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Removal [12/2024 - ]: Procedure

WARNING: This page is about a different car, the 2025 Toyota Corolla Cross, 2024 Toyota Corolla Cross, and 2023 Toyota Corolla Cross. However, it is still accessible from the selected car via links, so may be relevant.
  1. PRECAUTION 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal.

    Refer to BEFORE DISCONNECTING BATTERY [11/2023 - ]
  2. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [11/2022 - ] 

  3. DRAIN COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 1

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

    Wear insulated gloves.
    1. GTY1108962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt (A) *b Bolt (B)
      1. Remove the bolt (A).
      2. Using a T20 "TORX" socket wrench, remove the bolt (B) and connector cover assembly from the hybrid motor control inverter assembly.
        NOTE:
        • Do not touch the connector cover assembly waterproof seal.
        • Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
  5. 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 hybrid motor control inverter assembly.
    1. GTY1180828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Terminal - -
      1. Measure the voltage between the terminals of the high voltage DC line.

        Specified Voltage

        0 V

        HINT: 

        • Set the tester to the DC 750 V range or higher to measure the voltage.
        • Perform the measurement while holding the tips of the tester probes against the terminals as shown in the illustration.
  6. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.

    NOTE:

    Do not touch the waterproof seal of the connector cover assembly.
    1. GTY1108903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a T20 "TORX" socket wrench, temporarily install the connector cover assembly to the hybrid motor control inverter assembly with the bolt.

        Torque: 2.0 N.m (20 kgf/cm, 18 in.lbf) 

  7. DISCONNECT FLOOR UNDER WIRE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.

    NOTE:

    Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.

    NOTE:
    • Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
    • Do not touch the waterproof seal or terminals of the connector.
    • Do not damage the terminals, connector housing or hybrid motor control inverter 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 hybrid motor control inverter assembly.
    • Insulate the disconnected terminals with insulating tape.
    1. GTY1251166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE AIR CLEANER CAP SUB-ASSEMBLY 
    1. GTY1104625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  10. REMOVE AIR CLEANER CASE SUB-ASSEMBLY 
    1. GTY1104349Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE NO. 1 AIR CLEANER HOSE 
    1. GTY1106490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE ECM 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to REMOVAL [11/2022 - ]
  13. DISCONNECT HV AIR CONDITIONING WIRE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.

    NOTE:
    • Do not damage the terminals, connector housing or hybrid motor control inverter assembly during disconnection.
    • Insulate the disconnected terminals with insulating tape.
    1. GTY1105663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Green-colored Lock - -
      Slide - -
      1. Disengage the 2 clamps.
      2. Slide the green-colored lock of the connector as shown in the illustration to release it and disconnect the HV air conditioning wire.
  14. REMOVE NO. 2 RELAY BLOCK COVER 
    1. GTY1106493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DISCONNECT NO. 3 ENGINE WIRE 
    1. GTY1109036Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE VACUUM SWITCHING VALVE ASSEMBLY 
    1. GTY1106492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. GTY1106479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DISCONNECT ENGINE ROOM MAIN WIRE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.

    NOTE:

    Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
    1. GTY1108406Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Disengage the clamp and disconnect the connector.
      2. Move the lock lever while pushing the lock on the connector, and disconnect the hybrid motor control inverter assembly connector.
        NOTE:
        • Do not damage the terminals, connector housing or hybrid motor control inverter 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.
  19. DISCONNECT ENGINE WIRE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Be sure to wear insulated gloves.

    NOTE:

    Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
    1. GTY1105396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Move the lock lever while pushing the lock on the connector, and disconnect the hybrid motor control inverter assembly connector.
        NOTE:
        • Do not damage the terminals, connector housing or hybrid motor control inverter 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.
      2. Disconnect the 2 connectors.
      3. Disengage the 2 claws.
      4. Remove the 3 nuts.
      5. Disengage the 2 clamps.
  20. DISCONNECT OUTLET NO. 1 INVERTER COOLING HOSE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
    1. GTY1106481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. DISCONNECT INLET NO. 1 INVERTER COOLING HOSE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
    1. GTY1106480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT NO. 7 ENGINE, WIRE 
    1. GTY1106478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. SEPARATE INVERTER WITH CONVERTER ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Be sure to wear insulated gloves.

    NOTE:

    To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.
    1. GTY1103726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE UPPER INVERTER COVER 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. GTY1108464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the bolt and inverter cover from the hybrid vehicle transaxle assembly.
      2. To prevent the inverter with converter assembly from falling, temporarily install the bolt in the location shown in the illustration.
      3. Shift the position of the inverter with converter assembly and temporarily set it on top of the stud bolts as shown in the illustration.
        NOTE:

        When lifting, make sure not to apply force to the motor cable.

      4. Loosen the 2 bolts, leaving 2 to 3 threads at the tip of the bolt still engaged.
    2. GTY1106944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Interlock *b Waterproof Seal
      1. Using the 2 bolts as guides, remove the upper inverter cover from the inverter with converter assembly.
        NOTE:
        • Make sure to pull the upper inverter cover straight out, as a connector is connected to the inside of the upper inverter cover.
        • Do not touch the waterproof seal of the upper inverter cover.
        • Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
        • When removing the upper inverter cover, do not pull the areas (A) as they may deform.
        • Make sure that the interlock is installed to the upper inverter cover.
        • Do not remove or excessively tighten the screw of the upper inverter cover.
          GTY1108287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
          *1 Inverter Cover
          *a Screw
        • Although the inverter cover may feel loose, this is not due to a malfunction.
        • Hold the upper inverter cover horizontal while removing it.
          GTY1106468Courtesy 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 upper inverter cover.

        GTY1106470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Remove the 2 bolts.
    3. GTY1104400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Shift the position of the inverter with converter assembly and temporarily set it on the hybrid vehicle transaxle assembly as shown in the illustration.
        NOTE:

        When lifting, make sure not to apply force to the motor cable.

      2. Remove the bolt.
  25. DISCONNECT MOTOR CABLE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. GTY1107772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal - -
      1. Using an insulated tool, remove the 6 bolts.
        NOTE:
        • Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
        • Do not touch the waterproof seal or terminals of the connector.
      2. Remove the 4 bolts and disconnect the motor cable from the hybrid motor control inverter assembly.
        NOTE:
        • Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
        • Do not touch the waterproof seal or terminals of the connector.
        • Do not damage the terminals, connector housing or hybrid motor control inverter 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.
        • To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.
          GTY1106464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE INVERTER WITH CONVERTER ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Be sure to wear insulated gloves.

    NOTE:
    • When removing the hybrid motor control inverter assembly, be careful not to damage the parts around it.
    • To prevent damage, do not hold the hybrid motor control inverter assembly by the connectors, brackets or cooling pipes.
    • To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.
    1. GTY1106467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. 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 hybrid motor control inverter assembly so that coolant does not spill out.
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