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Home >> Toyota >> 2025 >> Prius Plug-In Hybrid SE >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Electric Motor Systems >> Hybrid Battery Control System - Service Information (2 Of 3) >> INVERTER WITH CONVERTER (for HEV Model) >> Removal [12/2022 - ] >> Procedure

Removal [12/2022 - ]: Procedure

  1. PRECAUTION 
    Refer to PRECAUTION [12/2022 - 03/2023] , or refer to PRECAUTION [03/2023 - ]
  2. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [12/2022 - ]

  3. DRAIN COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 1

  4. REMOVE FRONT WIPER ARM HEAD CAP 
    Refer to PROCEDURE - Step 1
  5. REMOVE SHIELD CAP (for M20A-FXS) 
    Refer to PROCEDURE - Step 2
  6. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH 

    Refer to PROCEDURE - Step 3

  7. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH 

    Refer to PROCEDURE - Step 4

  8. REMOVE WINDSHIELD LOWER OUTSIDE MOULDING LH 
    Refer to PROCEDURE - Step 1 [12/2022 - 03/2023] , or refer to PROCEDURE - Step 1 [03/2023 - ]
  9. REMOVE WINDSHIELD LOWER OUTSIDE MOULDING RH 
    1. Use the same procedure as for the LH side.
  10. REMOVE COWL WATER EXTRACT SHIELD LH 

    Refer to PROCEDURE - Step 7

  11. REMOVE COWL WATER EXTRACT SHIELD RH 
    1. Use the same procedure as for the LH side.
  12. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 9

  13. CHECK TERMINAL VOLTAGE 
    WARNING:

    Be sure to wear insulated gloves.
    1. GTY1141598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the bolt (A).
      2. Using a T20 "TORX" socket wrench, remove the bolt (B) 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.
    2. GTY1158130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Terminal - -
      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.
        • Perform the measurement while holding the tips of the tester probes against the terminals as shown in the illustration.
    3. GTY1141598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a T20 "TORX" socket wrench, install the connector cover assembly to the inverter with converter assembly with the bolt (B).

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

        NOTE:

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

      2. Install the bolt (A).

        Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

        HINT: 

        It is not necessary to install the bolt (B) if it is to be removed in the next step or later, such as when removing the inverter with converter assembly.

  14. REMOVE ECM 
  15. DISCONNECT NO. 2 VENTILATION HOSE (for M20A-FXS) 

    Refer to PROCEDURE - Step 2

  16. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE (for M20A-FXS) 

    Refer to PROCEDURE - Step 3

  17. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY (for M20A-FXS) 

    Refer to PROCEDURE - Step 2

  18. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (for M20A-FXS) 
    1. GTY1150025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE AIR CLEANER BRACKET (for M20A-FXS) 
    1. GTY1150024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. DISCONNECT HV AIR CONDITIONING WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    NOTE:
    • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
    • Insulate the disconnected terminals with insulating tape.
    1. for 2ZR-FXE:
      GTY1147672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Green-colored Lock - -
      Slide - -
      1. Slide the green-colored lock of the connector as shown in the illustration to release it and disconnect the HV air conditioning wire.
    2. for M20A-FXS:
      GTY1156626Courtesy 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.
  21. REMOVE NO. 2 RELAY BLOCK COVER 
    1. GTY1150039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT NO. 3 ENGINE WIRE 
    1. GTY1149983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT VACUUM SWITCHING VALVE ASSEMBLY NO. 1 
    1. GTY1150044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. 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. GTY1152214Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
    2. GTY1150045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. GTY1140705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. 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. GTY1159258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
    2. GTY1150040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. DISCONNECT FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    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.
    • 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.
    1. GTY1149067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal - -
    2. for 4WD:
      GTY1153520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal - -
  27. DISCONNECT NO. 7 ENGINE WIRE 
    WARNING:

    Be sure to wear insulated gloves.
    1. GTY1149982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. DISCONNECT OUTLET NO. 1 INVERTER COOLING HOSE 
    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. GTY1149991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. DISCONNECT INLET NO. 1 INVERTER COOLING HOSE 
    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. GTY1149988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. 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. GTY1149987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. SEPARATE INVERTER WITH CONVERTER ASSEMBLY 
    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. GTY1149990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE UPPER INVERTER COVER 
    WARNING:

    Be sure to wear insulated gloves.
    1. GTY1142961Courtesy 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. GTY1144921Courtesy 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 inverter with converter 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.

        GTY1149984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Remove the 2 bolts.
    3. GTY1155268Courtesy 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.
  33. DISCONNECT MOTOR CABLE 
    WARNING:

    Be sure to wear insulated gloves.
    1. GTY1158057Courtesy 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 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.
        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.
        • To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.
          GTY1149998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE INVERTER WITH CONVERTER ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    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.
    1. GTY1140698Courtesy 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 inverter with converter assembly so that coolant does not spill out.
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