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Inverter With Converter: Removal

  1. PRECAUTION 

    (See PRECAUTION )

  2. REMOVE ENGINE ROOM SIDE LH COVER No. 2  (See REMOVAL )
  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  4. REMOVE SERVICE PLUG GRIP  (See REMOVAL )
  5. DRAIN COOLANT  (See COOLANT )
  6. REMOVE FRONT SUSPENSION BRACE SUB-ASSEMBLY UPPER CENTER  (See REMOVAL )
  7. REMOVE AIR CLEANER CAP W/INLET  (See REMOVAL )
  8. REMOVE AIR CLEANER W/RESONATOR  (See REMOVAL )
  9. REMOVE INVERTER BRACKET No. 5  (See REMOVAL )
  10. REMOVE POWER STEERING ECU ASSEMBLY  (See REMOVAL )
  11. DISCONNECT 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 1: Locating Circuit Breaker Sensor No. 1
      G05201734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. DISCONNECT ENGINE ROOM WIRE No. 2 
    1. Remove the nut from the engine room wire No. 2.
    2. Release the claw, and disconnect the engine room wire No. 2.
      Fig 2: Disconnecting Engine Room Wire No. 2
      G05201735Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE INVERTER RESERVE TANK SUB-ASSEMBLY 
    1. Remove the 2 bolts and inverter reserve tank sub-assembly.
      Fig 3: Locating Inverter Reserve Tank Bolts
      G05201736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the 2 clamps, and disconnect the 2 water hoses from the inverter reserve tank sub-assembly.
      Fig 4: Locating Water Hoses To Inverter Reserve Tank Sub-Assembly
      G05201737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. DISCONNECT WATER HOSE 
    1. Slide the clamp, and disconnect the water hose from the w/ converter inverter assembly.
      Fig 5: Locating Water Hose To W/ Converter Inverter Assembly
      G05201738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DISCONNECT POWER STEERING ECU BRACKET 
    1. Remove the bolt, and disconnect the power steering ECU bracket.
      Fig 6: Locating Power Steering ECU Bracket Bolt
      G05201739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE INVERTER COVER 
    1. Remove the bolt and interlock bracket.
      Fig 7: Locating Interlock Bracket Bolt
      G05201740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Insulate the removed terminal with insulating tape.
      NOTE: Make sure that the terminal does not stick out from the insulating tape.
      Fig 8: Insulating Terminal With Tape
      G05201741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 12 bolts and inverter cover.
      Fig 9: Installing Inverter Cover
      G05201742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. VERIFY THAT VOLTAGE OF W/CONVERTER INVERTER ASSEMBLY IS 0V 
    CAUTION: Wear insulating gloves.
    NOTE:
    • Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly (See PRECAUTION ).
    • Do not allow any foreign objects or waterdrops to enter the w/ converter inverter assembly.
    1. Using the voltmeter, measure the voltage between the terminals of the 2 phase connectors (N-P).

      Standard voltage: 0V 

      Fig 10: Measuring Voltage Between Terminals Of 2 Phase Connectors (N-P)
      G05201743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Use measuring range of DC 750 V or more on the voltmeter.

  18. SEPARATE ENGINE WIRE No. 4 
    CAUTION: Wear insulating gloves.
    NOTE:
    • Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly (See PRECAUTION ).
    • Do not allow any foreign objects or waterdrops to enter the w/ converter inverter assembly.
    1. Remove the bolt, and disconnect the engine wire No. 4 from the w/ converter inverter assembly.
      Fig 11: Locating Engine Wire No. 4 To W/ Converter Inverter Assembly
      G05201744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connector, clamps and grommet, and separate the engine wire No. 4 from the w/ converter inverter assembly.
  19. DISCONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR 
    CAUTION: Wear insulating gloves.
    NOTE:
    • Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly (See PRECAUTION ).
    • Insulate the removed terminals with insulating tape.
    • Do not allow any foreign objects or waterdrops to enter the w/ converter inverter assembly.
    1. Remove the 5 bolts, and disconnect the high voltage cables of the Motor from the w/ converter inverter assembly.
      Fig 12: Locating High Voltage Cable Bolts
      G05201745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 bolts, and disconnect the high voltage cables of the Generator from the w/ converter inverter assembly.
      3. Fig 13: Locating High Voltage Cable Bolts
      G05201746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. DISCONNECT MG ECU CONNECTOR 
    CAUTION: Wear insulating gloves.
    NOTE:
    • Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly (See PRECAUTION ).
    • Do not allow any foreign objects or waterdrops to enter the w/ converter inverter assembly.
    1. Disconnect the 2 connectors and grommets from the w/ converter inverter assembly.
      2. Fig 14: Locating Connectors And Grommets
      G05201747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. DISCONNECT No. 3 WIRE FRAME 
    CAUTION: Wear insulating gloves.
    NOTE:
    • Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly (See PRECAUTION ).
    • Insulate the removed terminals with insulating tape.
    • Do not allow any foreign objects or waterdrops to enter the w/ converter inverter assembly.
    1. Remove the 5 bolts, and disconnect the No. 3 wire frame (high voltage cables of the rear motor) from the w/ converter inverter assembly, (for 4WD)
      Fig 15: Locating No. 3 Wire Frame Bolts
      G05201748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and lift the lever to disconnect the No. 3 wire frame from the w/ converter inverter assembly.
      Fig 16: Disconnecting No. 3 Wire Frame From W/ Converter Inverter Assembly
      G05201749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL INVERTER COVER 
    1. Temporarily install the inverter cover with the 2 bolts to prevent any foreign objects or waterdrops from entering the w/ converter inverter assembly.
      Fig 17: Locating Inverter Cover Bolts
      G05201750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. SEPARATE ENGINE ROOM RELAY BLOCK ASSEMBLY 
    1. Disconnect the clamp, and release the engine room relay block assembly.
      Fig 18: Identifying Engine Room Relay Block Assembly
      G05201751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE INVERTER BRACKET No. 4 
    1. Remove the 2 bolts and inverter bracket No. 4.
      2. Fig 19: Locating Inverter Bracket No. 4 Bolts
      G05201752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE W/CONVERTER INVERTER ASSEMBLY 
    CAUTION: Wear insulating gloves.
    1. Remove the 2 nuts, bolt and w/ converter inverter assembly.
      Fig 20: Locating W/ Converter Inverter Assembly Nuts And Bolt
      G05201753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • 2 people are needed to remove the w/ converter inverter assembly.
      • If removing and storing the w/ converter inverter assembly, make sure to install the inverter cover to prevent any foreign objects or warterdrops from entering the w/ converter inverter assembly.
      • Attach tape or equivalent (any adhesive should not be remained) to the holes for the connectors and grommets to prevent foreign matter or water from entering.
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