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Home >> Toyota >> 2016 >> Highlander Limited, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 86 (Hybrid Battery Control System (Service Information)) >> Inverter With Converter >> Removal [02/2014 - 11/2016] >> Procedure

Removal [02/2014 - 11/2016]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. PRECAUTION 

    Refer to PRECAUTION [02/2014 - 11/2016]

  2. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [02/2014 - ] 

  3. REMOVE NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 11 (REMOVAL [02/2014 - 11/2015])

    Refer to PROCEDURE - Step 11 (REMOVAL [11/2015 - 11/2016])

  4. DRAIN COOLANT (for Inverter) 

    See step  2

  5. REMOVE AIR CLEANER ASSEMBLY 

    Refer to REMOVAL [02/2014 - 11/2016]

  6. REMOVE NO. 3 INVERTER BRACKET 
    1. Remove the bolt, nut and No. 3 inverter bracket.
      GTY301555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE INVERTER RESERVE TANK ASSEMBLY 
    1. Disconnect the inverter drain hose from the clamp.
      GTY446909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Inverter Cooling Hose
      *2 Inverter Drain Hose
    2. Slide the 3 clips and disconnect the No. 1 inverter cooling hose and 2 inverter drain hoses from the inverter reserve tank assembly.
      NOTE:

      Put pieces of cloth into the pipes and disconnected hoses or cover the pipes and hoses with plastic bags to prevent entry of foreign matter.

    3. Remove the bolt, nut and inverter reserve tank assembly.
      GTY304271Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE NO. 1 INVERTER RESERVE TANK BRACKET 
    1. Remove the 2 bolts and No. 1 inverter reserve tank bracket from the inverter with converter assembly.
      GTY307544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE INVERTER TERMINAL COVER 
    WARNING:

    Wear insulated gloves.

    1. Remove the 11 bolts and inverter terminal cover from the inverter with converter assembly.
      NOTE:
      • Make sure to pull the inverter terminal cover straight up, as a connector is connected to the bottom of the inverter terminal cover.
      • Do not touch the inverter terminal cover waterproofing rubber.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      GTY448692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. 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 of the 2 phase connectors.

      Standard Voltage

      0 V

      HINT: 

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

      GTY447786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. DISCONNECT NO. 4 ENGINE WIRE 
    WARNING:

    Wear insulated gloves.

    1. Using an insulated tool, remove the 5 bolts and disconnect the No. 4 engine wire from the inverter with converter assembly.
      GTY424639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Do not touch the connector waterproofing rubber or terminals.
      • Do not damage the terminals, connector housings or inverter with converter assembly during disconnection.
      • Insulate the disconnected terminals with insulating tape.
      • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
  12. DISCONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR 
    WARNING:

    Wear insulated gloves.

    1. Using an insulated tool, remove the 5 bolts and disconnect the high voltage cable of front motor (for Generator (MG1)) from the inverter with converter assembly.
      NOTE:
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Do not touch the connector waterproofing rubber or terminals.
      • Do not damage the terminals, connector housings or inverter with converter assembly during disconnection.
      • Insulate the disconnected terminals with insulating tape.
      • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
      GTY450583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an insulated tool, remove the 5 bolts and disconnect the high voltage cable of front motor (for Motor (MG2)) from the inverter with converter assembly.
      NOTE:
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Do not touch the connector waterproofing rubber or terminals.
      • Do not damage the terminals, connector housings or inverter with converter assembly during disconnection.
      • Insulate the disconnected terminals with insulating tape.
      • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
      GTY424637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. DISCONNECT NO. 6 FLOOR WIRE 
    WARNING:

    Wear insulated gloves.

    1. Using an insulated tool, remove the 5 bolts and disconnect the No. 6 floor wire (for Rear Motor (MGR)) from the inverter with converter assembly.
      NOTE:
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Do not touch the connector waterproofing rubber or terminals.
      • Do not damage the terminals, connector housings or inverter with converter assembly during disconnection.
      • Insulate the disconnected terminals with insulating tape.
      • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
      GTY450580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clamp.
      GTY304153Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using an insulated tool, remove the 4 bolts and disconnect the No. 6 floor wire (for HV Battery) from the inverter with converter assembly.
      NOTE:
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Do not touch the connector waterproofing rubber or terminals.
      • Do not damage the terminals, connector housings or inverter with converter assembly during disconnection.
      • Insulate the disconnected terminals with insulating tape.
      • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
      GTY424626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the 3 clamps.
      GTY307475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. TEMPORARILY INSTALL INVERTER TERMINAL COVER 
    WARNING:

    Wear insulated gloves.

    1. Temporarily install the inverter terminal cover with the 11 bolts to prevent any foreign matter or water from entering the inverter with converter assembly.
      NOTE:
      • Visually confirm that the inverter terminal cover waterproofing rubber is securely installed before installing the inverter terminal cover.
      • Do not touch the inverter terminal cover waterproofing rubber.
      • Make sure that the interlock is fully engaged.
      GTY448692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DISCONNECT NO. 3 ENGINE ROOM RELAY BLOCK 
    1. Disengage the clamp and disconnect the No. 3 engine room relay block.
      GTY307412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. DISCONNECT MG ECU CONNECTOR 
    WARNING:

    Wear insulated gloves.

    NOTE:
    • Insulate the disconnected connectors with insulating tape.
    • Cover the hole where the connector was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
    • To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.
    1. Move the lock lever as shown in the illustration and disconnect the MG ECU connector.
      GTY304156Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the MG ECU connector.
      GTY448493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT WATER HOSE 
    1. Disengage the clamp.
      GTY440199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Inlet No. 1 Inverter Cooling Hose
      *2 No. 2 Inverter Cooling Hose
    2. Slide the 2 clips and disconnect the inlet No. 1 inverter cooling hose and No. 2 inverter cooling hose from the inverter with converter assembly.
      NOTE:

      Put pieces of cloth into the pipes and disconnected hoses or cover the pipes and hoses with plastic bags to prevent entry of foreign matter.

    3. Release the retainer and disconnect the outlet No. 1 inverter cooling hose from the inverter with converter assembly as shown in the illustration.
      NOTE:

      Put pieces of cloth into the pipe and disconnected hose or cover the pipe and hose with plastic bags to prevent entry of foreign matter.

      GTY436053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
  18. DISCONNECT NO. 2 ENGINE ROOM RELAY BLOCK ASSEMBLY 
    1. Disengage the clamp and disconnect the No. 2 engine room relay block assembly.
      GTY424627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. DISCONNECT NO. 2 ENGINE ROOM WIRE 
    1. Remove the No. 1 relay block cover from the No. 1 relay block cover.
      GTY424629Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 4 claws and remove the No. 1 relay block cover from the No. 1 engine room relay block and No. 1 junction block assembly.
      GTY450581Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the nut from the No. 2 engine room wire.
      GTY424631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the claw and disconnect the No. 2 engine room wire from the No. 1 engine room relay block and No. 1 junction block assembly.
  20. REMOVE NO. 4 INVERTER BRACKET 
    1. Disengage the clamp from the No. 4 inverter bracket.
      GTY424630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt, nut and No. 4 inverter bracket.
  21. REMOVE INVERTER WITH CONVERTER ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. Remove the 2 bolts, nut and inverter with converter assembly.
      GTY304161Courtesy 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.
      • Cover the connectors with insulating tape to prevent foreign matter or water from entering.

      HINT: 

      Even after the coolant is drained, coolant remains in the inverter due to its internal structure. Therefore, seal or cover the pipes when removing the inverter with converter assembly so that coolant does not spill out.

  22. REMOVE INVERTER DRAIN HOSE 
    1. Slide the clip and remove the inverter drain hose from the inverter with converter assembly.
      NOTE:

      Put pieces of cloth into the pipe and disconnected hose or cover the pipe and hose with plastic bags to prevent entry of foreign matter.

      GTY424634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE INVERTER COOLING PIPE 
    1. Slide the clip and remove the inlet No. 2 inverter cooling hose from the inverter with converter assembly.
      GTY450582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Put pieces of cloth into the pipe and disconnected hose or cover the pipe and hose with plastic bags to prevent entry of foreign matter.

    2. Remove the 2 bolts and inverter cooling pipe from the inverter with converter assembly.
  24. 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 11 bolts and inverter terminal cover from the inverter with converter assembly.
      NOTE:
      • Make sure to pull the inverter terminal cover straight up, as a connector is connected to the bottom of the inverter terminal cover.
      • Do not touch the inverter terminal cover waterproofing rubber.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      GTY448692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 nuts and holder from the inverter with converter assembly.
      NOTE:

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

      GTY303618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Temporarily install the inverter terminal cover with the 11 bolts to prevent any foreign matter or water from entering the inverter with converter assembly.
      NOTE:
      • Visually confirm that the inverter terminal cover waterproofing rubber is securely installed before installing the inverter terminal cover.
      • Do not touch the inverter terminal cover waterproofing rubber.
      • Make sure that the interlock is fully engaged.
      GTY448692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Place the holder as shown in the illustration.
      GTY303886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Use either the location shown in the illustration or another method to hold the holder for the subsequent step.

    5. Remove the 2 nuts and high voltage fuse from the holder.
      GTY303619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE WIRE HARNESS CLAMP BRACKET 

    HINT: 

    Perform this procedure only when replacement of a wire harness clamp bracket is necessary.

    1. Remove the bolt and wire harness clamp bracket from the inverter with converter assembly.
      GTY424643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage each clamp and remove the 2 clamps from the wire harness clamp bracket.
      GTY424641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and wire harness clamp bracket from the inverter with converter assembly.
      GTY424642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 bolts and wire harness clamp bracket from the inverter with converter assembly.
      GTY424650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE NO. 2 ENGINE ROOM WIRE 

    HINT: 

    Perform this procedure only when replacement of the No. 2 engine room wire is necessary.

    1. Remove the clamp.
      GTY436152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Terminal Cover
    2. Open the terminal cover.
    3. Remove the nut and No. 2 engine room wire from the inverter with converter assembly.
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