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Home >> Toyota >> 2019 >> RAV4 XLE, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 10 (Hybrid Battery Control System - Service Information (1 Of 7)) >> INVERTER WITH CONVERTER (for AWD) >> Removal [10/2019 - 06/2020] >> Procedure

Removal [10/2019 - 06/2020]: Procedure

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

    After turning the ignition 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.

  2. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [10/2019 - 06/2020]

  3. DRAIN COOLANT (for Inverter) 

    See step  1

  4. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 26

  5. REMOVE INLET AIR CLEANER ASSEMBLY 

    Refer to PROCEDURE - Step 3

  6. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 4

  7. REMOVE ECM 

    Refer to REMOVAL [02/2019 - 08/2020]

  8. REMOVE NO. 2 INVERTER PROTECTOR (w/ NO. 2 INVERTER PROTECTOR) 
    1. Remove the 2 bolts and No. 2 inverter protector from the inverter with converter assembly.
      GTY842242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. DISCONNECT ENGINE ROOM MAIN WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    NOTE:

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

    1. Move the lock lever while pushing the lock on the connector, and disconnect the inverter with converter assembly connector.
      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.
      • Insulate the disconnected terminals with insulating tape.
      • Do not touch the waterproof seal or terminals of the connector.
      GTY842209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt.
      GTY842206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the clamp and disconnect the engine room main wire.
  10. REMOVE CONNECTOR COVER ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    1. Remove the bolt (B).
      GTY929762Courtesy 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.
  11. CHECK TERMINAL VOLTAGE 
    WARNING:

    Be sure to wear insulated gloves.

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

      Standard Voltage

      0 V

      NOTE:

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

      HINT: 

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

      GTY842207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    1. Temporarily install the connector cover assembly to the inverter with converter assembly.
      GTY842216Courtesy 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 connector cover assembly waterproof seal.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
  13. DISCONNECT FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Remove the 2 bolts and disconnect the HV floor under wire from the inverter with converter assembly.
      GTY936929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
      NOTE:
      • Do not damage the terminals, interlock connector or inverter with converter assembly during disconnection.
      • Do not touch the waterproof seal or terminals of the connector.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Although the connector may feel loose, this is not due to a malfunction.
    2. Remove the 2 nuts and disconnect the HV floor under wire from the inverter with converter assembly.
      GTY842243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and disconnect the HV floor under wire from the inverter with converter assembly.
      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.
      GTY875892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
  14. DISCONNECT HV AIR CONDITIONING WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Remove the 2 bolts.
      GTY872530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
    2. Disengage the clamp and disconnect the HV air conditioning wire 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 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.
  15. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. Remove the nut and wire harness clamp bracket.
      GTY842219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. DISCONNECT ENGINE WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    NOTE:

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

    1. Move the lock lever while pushing the lock on the connector, and disconnect the inverter with converter assembly connector.
      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.
      • Insulate the disconnected terminals with insulating tape.
      • Do not touch the waterproof seal or terminals of the connector.
      GTY842220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clamp (A) and disconnect the No. 1 fuel vapor feed hose.
      GTY886133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt.
    4. Disengage the 3 clamps (B).
    5. Disengage the 2 clamps (A) and disconnect the No. 1 fuel vapor feed hose and No. 2 fuel vapor feed hose.
      GTY938557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the bolt.
    7. Disengage the clamp (B).
    8. Disconnect the EGR valve connector.
    9. Disconnect the generator temperature sensor connector, resolver (transmission fluid temperature sensor) connector and shift lever position sensor connector and disengage the clamp.
      GTY912198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Generator Temperature Sensor Connector
      *b Resolver (Transmission Fluid Temperature Sensor) Connector
      *c Shift Lever Position Sensor Connector
      NOTE:

      After disconnecting the engine wire, cover the connector of the generator temperature sensor, resolver (transmission fluid temperature sensor) and shift lever position sensor with tape (non-residue type) or equivalent to prevent the entry of foreign matter or water.

      GTY977388Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Disengage the 2 clamps.
      GTY842211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Remove the bolt.
      GTY842212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Remove the bolt.
      GTY842213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Disengage the 2 claws and open the engine wire terminal cover.
      GTY842226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    14. Remove the nut.
      GTY842227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    15. Disengage the 2 clamps and disconnect the engine wire from the inverter with converter assembly.
  17. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Remove the nut and disconnect the transmission control cable assembly from the control shaft lever.
      GTY842228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, disengage the 4 claws and disconnect the transmission control cable assembly with the clip from the No. 1 transmission control cable bracket.
      GTY842229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, disengage the 2 claws and remove the clip from the transmission control cable assembly.
      GTY745662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 bolts and disconnect the transmission control cable assembly from the inverter with converter assembly.
      GTY927070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DISCONNECT NO. 1 INVERTER COOLING HOSE 
    1. Slide the clip and disconnect the 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.

      GTY842230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. DISCONNECT NO. 4 INVERTER COOLING HOSE 
    1. Slide the clip and disconnect the No. 4 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.

      GTY842222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE INVERTER COVER 
    WARNING:

    Be sure to wear insulated gloves.

    1. Loosen the bolt leaving 2 or 3 threads from the end of the bolt.
      GTY1250498Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using the 2 bolts as guides, remove the upper inverter cover from the hybrid motor control inverter 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 Do not remove or excessively tighten the screw
      • Although the inverter cover may feel loose, this is not due to a malfunction.
      • Remove the inverter cover while keeping it horizontal.
        GTY1156555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

      GTY1250516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      GTY1250536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Interlock
      *b Waterproof Seal
    3. Remove the 2 bolts.
  21. DISCONNECT MOTOR CABLE 
    WARNING:

    Be sure to wear insulated gloves.

    NOTE:

    Adhere to the following removal procedure. Otherwise, the connector and the inverter with converter assembly may be damaged.

    1. Using an insulated tool, remove the 6 bolts.
      GTY927069Courtesy 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 motor cable.
    2. Remove the 4 bolts and disconnect the motor cable from the inverter with converter assembly.
      GTY913904Courtesy 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 motor cable.
      • 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.
        GTY842236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE INVERTER WITH CONVERTER ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    1. Remove the 5 bolts, 2 nuts and inverter with converter assembly.
      GTY927071Courtesy 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.

  23. REMOVE NO. 1 INVERTER BRACKET 
    NOTE:

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

    GTY884543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Bottom of Inverter with Converter Assembly
    *b Support
    1. Set the inverter with converter assembly on wooden blocks.
      GTY839627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
    2. Remove the 2 bolts and No. 1 inverter bracket from the inverter with converter assembly.
  24. REMOVE NO. 2 INVERTER BRACKET 
    1. Remove the 2 bolts and No. 2 inverter bracket from the inverter with converter assembly.
      GTY844373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
  25. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. w/o hybrid inverter protector assembly:
      1. Remove the 2 bolts and wire harness clamp bracket from the inverter with converter assembly.
        GTY842239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and wire harness clamp bracket from the inverter with converter assembly.
      GTY842231Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and wire harness clamp bracket from the inverter with converter assembly.
      GTY842232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 bolts and wire harness clamp bracket from the inverter with converter assembly.
      GTY859164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 2 bolts and wire harness clamp bracket from the inverter with converter assembly.
      GTY859163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE HYBRID INVERTER PROTECTOR ASSEMBLY (w/ HYBRID INVERTER PROTECTOR ASSEMBLY) 
    1. Remove the 4 bolts and hybrid inverter protector assembly from the inverter with converter assembly.
      GTY903858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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