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Removal [10/2014 - ]: Procedure

  1. PRECAUTION 

    (Refer to PRECAUTION [10/2014 - ] )

  2. REMOVE SERVICE PLUG GRIP 

    (Refer to REMOVAL [10/2014 - ] )

  3. DRAIN COOLANT (for Inverter) 

    See step  1

  4. REMOVE CONNECTOR COVER ASSEMBLY 
    WARNING:
    • Do not touch the high voltage connectors and terminals for 10 minutes after the service plug grip is removed.
    • Wear insulated gloves.
    NOTE:

    Do not start the hybrid system with the service plug grip removed because it may cause a malfunction.

    1. Remove the 2 bolts and connector cover assembly from the inverter with converter assembly.
      GTY541826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure to pull the connector cover assembly straight up, as a connector is connected to the bottom of the cover.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
  5. CHECK TERMINAL VOLTAGE 
    WARNING:

    Wear insulated gloves.

    NOTE:

    Do not allow any foreign matter or water to enter the inverter with converter assembly.

    1. Using a voltmeter, measure the voltage between the terminals.
      GTY541828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Voltage

      0 V

      HINT: 

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

  6. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. Temporarily install the connector cover assembly with the bolt to prevent any foreign matter or water from entering the inverter with converter assembly.
      GTY317959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 1 and PROCEDURE - Step 1

  8. REMOVE INLET AIR CLEANER ASSEMBLY 

    Refer to PROCEDURE - Step 23

  9. REMOVE AIR CLEANER CAP SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  10. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 25

  11. REMOVE AIR CLEANER CASE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 26

  12. REMOVE NO. 5 INVERTER BRACKET 
    1. Remove the 2 bolts and No. 5 inverter bracket.
      GTY317960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE NO. 4 INVERTER BRACKET 
    1. Remove the 3 bolts and No. 4 inverter bracket.
      GTY370091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE UPPER INVERTER COVER 
    WARNING:

    Wear insulated gloves.

    1. Remove the 2 bolts and upper inverter cover (generator cable side) from the inverter with converter assembly.
      GTY322589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure to pull the upper inverter cover straight up, as a connector is connected to the bottom of the cover.
      • Do not touch the upper inverter cover waterproofing rubber.
  15. DISCONNECT GENERATOR CABLE 
    WARNING:

    Wear insulated gloves.

    1. Using an insulated tool, remove the 3 bolts from the inverter with converter assembly.
      GTY317956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 2 wire harness clamps and generator cable.
      GTY317922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not damage the terminals, connector housings or inverter with converter assembly during disconnection.
      • Do not touch the connector waterproofing rubber or terminals.
      • Insulate the removed terminals with insulating tape.
      • Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter.
  16. REMOVE UPPER INVERTER COVER 
    WARNING:

    Wear insulated gloves.

    1. Remove the 2 bolts and upper inverter cover (motor cable side) from the inverter with converter assembly.
      GTY317921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure to pull the upper inverter cover straight up, as a connector is connected to the bottom of the cover.
      • Do not touch the upper inverter cover waterproofing rubber.
  17. DISCONNECT MOTOR CABLE 
    WARNING:

    Wear insulated gloves.

    1. Using an insulated tool, remove the 3 bolts from the inverter with converter assembly.
      GTY369583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 3 wire harness clamps and motor cable.
      GTY369582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not damage the terminals, connector housings or inverter with converter assembly during disconnection.
      • Do not touch the connector waterproofing rubber or terminals.
      • Insulate the removed terminals with insulating tape.
      • Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter.
  18. REMOVE NO. 3 MOTOR CABLE BRACKET 
    1. Disconnect the hose clamp from the No. 3 motor cable bracket.
      GTY322581Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not remove the hose clamp from the hose.

    2. Remove the 2 bolts and No. 3 motor cable bracket from the inverter with converter assembly.
      GTY369584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE CONNECTOR COVER ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. Remove the bolt and connector cover assembly from the inverter with converter assembly.
      GTY317926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure to pull the connector cover assembly straight up, as a connector is connected to the bottom of the cover.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
  20. DISCONNECT NO. 4 ENGINE WIRE 
    WARNING:

    Wear insulated gloves.

    1. Disconnect the No. 4 engine wire from the inverter with converter assembly.
      GTY317920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not damage the terminals, connector housings or inverter with converter assembly during disconnection.
      • Do not touch the connector waterproofing rubber or terminals.
      • Insulate the removed terminals with insulating tape.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
    2. Disconnect the wire harness clamp from the No. 2 motor cable bracket.
      GTY368683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. DISCONNECT NO. 4 FLOOR WIRE 
    WARNING:

    Wear insulated gloves.

    1. Remove the bolt from the inverter with converter assembly.
      GTY541703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the wire harness clamp and No. 4 floor wire.
      GTY541704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not damage the terminals, connector housings or inverter with converter assembly during disconnection.
      • Do not touch the connector waterproofing rubber or terminals.
      • Insulate the removed terminals with insulating tape.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
  22. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. Temporarily install the connector cover assembly with the bolt to prevent any foreign matter or water from entering the inverter with converter assembly.
      GTY317959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT LOW VOLTAGE CONNECTOR 
    WARNING:

    Wear insulated gloves.

    1. Raise the lock lever and disconnect the 3 low voltage connectors from the inverter with converter assembly.
      GTY317928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Insulate the removed terminals with insulating tape.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
  24. DISCONNECT NO. 3 ENGINE ROOM WIRE 
    1. Remove the No. 1 relay block cover from the engine room relay block and junction block assembly.
    2. Remove the nut from the engine room relay block and junction block assembly.
      GTY317930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the wire harness clamp and No. 3 engine room wire from the engine room relay block and junction block assembly.
  25. REMOVE NO. 4 INVERTER COOLING HOSE 
    1. Release the retainer and disconnect the No. 4 inverter cooling hose from the inverter with converter assembly.
      GTY583517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
    2. Put pieces of cloth into the pipe and disconnected hose, or cover the pipes and hoses with plastic bags as shown in the illustration to prevent foreign matter from entering the cooling system and to prevent coolant from spilling near the inverter with converter assembly.
      GTY319548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE NO. 1 INVERTER COOLING HOSE ASSEMBLY 
    1. Release the retainer and disconnect the No. 1 inverter cooling hose assembly from the inverter with converter assembly.
      GTY589523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
    2. Put pieces of cloth into the pipe and disconnected hose, or cover the pipes and hoses with plastic bags as shown in the illustration to prevent foreign matter from entering the cooling system and to prevent coolant from spilling near the inverter with converter assembly.
      GTY319556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE INVERTER WITH CONVERTER ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. Temporarily secure the No. 3 engine room wire with the inverter with converter assembly hook as shown in the illustration.
      GTY561948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 3 Engine Room Wire
      *2 Hook
    2. Remove the 2 bolts, nut and inverter with converter assembly.
      GTY317929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Since the inverter with converter assembly is very heavy, 2 people are needed to remove the inverter with converter assembly. When removing the inverter with converter assembly, do not damage the parts around it.
      • To prevent damage, do not hold the inverter with converter assembly by the connectors.
      • To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.
      • If removing and storing the inverter with converter assembly, make sure to install the inverter cover to prevent any foreign matter or water from entering the inverter with converter assembly.
      • Cover the connectors with insulating tape to prevent foreign matter or water from entering.
    3. Even after the coolant is drained, coolant remains in the inverter with converter assembly due to its internal structure. Therefore, seal or cover the pipes when removing the inverter with converter assembly to prevent coolant from spilling out or foreign matter from entering the inverter with converter assembly.
      GTY226645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE HIGH VOLTAGE FUSE 
    WARNING:

    Wear insulated gloves.

    HINT: 

    Perform this procedure only when replacement of the high voltage fuse is necessary.

    1. Remove the bolt and connector cover assembly from the inverter with converter assembly.
      GTY319553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure to pull the connector cover assembly straight up, as a connector is connected to the bottom of the cover.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
    2. Remove the 2 nuts and high voltage fuse from the inverter with converter assembly.
      GTY319554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Temporarily install the connector cover assembly with the bolt to prevent any foreign matter or water from entering the inverter with converter assembly.
      GTY319553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE AIR CLEANER BRACKET 
    1. Remove the bolt and air cleaner bracket from the inverter with converter assembly.
      GTY322578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE AIR CLEANER BRACKET 
    1. Remove the bolt and air cleaner bracket from the inverter with converter assembly.
      GTY317908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE NO. 1 INVERTER BRACKET 
    1. Remove the 2 bolts and No. 1 inverter bracket from the inverter with converter assembly.
      GTY317910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE NO. 2 INVERTER BRACKET 
    1. Remove the 2 bolts and No. 2 inverter bracket from the inverter with converter assembly.
      GTY317911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE NO. 3 INVERTER BRACKET 
    1. Remove the 2 bolts and No. 3 inverter bracket from the inverter with converter assembly.
      GTY317909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE NO. 1 MOTOR CABLE BRACKET 
    1. Remove the 2 bolts and No. 1 motor cable bracket from the inverter with converter assembly.
      GTY317907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE NO. 2 MOTOR CABLE BRACKET 
    1. Remove the 2 bolts and No. 2 motor cable bracket from the inverter with converter assembly.
      GTY317906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE NO. 1 INVERTER COOLING HOSE 

    HINT: 

    Perform this procedure only when replacement of the No. 1 inverter cooling hose.

    1. Release the retainer and disconnect the No. 1 inverter cooling hose from the inverter with converter assembly.
      GTY585580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
    2. Remove the No. 1 inverter cooling hose from the inverter with converter assembly.
    3. Put pieces of cloth into the pipes and disconnected hoses, or cover the pipes and hoses with plastic bags as shown in the illustration to prevent foreign matter from entering the cooling system and to prevent coolant from spilling near the inverter with converter assembly.
      GTY319548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE NO. 3 ENGINE ROOM WIRE 
    1. Open the cover.
      GTY317913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not twist the cover excessively when opening it.

    2. Remove the nut and No. 3 engine room wire from the inverter with converter assembly.
  38. REMOVE INVERTER TRAY BRACKET SUB-ASSEMBLY 

    HINT: 

    Perform this procedure only when replacement of the inverter tray bracket sub-assembly.

    1. Remove the 4 bolts and inverter tray bracket sub-assembly.
      GTY316137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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