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Home >> Toyota >> 2006 >> Prius >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Testing and Diagnosis >> P112 Hybrid Vehicle Control - On-Vehicle Inspection, Removal & Installation >> Inverter With Converter >> Removal

Inverter With Converter: Removal

CAUTION:
  • When working on high voltage systems, always wear insulating gloves.
  • 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.
NOTE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU.
  1. PRECAUTION 
    CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures (see PRECAUTION ).
  2. REMOVE ENGINE UNDER COVER LH 
  3. REMOVE ENGINE UNDER COVER RH 
  4. DRAIN HV COOLANT (See  REPLACEMENT  ) 
  5. REMOVE REAR NO. 2 FLOOR BOARD (See  REMOVAL  ) 
  6. REMOVE REAR DECK FLOOR BOX (See  REMOVAL  ) 
  7. REMOVE REAR NO. 3 FLOOR BOARD (See  REMOVAL  ) 
  8. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
  9. REMOVE SERVICE PLUG GRIP (See  REMOVAL  ) 
  10. REMOVE FRONT WIPER ARM COVER 
  11. REMOVE FRONT WIPER ARM RH (see  REMOVAL  ) 
  12. REMOVE FRONT WIPER ARM LH (see  REMOVAL  ) 
  13. REMOVE HOOD TO COWL TOP SEAL (see  REMOVAL  ) 
  14. REMOVE COWL TOP VENTILATOR LOUVER LH (see  REMOVAL  ) 
  15. REMOVE COWL TOP VENTILATOR LOUVER RH (see  REMOVAL  ) 
  16. REMOVE FRONT WIPER LINK AND WIPER MOTOR ASSEMBLY (see  REMOVAL  ) 
  17. REMOVE FRONT COWL TOP PANEL OUTER ((See  REMOVAL  ) 
  18. REMOVE RADIATOR SUPPORT OPENING COVER 
  19. REMOVE INVERTER COVER 
    1. Using a T30 "Torx" socket, remove the screw.
    2. Remove the 12 bolts and inverter cover.
      Fig 1: Removing Screw
      G04473726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. VERIFY THAT VOLTAGE OF INVERTER WITH CONVERTER IS 0 V 
    CAUTION: Wear insulating gloves.
    1. Using a voltmeter, measure the voltage of the high voltage DC line.

      Standard voltage: 0 V 

      HINT:

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

      Fig 2: Measuring The Voltage Of The High Voltage DC Line
      G04473727Courtesy 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 voltage: 0 V 

      HINT:

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

      Fig 3: Identifying Terminals Of The Three Phase Connector
      G04473728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. DISCONNECT NO. 2 INVERTER COOLING HOSE 
    Fig 4: Disconnecting No 2 Inverter Cooling Hose
    G04473729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT NO. 1 INVERTER COOLING HOSE 
    Fig 5: Disconnecting No 1 Inverter Cooling Hose
    G04473730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT NO. 6 INVERTER COOLING HOSE 
    Fig 6: Disconnecting No 6 Inverter Cooling Hose
    G04473731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. DISCONNECT NO. 1 CIRCUIT BREAKER SENSOR 
    1. Move the outer section to the wire harness side as illustrated, and then disconnect the circuit breaker sensor.
      Fig 7: Disconnecting Circuit Breaker Sensor
      G04473732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. DISCONNECT FRAME WIRE 
    CAUTION:
    • 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 inverter with converter assembly.
      Fig 8: Removing Frame Wire Connectors
      G04473733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE INVERTER WITH CONVERTER ASSEMBLY 
    1. Using a small screwdriver, lift up the lock pin (green) as illustrated to unlock it.
      CAUTION: Wear insulating gloves.
    2. Disconnect the connector for the air conditioning inverter.
      CAUTION: Wear insulating gloves.
      Fig 9: Unlocking Lock Pin
      G04473734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the 3 connectors shown in the illustration.
      Fig 10: Disconnecting Connectors
      G04473735Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the 3 connectors shown in the illustration and the engine main wire harness.
      Fig 11: Disconnecting Connectors
      G04473736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 5 bolts, then disconnect the MG2 power cable.
      CAUTION:
      • Wear insulating gloves.
      • Insulate the connector parts with insulating tape.
      Fig 12: Disconnecting MG2 Power Cable
      G04473737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 5 bolts, then disconnect the MG1 power cable.
      CAUTION:
      • Wear insulating gloves.
      • Insulate the connector parts with insulating tape.
      Fig 13: Disconnecting MG1 Power Cable
      G04473738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 3 bolts and the inverter with converter assembly.
      Fig 14: Removing Inverter With Converter Assembly
      G04473739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Disconnect the connector for the air conditioning inverter from the bracket.
    9. Remove the bolt and connector bracket for the air conditioning inverter.
      Fig 15: Removing Connector Bracket For The Air Conditioning Inverter
      G04473740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE NO. 1 INVERTER BRACKET 
    1. Remove the 2 bolts and inverter bracket.
      Fig 16: Removing No 1 Inverter Bracket
      G04473741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE NO. 2 INVERTER BRACKET 
    1. Remove the 2 bolts and inverter bracket.
      Fig 17: Removing No 2 Inverter Bracket
      G04473742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE NO. 1 CIRCUIT BREAKER SENSOR 
    1. Remove the 2 bolts and circuit breaker sensor.
      Fig 18: Removing No 1 Circuit Breaker Sensor
      G04473743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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