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Removal [11/2015 - ]: Procedure

  1. PRECAUTION 

    (Refer to PRECAUTION [11/2015 - 06/2017] and Refer to PRECAUTION [06/2017 - ] )

  2. REMOVE SERVICE PLUG GRIP 

    (Refer to REMOVAL [11/2015 - ] )

  3. DRAIN COOLANT (for Inverter) 

    See step  1 and See step  1

  4. DISCONNECT ENGINE ROOM MAIN WIRE 
    WARNING:

    Wear insulated gloves.

    NOTE:
    • Insulate the disconnected 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.
    • To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.
    1. Raise the lock lever and disconnect the inverter with converter connector.
      GTY334030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the engine wire from the engine room main wire.
      GTY220528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the hose clamp.
      GTY326007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not remove the hose clamp from the hose.

    4. Remove the 2 bolts.
    5. Disconnect the clamp and engine room main wire.
  5. REMOVE INVERTER TERMINAL COVER 
    WARNING:

    Wear insulated gloves.

    1. Remove the 2 bolts and inverter terminal cover.
      GTY725882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Interlock Connector
      WARNING:

      An interlock connector is installed to the inverter terminal cover. Make sure to remove the inverter terminal cover before removing the inverter cover.

      NOTE:

      Make sure to pull the inverter cover straight up, as a connector is connected to the bottom of the cover.

  6. REMOVE INVERTER COVER 
    WARNING:

    Wear insulated gloves.

    1. Remove the 7 bolts and inverter cover.
      GTY702814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      WARNING:

      An interlock connector is installed to the inverter terminal cover. Make sure to remove the inverter terminal cover before removing the inverter cover.

  7. 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.
      GTY737995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard voltage

      0 V

      HINT: 

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

  8. DISCONNECT FRAME WIRE 
    WARNING:

    Wear insulated gloves.

    NOTE:
    • Insulate the disconnected 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.
    1. Disconnect the harness clamp.
      GTY334032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 bolts, and disconnect the frame wire (high voltage cables of the hybrid battery) from the inverter with converter assembly.
      GTY702815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. DISCONNECT MOTOR CABLE 
    WARNING:

    Wear insulated gloves.

    NOTE:
    • Insulate the disconnected 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.
    1. Disconnect the motor cable (for MG 1)
      1. Remove the 5 bolts, and disconnect the high voltage cables of the motor cable for (MG1) from the inverter with converter assembly.
        GTY334035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the motor cable (for MG 2)
      1. Remove the 5 bolts, and disconnect the high voltage cables of the motor cable (for MG2) from the inverter with converter assembly.
        GTY334033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. DISCONNECT NO. 2 ENGINE WIRE 
    WARNING:

    Wear insulated gloves.

    NOTE:
    • Insulate the disconnected 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.
    1. Remove the bolt (A).
      GTY693442Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 bolts (B), and disconnect the No. 2 engine wire (high voltage cables for the air conditioning compressor) from the inverter with converter assembly.
  11. INSTALL INVERTER COVER 
    WARNING:

    Wear insulated gloves.

    1. Temporarily install the inverter cover with the 7 bolts to prevent any foreign matter or water from entering the inverter with converter assembly.
      GTY702814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Visually confirm that the inverter cover waterproofing rubber is securely installed before installing the upper inverter cover.

  12. INSTALL INVERTER TERMINAL COVER 
    WARNING:

    Wear insulated gloves.

    1. Temporarily install the inverter terminal cover with the 2 bolts to prevent any foreign matter or water from entering the inverter with converter assembly.
      GTY725882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Interlock Connector
      NOTE:
      • Visually confirm that the inverter cover waterproofing rubber is securely installed before installing the inverter terminal cover.
      • Make sure that the interlock is fully engaged.
  13. DISCONNECT WIRE HARNESS 
    1. Remove the relay block cover.
      GTY334025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connector.
      GTY334027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the 2 claws and remove the No. 1 relay block cover.
      GTY326006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the nut and disconnect the wire harness.
      GTY338927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. DISCONNECT 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.
      GTY332646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
    2. Put pieces of cloth into the pipes and in the 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.
      GTY334679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DISCONNECT NO. 2 INVERTER COOLING HOSE ASSEMBLY 
    1. Release the retainer and disconnect the No. 2 inverter cooling hose assembly from the inverter with converter assembly.
      GTY701279Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
    2. Put pieces of cloth into the pipes and in the disconnected hoses, or cover the pipes and hose 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.
      GTY334679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE INVERTER WITH CONVERTER ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. Temporarily secure the No. 3 engine room wire with the inverter with converter assembly protector as shown in the illustration.
      GTY688258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Protector

      HINT: 

      To prevent the No. 2 engine room wire from getting caught by other components, connect it to the protector before removing the inverter with converter assembly.

    2. Remove the 3 bolts and inverter with converter assembly.
      GTY334681Courtesy 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.
    3. 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 so that coolant does not spill out.
      GTY226645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. 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 2 bolts and inverter terminal cover.
      GTY725882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Interlock Connector
      NOTE:

      Make sure to pull the inverter cover straight up, as a connector is connected to the bottom of the cover.

    2. Remove the 7 bolts and inverter cover.
      GTY702814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and high voltage fuse from the inverter with converter assembly.
      GTY334024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

    4. Temporarily install the inverter cover with the 7 bolts to prevent any foreign matter or water from entering the inverter with converter assembly.
      GTY702814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Visually confirm that the inverter cover waterproofing rubber is securely installed before installing the inverter cover.

    5. Temporarily install the inverter terminal cover with the 2 bolts to prevent any foreign matter or water from entering the inverter with converter assembly.
      GTY725882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Interlock Connector
      NOTE:
      • Visually confirm that the inverter terminal cover waterproofing rubber is securely installed before installing the inverter terminal cover.
      • Make sure that the interlock is fully engaged.
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