LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2025 >> RAV4 Plug-In Hybrid SE >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Electric Motor Systems >> Hybrid Battery Control System (PHEV) - Service Information (1 Of 3) >> Inverter With Converter >> Removal [12/2021 - 10/2022] >> Procedure

Removal [12/2021 - 10/2022]: Procedure

  1. PRECAUTION 
    NOTE:

    After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

    Refer to BEFORE DISCONNECTING BATTERY [06/2020 - 10/2022]

  2. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [12/2021 - 10/2022]

  3. DRAIN COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 1

  4. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 23

  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 [12/2021 - 10/2022]

  8. REMOVE NO. 2 INVERTER PROTECTOR 
    1. Remove the 2 bolts and No. 2 inverter protector from the hybrid motor control inverter assembly.
      GTY997671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE CONNECTOR COVER ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    1. Remove the 2 bolts (B).
      GTY998396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt (A)
      *b Bolt (B)
    2. Using a T20 "TORX" socket wrench, remove the bolt (A) and connector cover assembly from the hybrid motor control inverter assembly.
      NOTE:

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

  10. 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 hybrid motor control inverter assembly.

      HINT: 

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

      GTY997683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    1. Temporarily install the connector cover assembly to the hybrid motor control inverter assembly.
      GTY997217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a T20 "TORX" socket wrench, install the bolt.
      NOTE:

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

  12. DISCONNECT ENGINE ROOM MAIN WIRE 
    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. 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.
      GTY997698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt.
      GTY997696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the clamp and disconnect the engine room main wire.
  13. DISCONNECT FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Remove the 2 nuts.
      GTY997682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and wire harness clamp bracket from the hybrid motor control inverter assembly.
      GTY997681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt, nut and wire harness clamp bracket from the hybrid motor control inverter assembly.
      GTY997542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    4. Remove the 2 bolts, nut and wire harness clamp bracket from the hybrid motor control inverter assembly.
      GTY997274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    5. Disengage the clamp.
    6. Remove the 2 bolts and disconnect the HV floor under wire from the hybrid motor control inverter assembly.
      GTY997185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
      NOTE:
      • Do not damage the terminals, interlock connector or hybrid motor control inverter 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 hybrid motor control inverter assembly.
      • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
      • Although the connector may feel loose, this is not due to a malfunction.
    7. Disconnect the HV floor under wire from the hybrid motor control inverter assembly.
      NOTE:
      • 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.
      GTY999535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
  14. DISCONNECT ENGINE WIRE 
    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. 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.
      GTY998492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. GTY997537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Disengage the clamp (A) and disconnect the No. 1 fuel vapor feed hose.

    3. Remove the bolt.
    4. Disengage the clamp (B).
    5. Disengage the 2 clamps (A) and disconnect the No. 1 fuel vapor feed hose and No. 2 fuel vapor feed hose.
      GTY997753Courtesy 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.
      GTY998218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Generator Temperature Sensor Connector
      *b Resolver (Transmission Fluid Temperature Sensor) Connector
      *c Shift Lever Position Sensor Connector
    10. Disconnect the resolver (transmission fluid temperature sensor) connector.
    11. Disconnect the shift lever position sensor connector.
    12. Disengage the clamp.
    13. Disengage the 2 clamps.
      GTY998500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    14. GTY998518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the bolt.

    15. Disengage the 2 clamps and disconnect the engine wire from the hybrid motor control inverter assembly.
  15. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Remove the nut and disconnect the transmission control cable assembly from the control shaft lever.
      GTY998517Courtesy 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.
      GTY998515Courtesy 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 hybrid motor control inverter assembly.
      GTY998513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. DISCONNECT NO. 1 INVERTER COOLING HOSE 
    1. Slide the clip and disconnect the No. 1 inverter cooling hose from the hybrid motor control inverter 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.

      GTY998533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT NO. 4 INVERTER COOLING HOSE 
    1. Slide the clip and disconnect the No. 4 inverter cooling hose from the hybrid motor control inverter 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.

      GTY997160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE UPPER INVERTER COVER SUB-ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    1. Loosen the 2 bolts, leaving 2 to 3 threads at the tip of the bolt still engaged.
      GTY1255118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using the 2 bolts as guides, remove the upper inverter cover sub-assembly from the hybrid motor control inverter assembly.
      NOTE:
      • Make sure to pull the upper inverter cover sub-assembly straight out, as a connector is connected to the inside of the upper inverter cover sub-assembly.
      • Do not touch the waterproof seal of the upper inverter cover sub-assembly.
      • Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
      • When removing the upper inverter cover sub-assembly, do not pull the areas (A) as they may deform.
      • Make sure that the interlock is installed to the upper inverter cover sub-assembly.
      • Do not remove or excessively tighten the screw of the upper inverter cover sub-assembly.
        GTY596587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Upper Inverter Cover Sub-assembly
        *a Do not remove or excessively tighten the screw
      • Although the upper inverter cover sub-assembly may feel loose, this is not due to a malfunction.
      • Hold the upper inverter cover sub-assembly horizontal while removing it.
        GTY1255121Courtesy 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 sub-assembly.

      GTY1255120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      GTY1255555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Interlock
      *b Waterproof Seal
    3. Remove the 2 bolts.
  19. DISCONNECT MOTOR CABLE 
    WARNING:

    Be sure to wear insulated gloves.

    NOTE:

    Adhere to the following removal procedure. Otherwise, the connector and the hybrid motor control inverter assembly may be damaged.

    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 motor cable.
      GTY998545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 motor cable.
      • Do not damage the terminals, connector housing or hybrid motor control inverter 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.
        GTY998538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      GTY997561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
  20. REMOVE HYBRID MOTOR CONTROL INVERTER ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    1. Remove the 5 bolts, 2 nuts and hybrid motor control inverter assembly.
      GTY998554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.

      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 hybrid motor control inverter assembly so that coolant does not spill out.

  21. REMOVE NO. 1 INVERTER BRACKET 
    NOTE:

    Make sure to support the hybrid motor control inverter assembly at the positions shown in the illustration, otherwise it may be damaged.

    GTY998052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Bottom of Hybrid Motor Control Inverter Assembly
    *b Support
    1. Set the hybrid motor control inverter assembly on wooden blocks.
      GTY997911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
    2. Remove the 2 bolts and No. 1 inverter bracket from the hybrid motor control inverter assembly.
  22. REMOVE NO. 2 INVERTER BRACKET 
    1. Remove the 2 bolts and No. 2 inverter bracket from the hybrid motor control inverter assembly.
      GTY998086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
  23. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. GTY998435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the bolt and wire harness clamp bracket from the hybrid motor control inverter assembly.

    2. GTY998432Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the 2 bolts and wire harness clamp bracket from the hybrid motor control inverter assembly.

    3. Remove the bolt and wire harness clamp bracket from the hybrid motor control inverter assembly.
      GTY998431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE HYBRID INVERTER PROTECTOR ASSEMBLY 
    1. Remove the 4 bolts and hybrid inverter protector assembly from the hybrid motor control inverter assembly.
      GTY998436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
scientia non olet · About LEMON Manuals