INVERTER WITH CONVERTER REMOVAL

Info Added 2017-10-06

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during inverter with converter assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure Necessary Procedures Effect/Inoperative Function when Necessary Procedure not Performed Link
Disconnect cable from negative auxiliary battery terminal Memorize steering angle neutral point Lane departure alert system (w/ Steering Control)

Click here

Simple intelligent parking assist system*1
Toyota parking assist-sensor system*1
Pre-collision system
Initialize back door lock Power door lock control system

Click here

Replacement of inverter with converter assembly Resolver learning

  • DTCs are stored

  • Slight vibration at a vehicle speed of 5 km/h (3 mph) or less

  • Shock or vibration during acceleration

Click here


    for SFI system

  • Replacement of ECM

 Perform Vehicle Identification Number (VIN) registration MIL comes on

Click here

*1: When performing learning using the GTS.
Click here Click here

CAUTION:


  • B0048QR

    This vehicle has contains high voltage circuits standardized with orange colored wiring and connectors, so follow the instructions in this manual to perform the procedures correctly.

    Click here

  • If the correct procedures are not followed according to the instructions in this manual, there is a danger of electric shock from the high voltage circuits.

  • B0048QQ

    Be sure to wear insulating gloves when working on high voltage wiring or components.

  • If work is performed without wearing insulating gloves, there is a danger of electric shock.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the power 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.

    Click here

  2. DISCONNECT ENGINE WIRE


    1. A001NRM

      Disengage the 2 claws and disconnect the engine wire from the battery current sensor holder.

    2. Disconnect the battery state sensor assembly connector.

  3. REMOVE AUXILIARY BATTERY

    Click here

  4. REMOVE SERVICE PLUG GRIP

    Click here

  5. REMOVE REAR ENGINE UNDER COVER LH

    Click here

  6. DRAIN COOLANT (for Inverter)

    Click here

  7. REMOVE ECM

    Click here

  8. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. A001O6Q

      Remove the 3 bolts and battery clamp sub-assembly from the vehicle.

  9. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A001PFC

      Disengage the clamp to separate the transmission control cable assembly.

  10. DISCONNECT ENGINE WIRE

    CAUTION:

    Wear insulated gloves.

    Note

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


    1. A001S8A

      Remove the No. 1 relay block cover from the No. 1 engine room relay block.

    2. A001Q31

      Disconnect the 3 No. 1 engine room relay block connectors.

    3. Disengage the 2 claws to separate the engine wire from the No. 1 engine room relay block.

    4. A001Q97

      Move each lock lever as shown in the illustration and disconnect the 2 inverter with converter assembly connectors.

      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.

    5. A001P4NN01

      Remove the bolt.

    6. Disengage the clamp (A) and remove the inverter protector.

    7. Disengage the clamp (B).

    8. Remove the 2 bolts.

      A001R6I

    9. Disengage the clamp and disconnect the engine wire.

  11. REMOVE CONNECTOR COVER ASSEMBLY

    CAUTION:

    Wear insulated gloves.


    1. A001Q9OC06
      *a Bolt (A)
      *b Bolt (B)

      Remove the 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.

  12. CHECK TERMINAL VOLTAGE

    CAUTION:

    Wear insulated gloves.

    Note

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


    1. A001OAU

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

      Standard Voltage
      0 V

      Tech Tips

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

  13. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

    CAUTION:

    Wear insulated gloves.


    1. A001NYC

      Temporarily install the connector cover assembly to the inverter with converter assembly.

    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 waterproof seal of the connector cover assembly.

  14. DISCONNECT HV FLOOR UNDER WIRE

    CAUTION:

    Wear insulated gloves.

    Note

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


    1. A001R2IC02
      *a Waterproof Seal

      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.

    2. Disengage the 2 clamps.

  15. DISCONNECT HV AIR CONDITIONING WIRE

    CAUTION:

    Wear insulated gloves.


    1. A001R1NC02
      *a Waterproof Seal

      Remove the 2 bolts and disconnect the HV air conditioning 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.

    2. Disengage the clamp.

  16. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A001OY5

      Remove the nut and wire harness clamp bracket.

  17. DISCONNECT NO. 3 ENGINE WIRE

    CAUTION:

    Wear insulated gloves.


    1. A001RY6

      Remove the bolt and disconnect the No. 3 engine wire from the inverter with converter assembly.

    2. A001QDF

      Remove the bolt and disconnect the No. 3 engine wire from the inverter with converter assembly.

    3. A001R39

      Disengage the 2 claws and open the No. 3 engine wire terminal cover.

    4. A001S5G

      Remove the nut.

    5. Disengage the clamp and disconnect the No. 3 engine wire from the inverter with converter assembly.

  18. DISCONNECT OUTLET NO. 1 INVERTER COOLING HOSE


    1. A001RX6

      Slide the clip and disconnect the outlet 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.

  19. DISCONNECT INLET NO. 1 INVERTER COOLING HOSE


    1. A001P6H

      Slide the clip and disconnect the inlet 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.

  20. REMOVE INVERTER COVER

    CAUTION:

    Wear insulated gloves.


    1. A001QZCC02
      *a Interlock
      *b Waterproof Seal

      Remove the 2 bolts and inverter cover from the inverter with converter 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.

      • A001RDIC02
        *1 Inverter Cover
        *a Screw

        Do not remove or excessively tighten the screw of the inverter cover.

      • Although the inverter cover may feel loose, this is not due to a malfunction.

  21. DISCONNECT MOTOR CABLE

    CAUTION:

    Wear insulated gloves.


    1. A001PKD

      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. A001NVAC03
      *a Waterproof Seal

      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.

      • A001PWE

        To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.

  22. REMOVE INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Wear insulated gloves.


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

      A001R9F

      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.

      Tech Tips

      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


    1. A001RD1C01
      *a Wooden Block

      Set the inverter with converter assembly on wooden blocks.

      Note

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

      A001RV5

    2. Remove the 2 bolts and No. 1 inverter bracket from the inverter with converter assembly.

  24. REMOVE NO. 2 INVERTER BRACKET


    1. A001Q8KC01
      *a Wooden Block

      Remove the 2 bolts and No. 2 inverter bracket from the inverter with converter assembly.

  25. REMOVE TRANSMISSION CONTROL CABLE BRACKET


    1. A001OMU

      Remove the bolt and transmission control cable bracket from the inverter with converter assembly.

  26. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A001RA3

      Remove the bolt and wire harness clamp bracket from the inverter with converter assembly.

    2. A001QKM

      Remove the bolt and wire harness clamp bracket from the inverter with converter assembly.

    3. A001Q08

      Remove the bolt and wire harness clamp bracket from the inverter with converter assembly.