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Home >> Toyota >> 2017 >> Prius Three >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Battery Management Systems >> Hybrid Battery Control System - Service Information (1 Of 3) >> Inverter With Converter >> Removal [11/2015 - 12/2018] >> Procedure

Removal [11/2015 - 12/2018]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    Refer to PRECAUTION [11/2015 - 11/2017] , or refer to PRECAUTION [11/2017 - 12/2018]

  2. DISCONNECT ENGINE WIRE 
    1. Disengage the 2 claws and disconnect the engine wire from the battery current sensor holder.
      GTY590807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the battery state sensor assembly connector.
  3. REMOVE AUXILIARY BATTERY 

    Refer to REMOVAL [11/2015 - 12/2018]

  4. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [11/2015 - 12/2018]

  5. REMOVE REAR MOTOR UNDER COVER LH 

    See step  1

  6. DRAIN COOLANT (for Inverter) 

    See step  2

  7. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 13 [11/2015 - 08/2016] , or refer to PROCEDURE - Step 13 [08/2016 - 12/2018]

  8. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [11/2015 - ]

  9. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL 

    Refer to PROCEDURE - Step 3

  10. REMOVE WATER GUARD PLATE LH 

    Refer to PROCEDURE - Step 4

  11. REMOVE COWL BODY MOUNTING REINFORCEMENT LH 

    Refer to PROCEDURE - Step 5

  12. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  13. REMOVE ECM 

    Refer to REMOVAL [11/2015 - 12/2018]

  14. REMOVE BATTERY CLAMP SUB-ASSEMBLY 
    1. Remove the 3 bolts and battery clamp sub-assembly.
      GTY598493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DISCONNECT ENGINE WIRE 
    WARNING:

    Wear insulated gloves.

    NOTE:

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

    1. Remove the No. 1 relay block cover.
      GTY542991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 3 No. 1 engine room relay block and No. 1 junction block assembly connectors.
      GTY542992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the 2 claws.
    4. Move each lock lever as shown in the illustration and disconnect the 2 inverter with converter assembly connectors.
      NOTE:
      • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
      • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Insulate the disconnected terminals with insulating tape.
      • Do not touch the waterproof seal or terminals of the connector.
      GTY541775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the bolt.
      GTY605621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disengage the clamp (A) and remove the inverter protector.
    7. Disengage the clamp (B).
    8. Remove the bolt.
      GTY552146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Disengage the 2 clamps and disconnect the engine wire.
  16. REMOVE CONNECTOR COVER ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. Remove the bolt (B).
      GTY587645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt (A)
      *b Bolt (B)
    2. Using a T25 "TORX" socket wrench, remove the bolt (A) and connector cover assembly from the inverter with converter assembly.
      NOTE:
      • Do not touch the connector cover assembly waterproof seal.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
  17. 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.

      GTY541774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. Temporarily install the connector cover assembly to the inverter with converter assembly.
      GTY598219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a T25 "TORX" socket wrench, install the bolt.

      Torque: 4.5 N.m (46 kgf.cm, 40 in/lbf) 

      NOTE:

      Do not touch the waterproof seal of the connector cover assembly.

  19. DISCONNECT HV FLOOR UNDER WIRE 
    WARNING:

    Wear insulated gloves.

    NOTE:

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

    1. Remove the bolt and disconnect the HV floor under wire from the inverter with converter assembly.
      GTY577112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
      NOTE:
      • Do not touch the waterproof seal or terminals of the connector.
      • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
      • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Insulate the disconnected terminals with insulating tape.
    2. Disengage the 2 clamps.
  20. DISCONNECT AIR CONDITIONING WIRE 
    WARNING:

    Wear insulated gloves.

    1. Remove the 2 bolts and disconnect the air conditioning wire from the inverter with converter assembly.
      GTY574767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
      NOTE:
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Do not touch the waterproof seal or terminals of the connector.
      • Do not damage the terminals, connector housing 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.
    2. Disengage the clamp.
  21. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. Remove the nut and wire harness clamp bracket.
      GTY542942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT NO. 3 ENGINE WIRE 
    WARNING:

    Wear insulated gloves.

    1. Remove the bolt.
      GTY542944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt.
      GTY542937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the 2 claws and open the No. 3 engine wire terminal cover.
      GTY598481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the nut.
      GTY542938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disengage the clamp and disconnect the No. 3 engine wire from the inverter with converter assembly.
  23. DISCONNECT OUTLET NO. 1 INVERTER COOLING HOSE 
    1. Slide the clip and disconnect the outlet No. 1 inverter cooling 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.

      GTY542939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. DISCONNECT INLET NO. 1 INVERTER COOLING HOSE 
    1. Slide the clip and disconnect the inlet No. 1 inverter cooling 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.

      GTY542935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE INVERTER COVER 
    WARNING:

    Wear insulated gloves.

    1. Remove the 2 bolts and inverter cover from the inverter with converter assembly.
      NOTE:
      • Make sure to pull the inverter cover straight out, as a connector is connected to the inside of the inverter cover.
      • Do not touch the waterproof seal of the inverter cover.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • When removing the inverter cover, do not pull the areas (A) as they may deform.
      • Make sure that the interlock is installed to the inverter cover.
      • Do not remove or excessively tighten the screw of the inverter cover.
        GTY596587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Inverter Cover
        *a Screw
      • Although the inverter cover may feel loose, this is not due to a malfunction.

      HINT: 

      If necessary, use a screwdriver with its tip wrapped with protective tape as shown in the illustration to remove the inverter cover.

      GTY608346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      GTY543461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Interlock
      *b Waterproof Seal
  26. DISCONNECT MOTOR CABLE 
    WARNING:

    Wear insulated gloves.

    1. Using an insulated tool, remove the 6 bolts.
      GTY542955Courtesy 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 waterproof seal or terminals of the connector.
    2. Remove the 4 bolts and disconnect the motor cable from the inverter with converter assembly.
      GTY545409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
      NOTE:
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Do not touch the waterproof seal or terminals of the connector.
      • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
      • Insulate the disconnected terminals with insulating tape.
      • After disconnecting the motor cable, wrap it with a plastic bag or equivalent to protect it.
      • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
      • To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.
        GTY586920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE INVERTER WITH CONVERTER ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. Remove the 5 bolts, 2 nuts and inverter with converter assembly.
      GTY598484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • When removing the inverter with converter assembly, be careful not to damage the parts around it.
      • To prevent damage, do not hold the inverter with converter assembly by the connectors, brackets or cooling pipes.
      • To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.

      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.

  28. REMOVE NO. 1 INVERTER BRACKET 
    1. Set the inverter with converter assembly on wooden blocks.
      GTY587618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
      NOTE:

      Make sure to support the inverter with converter assembly at the positions shown in the illustration, otherwise it may be damaged.

      GTY586919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and No. 1 inverter bracket from the inverter with converter assembly.
  29. REMOVE NO. 2 INVERTER BRACKET 
    1. Remove the 2 bolts and No. 2 inverter bracket from the inverter with converter assembly.
      GTY594379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
  30. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. Remove the 2 bolts and 2 wire harness clamp brackets from the inverter with converter assembly.
      GTY542945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and wire harness clamp bracket from the inverter with converter assembly.
      GTY543046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and wire harness clamp bracket from the inverter with converter assembly.
      GTY542959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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