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Home >> Toyota >> 2021 >> Mirai XLE >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Electric Motor Systems >> Hybrid Battery Control System - Service Information (1 Of 6) >> Inverter With Converter >> Removal [11/2020 - 11/2021] >> Procedure

Removal [11/2020 - 11/2021]: Procedure

  1. PRECAUTION 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PRECAUTION [11/2020 - ]
  2. CAUTIONS FOR HIGH VOLTAGE SYSTEM COMPONENTS 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 1
  3. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [11/2020 - 11/2021]

  4. REMOVE UPPER RADIATOR SUPPORT SEAL 

    Refer to PROCEDURE - Step 5

  5. REMOVE RADIATOR COVER PLATE 

    Refer to PROCEDURE - Step 6

  6. REMOVE LOWER RADIATOR AIR DEFLECTOR 

    Refer to PROCEDURE - Step 7

  7. DRAIN COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 5

  8. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 

    Refer to REMOVAL [11/2020 - ]

  9. REMOVE FC STACK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8

  10. DISCONNECT FC CONVERTER POWER OUTLET CABLE (INVERTER WITH CONVERTER ASSEMBLY) 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:
    • Be sure to wear insulated gloves.
    • Do not inspect or service the high voltage system with the service plug grip and FC converter power outlet cable (inverter with converter assembly) installed.
      GTY1004993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • To reduce the risk of electric shock, make sure to remove the service plug grip and FC converter power outlet cable (inverter with converter assembly) to cut off the high voltage circuit before servicing the vehicle.
    • Make sure to remove the service plug grip first, and then remove the (inverter with converter assembly).
    • To reduce the risk of electric shock, make sure to wait at least 10 minutes after removing the service plug grip and FC converter power outlet cable (inverter with converter assembly) to fully discharge the high voltage capacitor inside the inverter with converter assembly.
      GTY1004988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Keep the removed service plug grip in your pocket to prevent other technicians from accidentally installing it while you are servicing the vehicle.
    NOTE:
    • After removing the service plug grip and FC converter power outlet cable (inverter with converter assembly), turning the ignition switch to ON (READY) may cause a malfunction. Do not turn the ignition switch to ON (READY) unless instructed by the appropriate service information .
    • Do not touch the terminals of the service plug grip and FC converter power outlet cable (inverter with converter assembly).
    • If the service plug grip has been struck or dropped, replace it.
    HINT: Waiting for at least 10 minutes is required to discharge the high voltage capacitor inside the inverter with converter assembly.
    1. GTY1165620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the bolt.
      2. Disengage the clamp.
      3. Remove the 2 bolts A.
        NOTE:

        Removing the bolts in an incorrect order may damage the FC stack and FC converter power outlet cable (inverter with converter assembly).

      4. Remove the bolt B.
        NOTE:
        • Removing the bolts in an incorrect order may damage the FC stack and FC converter power outlet cable (inverter with converter assembly).
        • When removing bolt B, the connector will be tilted. If bolt B is removed with the connector tilted, the front holder may be removed and left in the stack. Therefore, push the cable from below so that the connector is not tilted while removing bolt B.
          GTY1166678Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
          *a Bolt B
          Push The Cable
      5. Disconnect the FC converter power outlet cable (inverter with converter assembly).
      6. Protect the openings of the FC converter assembly with protective tape (non-residue type) to prevent the entry of foreign matter or water.
    2. GTY1004334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Use the "CAUTION: HIGH VOLTAGE DO NOT TOUCH" sign to notify other technicians that the high-voltage system is being inspected and/or repaired.
        NOTE:

        Be careful not to touch the terminal before or during attaching the display label.

    3. If the FC converter power outlet front holder and FC converter power outlet front gasket are left in the stack, remove them using the following procedure.
      GTY1165432Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a + Side *b - Side
      1. Check the voltage using the voltage detector hole.

        Standard Voltage

        0 V

        NOTE:

        Do not touch the terminal contact point.

        GTY1167163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Terminal Contact Point

        HINT: 

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

      2. Using needle-nose pliers with their tips wrapped with insulating tape, remove the FC converter power outlet front holder and FC converter power outlet front gasket.

        HINT: 

        When removing the FC converter power outlet front holder, pull it out straight up.

  11. REMOVE CONNECTOR COVER ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.

    NOTE:
    • Make sure to pull the connector cover assembly straight up, as a connector is connected to the bottom of the cover.
    • Do not touch the connector cover assembly waterproofing rubber.
    • Do not allow any foreign matter or water to enter the inverter with converter assembly.
    1. GTY1004233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. CHECK TERMINAL VOLTAGE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.

    NOTE:

    Do not allow any foreign matter or water to enter the inverter with converter assembly.
    1. GTY1004103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.

  13. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.

    NOTE:
    • Visually confirm that the connector cover assembly waterproofing rubber is securely installed before installing the connector cover assembly.
    • Do not touch the connector cover assembly waterproofing rubber.
    • Make sure that the interlock is fully engaged.
    1. GTY1004233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE INVERTER TERMINAL COVER 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.

    NOTE:
    • Make sure to pull the inverter terminal cover straight up, as a connector is connected to the bottom of the 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.
    1. GTY1003805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DISCONNECT FC AIR COMPRESSOR MOTOR CABLE ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. GTY1003238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an insulated tool, remove the 3 bolts (A).
      2. Using an insulated tool, remove the 2 bolts (B), and disconnect the FC air compressor motor cable assembly 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.
      3. Protect the openings of the inverter with converter assembly with protective tape (non-residue type) to prevent the entry of foreign matter or water.
  16. DISCONNECT NO. 2 BATTERY PACK WIRE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. GTY1003361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an insulated tool, remove the 3 bolts (A).
      2. Using an insulated tool, remove the 2 bolts (B), and disconnect the No. 2 battery pack 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 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.
      3. Protect the openings of the inverter with converter assembly with protective tape (non-residue type) to prevent the entry of foreign matter or water.
  17. REMOVE INVERTER MOTOR CABLE BRACKET ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. GTY1003806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DISCONNECT FC CONVERTER POWER OUTLET CABLE (INVERTER WITH CONVERTER ASSEMBLY) 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. GTY1004861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE FENDER APRON BRACE SUB-ASSEMBLY RH 
    1. GTY1003717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. DISCONNECT NO. 1 FC INVERTER COOLING HOSE SUB-ASSEMBLY 
    1. GTY1003615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Release the retainer and disconnect the No. 1 FC inverter cooling hose sub-assembly from the inverter with converter assembly as shown in the illustration.
      2. Protect the connecting part of the No. 1 FC inverter cooling hose sub-assembly with a plastic bag to prevent entry of foreign matter.
      3. Protect the openings of the inverter with converter assembly with protective tape (non-residue type) to prevent the entry of foreign matter or water.
        NOTE:

        Apply insulating tape to the pipes and in the disconnected hoses, or cover the pipes and hoses with plastic bags to prevent foreign matter from entering the cooling system and to prevent coolant from spilling near the inverter with converter assembly.

  21. DISCONNECT NO. 3 FC INVERTER COOLING HOSE 
    1. GTY1003986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Release the hose clip and disconnect the No. 3 FC inverter cooling hose from the inverter with converter assembly.
      2. Protect the connecting part of the No. 3 FC inverter cooling hose with a plastic bag to prevent entry of foreign matter.
      3. Protect the openings of the inverter with converter assembly with protective tape (non-residue type) to prevent the entry of foreign matter or water.
        NOTE:

        Apply insulating tape to the pipes and in the disconnected hoses, or cover the pipes and hoses with plastic bags to prevent foreign matter from entering the cooling system and to prevent coolant from spilling near the inverter with converter assembly.

  22. DISCONNECT INVERTER BUS-BAR PLATE SUB-ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. GTY1003708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. GTY1005068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. DISCONNECT FRONT COMPARTMENT MAIN WIRE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. GTY1003797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Raise the lock lever and disconnect the front compartment main wire from the inverter with converter assembly as shown in the illustration.
        NOTE:
        • Insulate the disconnected connector with insulating tape.
        • Cover the hole where the connector was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
      2. Remove the connector cover assembly.

        See step  11

      3. Disconnect the front compartment main 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 connector waterproofing rubber or terminals.
        • Do not damage the connectors, 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.
      4. Temporarily install the connector cover assembly.

        See step  13

  25. REMOVE FC JUNCTION CABLE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. GTY1003923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the connector cover assembly.

        See step  11

      2. Remove the bolt, and disconnect the FC junction cable 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 connectors, 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.
      3. Temporarily install the connector cover assembly.

        See step  13

  26. REMOVE INVERTER WITH CONVERTER ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.

    NOTE:

    Even after the coolant is drained, coolant remains in the inverter with converter assembly due to its internal structure. Therefore, plug or cover the pipes with a plastic bag when removing the inverter with converter assembly from the vehicle so that coolant does not spill out.
    1. GTY1003484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Disengage the clamp from the No. 6 inverter bracket.
      2. Remove the 6 bolts, No. 6 inverter bracket and inverter with converter assembly.
        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 so that coolant does not spill out.

    2. GTY1003200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Cushion - -
      1. When removing and storing the inverter with converter assembly, make sure to install the inverter terminal cover and place a cushion under the inverter with converter assembly to protect it.
        NOTE:

        Do not place the inverter with converter assembly upside down.

  27. REMOVE NO. 4 INVERTER BRACKET 
    1. GTY1003735Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE INVERTER BUS-BAR PLATE SUB-ASSEMBLY 
    1. GTY1003817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Disengage the clamp and remove the bolt.
      2. Open the terminal cover.
      3. Remove the nut.
        NOTE:

        If the stud bolt becomes loose when removing the nut, tighten the stud bolt to a torque of 10 N.m (102 kgf/cm 7 ft.lbf).

      4. Remove the inverter bus-bar plate sub-assembly.
        NOTE:

        If the inverter bus-bar plate sub-assembly is dropped or deformed, replace it with a new one.

  29. REMOVE NO. 1 INVERTER COOLING HOSE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

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

    HINT: Perform this procedure only when replacement of the No. 1 inverter cooling hose is necessary.
    1. GTY1004216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE HIGH VOLTAGE FUSE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.

    HINT: Perform this procedure only when replacement of the high voltage fuse is necessary.
    1. GTY1003729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the connector cover assembly.
      2. Remove the 2 nuts and high voltage fuse.
        NOTE:

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

      3. Temporarily install the connector cover assembly.
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