. 
  50. CONNECT BATTERY NEGATIVE TERMINAL 

    Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf) 

  51. INSTALL REAR FLOOR BOARD NO.3 
  52. INSTALL DECK FLOOR BOX REAR 
  53. INSTALL REAR FLOOR BOARD NO.2 
  54. ADD HV COOLANT (See  COOLANT  ) 
  55. CHECK FOR ENGINE COOLANT LEAKS (SEE  ON-VEHICLE INSPECTION  ) 
  56. INSTALL ENGINE UNDER COVER RH 
  57. INSTALL ENGINE UNDER COVER LH 
  58. POWER WINDOW CONTROL SYSTEM INITIALIZE (SEE  INITIALIZATION  ) 
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