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Removal [06/2015 - 11/2018]: Procedure

  1. CAUTIONS FOR HIGH VOLTAGE SYSTEM COMPONENTS 

    Refer to PROCEDURE - Step 1

  2. CAUTIONS FOR INTAKE SYSTEM COMPONENTS 

    Refer to PROCEDURE - Step 3

  3. REMOVE SERVICE PLUG GRIP (for EV) 

    Refer to REMOVAL [06/2015 - 11/2018] 

  4. REMOVE FC STACK SERVICE PLUG GRIP 

    Refer to REMOVAL [06/2015 - 11/2018]

  5. REMOVE LOWER FRONT BUMPER ABSORBER 

    Refer to PROCEDURE - Step 7

  6. REMOVE NO. 3 REMOVE RADIATOR AIR GUIDE 

    Refer to PROCEDURE - Step 9

  7. DRAIN COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 3

  8. REMOVE WINDSHIELD WIPER MOTOR AND LINK 

    Refer to REMOVAL [06/2015 - ]

  9. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL 

    Refer to PROCEDURE - Step 8

  10. REMOVE WATER GUIDE PLATE LH 

    Refer to PROCEDURE - Step 9

  11. REMOVE COWL BODY MOUNTING REINFORCEMENT RH 

    Refer to PROCEDURE - Step 10

  12. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 11

  13. REMOVE COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 1

  14. REMOVE AIR CLEANER INLET 

    Refer to PROCEDURE - Step 24

  15. REMOVE AIR CLEANER ASSEMBLY WITH ELEMENT 

    Refer to PROCEDURE - Step 25

  16. REMOVE INVERTER COVER 
    1. GTY543029Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Place Hands Here
      Remove in this Direction

      Disengage the 4 grommets and remove the inverter cover from the inverter with converter assembly and inverter protector.

      NOTE:

      To avoid damaging the inverter cover, pull it upwards and disengage the grommet.

    2. GTY603362Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the 4 bolts from the inverter with converter assembly and inverter protector.

  17. REMOVE INVERTER TERMINAL COVER 
    WARNING:

    Wear insulated gloves.

    NOTE:

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

    1. GTY555817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Disconnect the 4 connectors.

    2. GTY555820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Disengage the 2 clamps to separate the wire harness from the inverter terminal cover.

    3. GTY541464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Interlock Connector

      Remove the 11 bolts and inverter terminal cover from the inverter with converter assembly.

      NOTE:
      • The inverter terminal cover has an interlock connector, so pull it up perpendicularly.
      • Do not touch the rubber seal of the inverter terminal cover.
  18. CHECK TERMINAL VOLTAGE 
    WARNING:

    Wear insulated gloves.

    NOTE:

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

    1. GTY555799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Using a voltmeter, measure the voltage between the terminals of the 2 phase connectors.

      Standard Voltage

      0 V

      HINT: 

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

  19. TEMPORARILY TIGHTEN INVERTER TERMINAL COVER 
    WARNING:

    Wear insulated gloves.

    NOTE:

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

    1. Temporarily install the inverter cover with the 7 bolts to prevent any foreign matter or water from entering the inverter with converter assembly.
      GTY541460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Interlock Connector
      *2 Connector Bracket
      NOTE:
      • Make sure that the rubber seal of the inverter terminal cover is securely installed and that no foreign matter is adhering to it, then install it.
      • Do not touch the rubber seal of the inverter terminal cover.
      • Do not install the inverter terminal cover while pressing down on the connector bracket.
      • Securely connect the interlock connector.
  20. DISCONNECT WIRE HARNESS 
    WARNING:

    Wear insulated gloves.

    NOTE:
    • To prevent damage from static electricity, do not touch the connector terminal portion.
    • To prevent contamination by foreign matter or water droplets, cover the opening of the connector with protective tape.
    1. GTY554268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Lock Lever

      Lift the lock lever and disconnect the connector.

    2. Disengage the clamp to separate the wire harness from the inverter reserve tank assembly.
    3. GTY564862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Disconnect the 4 connectors.

    4. Disengage the 4 clamps to separate the wire harness from the FC inverter input junction cover, inverter protector and inverter reserve tank assembly.
    5. Remove the nut and separate the wire harness from the inverter protector.
  21. SEPARATE FC WATER PUMP DRAIN HOSE ASSEMBLY 
    1. GTY598921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the bolt and separate the FC water drain hose assembly from the FC inverter input junction assembly.

  22. REMOVE FC INVERTER INPUT JUNCTION COVER 
    WARNING:

    Wear insulated gloves.

    1. GTY589151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Interlock Connector

      Remove the 2 bolts and FC inverter input junction cover from the FC inverter input junction assembly.

      NOTE:
      • The FC inverter input junction cover has an interlock connector, so pull it out straight.
      • Do not touch the rubber seal of the FC inverter input junction cover.
  23. DISCONNECT FRAME WIRE 
    WARNING:

    Wear insulated gloves.

    1. GTY549693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Interlock Connector

      Using an insulated tool, remove the 4 bolts and disconnect the frame wire from the FC inverter input junction assembly.

      NOTE:
      • The frame wire has an interlock connector, so pull it out straight.
      • When disconnecting, be careful not to damage the terminal portion, connector housing, or FC inverter input junction assembly.
      • Do not touch the rubber seal or terminal portion of the frame wire.
      • Insulate the connector portion of the frame wire by wrapping it with insulating tape.
    2. GTY609224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape

      To prevent contamination by foreign matter or water droplets, cover the opening of the FC inverter input junction assembly with protective tape.

  24. REMOVE INVERTER TERMINAL COVER 
    WARNING:

    Wear insulated gloves.

    NOTE:

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

    1. GTY541461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Interlock Connector

      Remove the 11 bolts and inverter terminal cover from the inverter with converter assembly.

      NOTE:
      • The inverter terminal cover has an interlock connector, so pull it up perpendicularly.
      • Do not touch the rubber seal of the inverter terminal cover.
  25. REMOVE FC INVERTER INPUT JUNCTION ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    NOTE:

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

    1. GTY598037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Green-colored Lock

      Disengage the clamp to separate the wire harness from the FC inverter input junction assembly.

    2. As shown in the illustration, pull out the green lock of the connector, and disconnect the connector from the FC water and hydrogen pump inverter assembly.
      NOTE:
      • Do not touch the connector terminals.
      • Insulate the opening of the connector by wrapping it with insulating tape.
    3. GTY561682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Green-colored Lock

      As shown in the illustration, pull out the green lock of the connector, and disconnect the connector from the electric heater sub-assembly.

      NOTE:
      • Do not touch the connector terminals.
      • Insulate the opening of the connector by wrapping it with insulating tape.
    4. GTY563586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Interlock Connector

      Using an insulated tool, remove the 5 bolts and FC inverter input junction assembly from the inverter with converter assembly.

      NOTE:
      • The FC inverter input junction assembly has an interlock connector, so pull it out straight.
      • During removal, make sure not to damage the terminal portion, connector housing, or inverter with converter assembly.
      • Do not touch the seal packing or terminal portion of the FC inverter input junction assembly.
      • If the seal packing of the FC inverter input junction assembly has any damage or deformation, replace it with a new one.
      • Insulate the terminal portion of the FC inverter input junction assembly by wrapping it with insulating tape.
    5. GTY577413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape

      To prevent contamination by foreign matter or water droplets, cover the opening of the inverter with converter assembly with protective tape.

  26. SEPARATE NO. 3 MOTOR WIRE 
    WARNING:

    Wear insulated gloves.

    NOTE:

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

    1. GTY564878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Disengage the clamp to separate the No. 3 motor wire from the FC water and hydrogen pump inverter assembly.

    2. Using an insulated tool, remove the 4 bolts and separate the No. 3 motor wire from the inverter with converter assembly.
      NOTE:
      • When disconnecting, be careful not to damage the terminal portion, connector housing, or inverter with converter assembly.
      • Do not touch the rubber seal or terminal portion of the connector
      • After disconnecting, insulate the connector portion by wrapping it with insulating tape.
    3. GTY609218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape

      To prevent contamination by foreign matter or water droplets, cover the opening of the inverter with converter assembly with protective tape.

  27. DISCONNECT MOTOR CABLE 
    WARNING:

    Wear insulated gloves.

    NOTE:

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

    1. GTY603518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Using an insulated tool, remove the 5 bolts and disconnect the motor cable from the inverter with converter assembly.

      NOTE:
      • When disconnecting, be careful not to damage the terminal portion, connector housing, or inverter with converter assembly.
      • Do not touch the rubber seal or terminal portion of the connector
      • After disconnecting, insulate the connector portion by wrapping it with insulating tape.
    2. GTY540890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape

      To prevent contamination by foreign matter or water droplets, cover the opening of the inverter with converter assembly with protective tape.

  28. DISCONNECT FC AIR COMPRESSOR CABLE 
    WARNING:

    Wear insulated gloves.

    NOTE:

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

    1. GTY565582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Using an insulated tool, remove the 5 bolts and disconnect the FC air compressor cable from the inverter with converter assembly.

      NOTE:
      • When disconnecting, be careful not to damage the terminal portion, connector housing, or inverter with converter assembly.
      • Do not touch the rubber seal or terminal portion of the connector
      • After disconnecting, insulate the connector portion by wrapping it with insulating tape.
    2. GTY546347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape

      To prevent contamination by foreign matter or water droplets, cover the opening of the inverter with converter assembly with protective tape.

  29. SEPARATE FC CONVERTER POWER OUTLET CABLE 
    WARNING:

    Wear insulated gloves.

    NOTE:

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

    1. GTY559386Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Using an insulated tool, remove the 5 bolts and disconnect the FC converter power outlet cable from the inverter with converter assembly.

      NOTE:
      • When disconnecting, be careful not to damage the terminal portion, connector housing, or inverter with converter assembly.
      • Do not touch the rubber seal or terminal portion of the connector
      • After disconnecting, insulate the connector portion by wrapping it with insulating tape.
    2. GTY555149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape

      To prevent contamination by foreign matter or water droplets, cover the opening of the inverter with converter assembly with protective tape.

  30. TEMPORARILY TIGHTEN INVERTER TERMINAL COVER 

    See step  19

  31. SEPARATE WATER PIPE SUB-ASSEMBLY 
    1. GTY544934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the bolt and 2 nuts and separate the water pipe sub-assembly from the FC water and hydrogen pump inverter assembly and inverter protector.

  32. REMOVE NO. 2 INVERTER DRAIN HOSE 
    1. GTY559253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Slide the hose clip and disconnect the No. 2 inverter drain hose from the inverter reserve tank assembly.

      NOTE:
      • When disconnecting, be careful not to damage the hose interior surface or pipe portion.
      • Perform the procedures by hand. Do not use any tools.
    2. GTY572286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastic Bag

      To prevent contamination by foreign matter, cover the connecting portions of the No. 2 inverter drain hose and inverter reserve tank assembly with plastic bags.

    3. Disengage the 2 clamps to remove the No. 2 inverter drain hose from the inverter protector.
      GTY559295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Slide the hose clip and disconnect the No. 2 inverter drain hose from the EV water hose connector of the No. 1 inverter cooling hose.
      NOTE:
      • When disconnecting, be careful not to damage the hose interior surface or pipe portion.
      • Perform the procedures by hand. Do not use any tools.
    5. GTY565456Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastic Bag

      To prevent contamination by foreign matter, cover the connecting portions of the No. 2 inverter drain hose and No. 1 inverter cooling hose with plastic bags.

  33. DISCONNECT NO. 1 INVERTER COOLING HOSE 
    1. GTY559300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Disengage the 2 clamps to separate the No. 1 inverter cooling hose from the inverter protector.

    2. Slide the hose clip and disconnect the No. 2 inverter cooling hose from the inverter reserve tank assembly.
      NOTE:
      • When disconnecting, be careful not to damage the hose interior surface or pipe portion.
      • Perform the procedures by hand. Do not use any tools.
    3. GTY607424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastic Bag

      To prevent contamination by foreign matter, cover the connecting portions of the No. 2 inverter cooling hose and inverter reserve tank assembly with plastic bags.

    4. GTY600281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Retainer
      *a Protective Tape
      Pull out
      Slowly pull out

      Using a screwdriver with its tip wrapped in protective tape, pull out the retainer of the EV water hose connector to release the lock.

    5. Slowly pull out the EV water hose connector, and disconnect the No. 1 inverter cooling hose from the inverter with converter assembly.
      NOTE:
      • Perform the procedures by hand. Do not use any tools.
      • When pulling out the EV water hose connector, do not twist it or pull it at an angle.
      • If the 2 O-rings on the inner side of the EV water hose connector are damaged or falling out, replace the EV water hose connector with a new one.
    6. GTY590223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastic Bag

      To prevent contamination by foreign matter, cover the connecting portions of the No. 1 inverter cooling hose and inverter with converter assembly with plastic bags.

  34. REMOVE INVERTER RESERVE TANK ASSEMBLY 
    1. GTY559276Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Disengage the clamp to separate the wire harness from the inverter reserve tank assembly.

    2. Remove the 2 bolts and nut and separate the inverter reserve tank assembly from the inverter with converter assembly and inverter protector.
    3. GTY602115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Slide the hose clip and disconnect the No. 1 inverter drain hose from the inverter reserve tank assembly.

      NOTE:
      • When disconnecting, be careful not to damage the hose interior surface or pipe portion.
      • Perform the procedures by hand. Do not use any tools.
    4. GTY602327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastic Bag

      To prevent contamination by foreign matter, cover the connecting portions of the No. 1 inverter drain hose and inverter reserve tank assembly with plastic bags.

  35. DISCONNECT NO. 1 INVERTER COOLING INLET HOSE 
    1. GTY602113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Slide the hose clip and disconnect the No. 1 inverter cooling inlet hose from the inverter cooling inlet pipe.

      NOTE:
      • When disconnecting, be careful not to damage the hose interior surface or pipe portion.
      • Perform the procedures by hand. Do not use any tools.
    2. GTY566331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastic Bag

      To prevent contamination by foreign matter, cover the connecting portions of the No. 1 inverter cooling inlet hose and inverter cooling inlet pipe with plastic bags.

  36. REMOVE INVERTER PROTECTOR 
    1. GTY559270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the 3 bolts, nut and inverter protector from the inverter with converter assembly and center frame crossmember sub-assembly.

  37. REMOVE INVERTER WITH CONVERTER ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. GTY559280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Open the terminal cap cover.

    2. Remove the nut to disconnect the No. 2 motor compartment wire from the inverter with converter assembly.
      NOTE:

      After disconnecting, insulate the connector portion by wrapping it with insulating tape.

    3. GTY559279Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the bolt, 2 nuts and inverter with converter assembly from the center frame crossmember sub-assembly.

      NOTE:
      • The inverter with converter assembly is very heavy, so when removing it from the vehicle, perform the work with 2 people and be careful not to damage any of the surrounding components.
      • When lifting up the inverter with converter assembly, to prevent damage, do not hold it by the water pipe, water hose or connector portion.
      • To prevent damage from static electricity, do not touch the connector terminal portion of the inverter with converter assembly.
      • When removing and storing the inverter with converter assembly, to prevent foreign matter or water droplets from entering, make sure that the inverter terminal cover has been installed.
      • For the openings where connectors, etc. were removed, cover them with protective tape to prevent foreign matter and water droplets from entering.
  38. REMOVE NO. 1 INVERTER DRAIN HOSE 
    1. GTY559289Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Slide the hose clip and remove the No. 1 inverter drain hose from the inverter with converter assembly.

      NOTE:
      • When disconnecting, be careful not to damage the hose interior surface or pipe portion.
      • Perform the procedures by hand. Do not use any tools.
    2. GTY561373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastic Bag

      To prevent contamination by foreign matter, cover the connecting portions of the No. 1 inverter drain hose and inverter with converter assembly with plastic bags.

  39. REMOVE INVERTER COOLING INLET PIPE 
    1. GTY602110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the bolt and separate the inverter cooling inlet pipe from the inverter with converter assembly.

    2. Slide the hose clip and remove the No. 2 inverter cooling inlet hose from the inverter with converter assembly.
      NOTE:
      • When disconnecting, be careful not to damage the hose interior surface or pipe portion.
      • Perform the procedures by hand. Do not use any tools.
    3. GTY569755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plastic Bag

      To prevent contamination by foreign matter, cover the connecting portions of the No. 2 inverter cooling inlet hose and inverter with converter assembly with plastic bags.

  40. REMOVE FC CONVERTER CABLE INTER LOCK WIRE 
    GTY559256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disengage the clamp to remove the FC converter cable inter lock wire from the inverter terminal cover.
  41. REMOVE HIGH VOLTAGE FUSE 
    WARNING:

    Wear insulated gloves.

    NOTE:

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

    HINT: 

    This procedure is performed when the high voltage fuse must be replaced with a new one.

    1. GTY598149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Interlock Connector

      Remove the 11 bolts and inverter terminal cover from the inverter with converter assembly.

      NOTE:
      • The inverter terminal cover has an interlock connector, so pull it up perpendicularly.
      • Do not touch the rubber seal of the inverter terminal cover.
    2. GTY559252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Using an insulated tool, remove the 2 nuts and inverter terminal sub-assembly from the inverter with converter assembly.

      NOTE:

      Be careful not to drop any nuts into the inverter with converter assembly.

    3. GTY541463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Interlock Connector
      *2 Connector Bracket

      Temporarily install the inverter cover with the 7 bolts to prevent any foreign matter or water from entering the inverter with converter assembly.

      NOTE:
      • Make sure that the rubber seal of the inverter terminal cover is securely installed and that no foreign matter is adhering to it, then install it.
      • Do not touch the rubber seal of the inverter terminal cover.
      • Do not install the inverter terminal cover while pressing down on the connector bracket.
      • Securely connect the interlock connector.
    4. GTY559251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      As shown in the illustration, set the inverter terminal sub-assembly onto the inverter with converter assembly.

      HINT: 

      It is also acceptable to secure the inverter terminal sub-assembly using other tools, instead of setting it on the inverter with converter assembly.

    5. GTY559254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the 2 nuts and high voltage fuse from the inverter terminal sub-assembly.

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