ELECTRIC VEHICLE CONVERTER REASSEMBLY

CAUTION / NOTICE / HINT

Note

Do not cross-thread the bolts when installing them.

Tech Tips

Prepare 2 tubes of thermal grease X-23-7884-4 when replacing the hybrid converter kit.


PROCEDURE


  1. REMOVE THERMAL GREASE


    1. B001MC1E03
      Text in Illustration
      *1 Bolt
      *2 Nut
      *3 Antistatic Mat

      Working with another person, install the 4 bolts and 4 nuts to the power module intelligent transistor kit.

    2. Place the power module intelligent transistor kit on an antistatic mat.

      Note


      • Do not touch the circuit board.

      • Do not apply excessive force to the center of the hybrid converter kit.

      • Keep the parts free from foreign matter.

      • Keep thermal grease away from other parts.

      • Do not spray non-residue solvent directly onto the parts when cleaning.

      • Clean parts with a piece of cloth saturated with non-residue solvent.

      • Do not use compressed air when cleaning to prevent dust from flying.

    3. Using a piece of cloth, remove the thermal grease.

    4. Working with another person, remove the 4 bolts and 4 nuts from the power module intelligent transistor kit.

  2. REMOVE SEAL PACKING (FROM INVERTER CASE WITH CONDENSER CONTACT SURFACE)

    Note


    • Only remove seal packing which is uneven, has peeled off or seeped out from between the contact surfaces.

    • Do not drop any removed seal packing into the inverter case with condenser.

    • Do not bend the bus-bars.


    1. Set the inverter case with condenser on its side as shown in the illustration.

      Note

      To prevent the inverter case with condenser from falling over, hold it by hand or place an object behind it.

    2. Using a finger or a scraper with its tip wrapped with protective tape, remove any remaining seal packing which is uneven, has peeled off or seeped out from around the contact surface shown in the illustration and inside the bolt holes.

      B001K9BE04
      Text in Illustration
      *1 Seeped Out or Uneven Seal Packing *2 Light Coat of Seal Packing Remaining on Contact Surface
      *a Minimum Requirement for Removal of Seal Packing - -

  3. REMOVE ADHESIVE (FROM NO. 1 AND NO. 2 INVERTER DRAIN PLUGS SEALING SURFACE)


    1. B001MIYE01
      Text in Illustration
      *1 Protective Tape

      Remove the protective tape from the installation holes of the No. 1 and No. 2 inverter drain plugs.

    2. B001M9JE01
      Text in Illustration
      *1 Protective Tape

      Apply protective tape to the No. 1 and No. 2 inverter drain plugs installation holes from the inside.

      Note

      Do not bend the bus-bars when applying protective tape.

    3. B001N0BE01
      Text in Illustration
      *1 Sealing Surface

      Using a scraper with its tip wrapped with protective tape, remove any remaining adhesive from the sealing surface of 2 inverter drain plugs.

      Note

      Do not damage the sealing surfaces.

    4. Remove any adhesive shavings particles using tape or equivalent.

    5. Remove the protective tape from the inside of the inverter case with condenser.

    6. B001MIYE01
      Text in Illustration
      *1 Protective Tape

      Apply protective tape to the installation holes of the No. 1 and No. 2 inverter drain plugs as shown in the illustration.

  4. REMOVE RESIDUE (FROM INVERTER SIGNAL CONNECTOR COVER SEALING SURFACE)


    1. B001LSLE01
      Text in Illustration
      *1 Protective Tape

      Apply protective tape to the area shown in the illustration to prevent removed residue from entering the inverter case with condenser.

    2. B001K97

      Using 600-grit sandpaper, remove the residue from each grommet sealing surface until it feels smooth.

      Note


      • Use 600-grit or higher sandpaper.

      • Do not allow removed residue to enter the inverter case with condenser or hybrid vehicle converter kit.

      • Do not touch or allow grease or oil to contact the sealing surfaces of the inverter case with condenser.

    3. Remove any adhesive particles using tape or equivalent.

    4. Remove the protective tape.

    5. Thoroughly wash hands after performing this step.

      Tech Tips

      This step is not necessary if performing the "Remove Residue (from Grommet Sealing Surface)" procedure next.

  5. REMOVE RESIDUE (FROM GROMMET SEALING SURFACE)

    Tech Tips

    Perform the following procedure only when there is residue on the grommet sealing surfaces:


    1. B001KGXE03
      Text in Illustration
      *1 Inverter Case with Condenser
      *2 Protective Tape

      Apply protective tape to the areas shown in the illustration to prevent removed residue from entering the inverter case with condenser and hybrid vehicle converter kit.

    2. Using 600-grit sandpaper, remove the residue from each grommet sealing surface until it feels smooth.

      B001NE6E03
      Text in Illustration
      *a Residue - -

      Note


      • Use 600-grit or higher sandpaper.

      • Do not allow removed residue to enter the inverter case with condenser or hybrid vehicle converter kit.

    3. Remove any adhesive shavings particles using tape or equivalent.

    4. Remove the protective tape.

    5. Thoroughly wash hands after performing this step.

  6. CLEAN INVERTER SIGNAL CONNECTOR COVER


    1. B001LS3E01
      Text in Illustration
      *1 Gasket

      Remove the gasket from the inverter signal connector cover. Wash the gasket and inverter signal connector cover with water and dry them completely.

      Note

      Do not damage the gasket.

    2. Thoroughly wash hands after performing this step.

  7. INSTALL POWER MODULE INTELLIGENT TRANSISTOR KIT

    Note


    • Do not touch the circuit board.

    • Do not allow any moisture to come into contact with the circuit board.


    1. B001LZ0E03
      Text in Illustration
      *1 Guide Pins
      *a Thermal Grease Contacting Area

      Place the hybrid vehicle converter kit so that the guide pins are positioned as shown in the illustration and clean the thermal grease contacting area of the hybrid vehicle converter kit.

      Tech Tips

      Clean the hybrid vehicle converter kit contact surfaces with a piece of cloth saturated with non-residue solvent.

    2. B001NFZE01
      Text in Illustration
      *1 Protective Tape

      Apply protective tape to the wire harness to keep it free from grease.

    3. B001LKTE01
      Text in Illustration
      *1 Protective Tape

      Apply protective tape to prevent grease from entering the hybrid vehicle converter kit.

    4. B001KPQ

      Remove the protective paper from the masking seal.

    5. Align the guide holes of the masking seal with the guide pins as shown in the illustration, and attach the masking seal to the hybrid vehicle converter kit.

      B001KX6E03
      Text in Illustration
      *1 Masking Seal *2 Guide Pins
      *3 Guide Hole - -

    6. Check that the masking seal is attached correctly, then firmly press on it with your fingers to securely attach it.

      B001NDO

      Note


      • Securely attach the masking seal without leaving any air bubbles.

      • Do not touch the bus-bars when attaching the masking seal.

    7. B001L00

      Gently squeeze the tube of thermal grease and apply a small amount to a piece of cloth.

      Tech Tips

      Some clear liquid may come out first. Squeeze it out completely onto a piece of cloth.

    8. Apply thermal grease to 13 places as shown in the illustration.

      B001M2KE03
      Text in Illustration
      *a Reference Line *b Almost equally spaced
      *c Approximately 6.0 mm (0.236 in.) *d Approximately 2.0 mm (0.0787 in.)
    9. B001M4EE03
      Text in Illustration
      *1 SST
      *a 45°

      Using SST, carefully apply the thermal grease smoothly and evenly by spreading it as shown in the illustration. (Procedure A)

      SST
      09891-47010

      Note


      • Before performing work, check that the thermal grease contacting area of SST is not damaged.

      • Apply the thermal grease smoothly and evenly to ensure proper heat transfer.

      • Keep SST at a 45-degree angle and perform work carefully.

    10. Change the orientation of SST as shown in the illustration. (Procedure B)

      B001L3AE03
      Text in Illustration
      *1 SST - -
      *a 45° - -
    11. B001LABE01
      Text in Illustration
      *1 SST
      *a 45°

      Using SST, carefully apply the thermal grease smoothly and evenly by spreading it as shown in the illustration. (Procedure C)

    12. Repeat steps A through C until the thermal grease is smooth and even.

    13. Check that the thermal grease has been applied smoothly and evenly.

    14. B001N3B

      If the thermal grease layer is uneven and the part surface shows through, apply more thermal grease.

    15. Using SST, carefully apply the thermal grease smoothly and evenly.

      Note


      • Apply the thermal grease smoothly and evenly to ensure proper heat transfer.

      • Keep SST at a 45-degree angle and perform work carefully.

    16. B001LXC

      If foreign matter has attached to the part surface, scrape it off using the edge of the thermal grease tube, and apply more thermal grease.

    17. Using SST, carefully apply the thermal grease smoothly and evenly.

      Note


      • Apply the thermal grease smoothly and evenly to ensure proper heat transfer.

      • Keep SST at a 45-degree angle and perform work carefully.

    18. Check that the thermal grease has been applied smoothly and evenly.

    19. B001KEJE03
      Text in Illustration
      *1 Bus-bar
      *a Remove

      Remove the masking seal from the hybrid vehicle converter kit.

      Note


      • Slowly remove the masking seal without touching the thermal grease surface.

      • Be careful not to touch the bus-bars when removing the masking seal.

    20. Remove the protective tape.

    21. Align the guide holes with the guide pins as shown in the illustration, and temporarily install the power module intelligent transistor kit to the hybrid vehicle converter kit.

      B001KMYE03
      Text in Illustration
      *1 Guide Pins *2 Guide Hole (Oblong Hole)
      *3 Guide Hole (Circular Hole) - -

      Note


      • Do not apply any force the coolant pipes.

      • Make sure to align the guide pins correctly.

      • Be careful not to deform the bus-bars.

    22. Install the power module intelligent transistor kit with the 4 bolts.

    23. B001KB6E03

      Temporarily tighten the 4 bolts evenly in several steps in the order shown in the illustration, then fully tighten them.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
    24. B001M97

      Connect the connector to the power module intelligent transistor kit.

    25. B001K9D

      Install the 5 bolts to the bus-bars.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

      Note

      Do not touch the bus-bars.

  8. INSTALL MG CONTROL COMPUTER WITH BRACKET SUB-ASSEMBLY

    Note


    • Do not touch the circuit board.

    • Do not allow any moisture to come into contact with the circuit board.


    1. Align the holes of the MG control computer with bracket sub-assembly with the guide pins and temporarily install the power module intelligent transistor kit to the hybrid converter kit.

      B001KIXE03
      Text in Illustration
      *1 Guide Pins - -

      Note

      Make sure to align the guide pins correctly.

    2. Install the MG control computer with bracket sub-assembly with the 4 bolts.

    3. B001MGQE03

      Using an 8 mm deep socket wrench, temporarily tighten the 4 bolts evenly in several steps in the order shown in the illustration, then fully tighten them.

      Torque:
      4.5 N*m  { 46 kgf*cm, 40 in.*lbf }

    4. Engage the 2 wire harnesses to the 4 clamps.

      B001LL7

    5. Connect the 2 connectors to the MG control computer with bracket sub-assembly.

    6. B001MWL

      Disengage the lock claws of the white resin connector and connect the flat cable to the power module intelligent transistor kit.

    7. Check that the flat cable is connected securely.

      Note

      If the flat cable is not fully connected, connect it securely.

      B001MNY
    8. B001NC6E01
      Text in Illustration
      *1 Gasket

      If the gasket of the inverter signal connector is protruding, fully push it in.

  9. INSTALL INVERTER TERMINAL WITH SENSOR SUB-ASSEMBLY

    Note


    • Do not touch the circuit board.

    • Do not allow any moisture to come into contact with the circuit board.

    • For inverter with converter assembly with part number G9200-76010 or G9200-76011: Make sure to replace the inverter current sensor sub-assembly and inverter wire sub-assembly at the same time when replacing the MG control computer with bracket sub-assembly Click here.


    1. Align the holes of the power module intelligent transistor kit with the guide pins and temporarily install the power module intelligent transistor kit to the hybrid vehicle converter kit.

      B001M64E01
      Text in Illustration
      *1 Guide Pins - -

      Note

      Make sure to align the guide pins correctly.

    2. Install the inverter terminal with sensor sub-assembly with the 4 bolts.

    3. B001M2YE02

      Temporarily tighten the 4 bolts evenly in several steps in the order shown in the illustration, then fully tighten them.

      Torque:
      4.5 N*m  { 46 kgf*cm, 40 in.*lbf }

    4. Connect the 3 connectors to the MG control computer with bracket sub-assembly.

      Note

      The location of the connectors varies depending on the part number of the inverter with converter assembly. Confirm the part number before performing work.


      1. B001MFZ

        For inverter with converter assembly with part number G9200-76010 or G9200-76011:

      2. B001MAB

        For inverter with converter assembly with part number other than G9200-76010 or G9200-76011:

    5. Check that the 6 connectors and flat cable are connected securely as shown in the illustration.


      1. B001LAK

        For inverter with converter assembly with part number G9200-76010 or G9200-76011:

      2. B001LFC

        For inverter with converter assembly with part number other than G9200-76010 or G9200-76011:

    6. If a pen sheet is provided, check the installation condition of the pen sheet.

      Note


      • Do not touch the circuit board.

      • Do not allow any moisture to come into contact with the circuit board.


      1. While ensuring that the pen sheet does not interfere with components of the circuit board, insert the pen sheet between the inverter terminal with sensor sub-assembly and MG control computer with bracket sub-assembly.

        B001M8ME01
        Text in Illustration
        *1 PEN Sheet - -
      2. B001LOCE03
        Text in Illustration
        *1 Guide Pin
        *2 Double-sided Tape
        *3 PEN Sheet

        Set the pen sheet so that the pin of the motor generator control computer sub-assembly is aligned with the guide hole as shown in the illustration.

      3. Attach the double-sided tape of the pen sheet to the connector shown in the illustration.

    7. B001MDA

      Install the 6 bolts to the bus-bars.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

      Note

      Do not touch the bus-bars.

  10. INSTALL INVERTER CASE WITH CONDENSER

    Note


    • Do not touch the circuit board.

    • Do not allow any moisture to come into contact with the circuit board.

    • Do not touch or allow grease or oil to contact the sealing surfaces of the hybrid vehicle converter kit and inverter case with condenser.


    1. Apply seal packing (diameter: 2.0 to 3.0 mm (0.0787 to 0.118 in.)) in a continuous line to the locations shown in the illustration.

      B001KXTE03
      Text in Illustration
      *1 Seal Packing *2 Bolt Hole
      *3 Coolant Pipes - -
      *a 2.0 to 3.0 mm (0.0787 to 0.118 in.) *b 2.0 to 3.0 mm (0.0787 to 0.118 in.)
      *c Around Coolant Pipe - -
      Seal Packing
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

      Note


      • Install the inverter case with condenser within 3 minutes of applying seal packing.

      • Tighten the bolts within 15 minutes of applying seal packing.

      • Keep the coolant pipes free from seal packing.

    2. Install the inverter case with condenser.


      1. B001KRWE03
        Text in Illustration
        *1 Protective Tape

        Peel back the protective tape to the extent that the following steps can be performed.

        Note

        Do not touch or allow grease or oil to contact the sealing surfaces of the inverter case with condenser.

      2. Temporarily install the inverter case with condenser to the hybrid vehicle converter kit so that the bus-bar (A) does not contact the protrusion of the inverter terminal with sensor sub-assembly (B).

        B001KK4E01
        Text in Illustration
        *1 Guide Pins - -

        Note


        • Make sure to align the guide pins correctly.

        • B001KQN

          Check that the bus-bars of the hybrid converter kit overlap the bus-bars of the inverter case with condenser.

        • B001MNSE03

          Make sure that the bus-bar (A) is not resting on the resin part of the inverter terminal with sensor sub-assembly as shown in the illustration.

        Text in Illustration
        *1 Bus-bar (A)
    3. B001KSG

      Temporarily install the inverter case with condenser with the 11 bolts.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    4. Fully tighten the 11 bolts.

      Torque:
      9.2 N*m  { 94 kgf*cm, 81 in.*lbf }
    5. B001NBJ

      Install the 5 bolts to the bus-bars.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

      Note

      Do not touch the bus-bars.

  11. INSTALL INVERTER UNION GROMMET


    1. B001KDPE01
      Text in Illustration
      *1 Seal Packing

      Apply a light coat of seal packing to 2 new inverter union grommets.

      Seal Packing
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

      Note


      • Install the inverter union grommets within 60 minutes of installing the inverter case with condenser.

      • Apply a light coat of seal packing to the entire surface of the area shown in the illustration. If seal packing is applied excessively, it may seep out, however, sealing quality will not be affected.

      • Install the inverter union grommets within 3 minutes of applying seal packing.

    2. B001L5NE03
      Text in Illustration
      *1 Coolant Pipe
      *2 Inverter Union Grommet
      *a Flange

      Push in the inverter union grommet until it passes over the flange of the coolant pipe.

      Note

      Do not damage the coolant pipes.

    3. B001LS1E01
      Text in Illustration
      *1 30 mm Socket

      Using a 30 mm socket, install the inverter union grommet.

    4. Perform the same procedure to install the other inverter union grommet.

  12. INSTALL NO. 1 AND NO. 2 INVERTER DRAIN PLUGS

    Note

    Do not touch or allow grease or oil to contact the sealing surfaces of the inverter case with condenser.


    1. B001NDFE05
      Text in Illustration
      *1 Aluminum Tape

      Make sure that the sealing surfaces of the No. 1 and No. 2 inverter drain plugs are covered with aluminum tape.

      Note

      If the sealing surfaces of the No. 1 and No. 2 inverter drain plugs are not covered with aluminum tape, do not use them as they cannot be securely installed with only seal packing.

    2. B001KJ2E05
      Text in Illustration
      *1 Release Film

      Remove the release film from the No. 1 and No. 2 inverter drain plugs.

    3. B001KCDE05
      Text in Illustration
      *1 No. 1 Inverter Drain Plug
      *2 No. 2 Inverter Drain Plug
      *3 Seal Packing
      *a Approximately 3.0 mm (0.118 in.)
      *b Approximately 3.0 mm (0.118 in.)

      Apply seal packing (diameter: 3.0 mm (0.118 in.)) to new No. 1 and No. 2 inverter drain plugs.

      Seal Packing
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

      Note


      • Be sure to use the specified type of seal packing.

      • Install the No. 1 and No. 2 inverter drain plugs within 3 minutes of applying seal packing.

    4. B001MSVE01
      Text in Illustration
      *1 No. 1 Inverter Drain Plug
      *2 No. 2 Inverter Drain Plug

      Install the No. 1 and No. 2 inverter drain plugs to the inverter with converter assembly.

  13. INSTALL INVERTER SIGNAL CONNECTOR COVER


    1. B001LS3E03
      Text in Illustration
      *1 Gasket

      Install the gasket to the inverter signal connector cover.

      Tech Tips

      Make sure that the protrusion (A) of the gasket is securely inserted into the groove of the inverter signal connector cover.

    2. Clean the installation surface.

    3. B001LUKE02
      Text in Illustration
      *1 Inverter Signal Connector Cover

      Install the inverter signal connector cover with the 4 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  14. INSTALL NO. 2 ENGINE ROOM WIRE


    1. B001N8V

      Engage the clamp to Install the No. 2 engine room wire to the inverter with converter assembly.

      Note

      Check that the nut is not cross-threaded and the terminal is not loose.

    2. Install the nut to the No. 2 engine room wire.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    3. B001LPB

      Engage the 2 claws and close the terminal cover.

  15. INSTALL INVERTER TERMINAL COVER


    1. B001LBME01
      Text in Illustration
      *1 Protective Tape

      Remove the protective tape.

    2. B001LYD

      Temporarily install the inverter terminal cover with the 9 bolts to prevent any foreign objects or water from entering the inverter with converter assembly.

  16. INSTALL INVERTER WITH CONVERTER ASSEMBLY

    Click here

  17. CHECK FOR COOLANT LEAK (for Inverter)


    1. Remove the reserve tank cap.

      CAUTION:

      To avoid the danger of being burned, do not remove the reserve tank cap while the coolant for the inverter is still hot.

    2. B001M7P

      Install the radiator cap tester.

    3. Pump the radiator cap tester to 122 kPa (1.2 kgf/ cm2, 17.7 psi), and then check that the pressure does not drop.

      Tech Tips

      If the pressure drops, check the hoses, radiator, water pump, inverter with converter, and hybrid vehicle transaxle assembly for leaks.

    4. Reinstall the reserve tank cap.

  18. OPERATION CHECK

    Tech Tips


    • After the repair, check the operation as follows. Then check for DTCs again.

    • The current at the AMD terminal cannot be measured directly because of space limitations. Measure the current flowing at the auxiliary battery instead.


    1. B001MBUE02
      *1 Probe Direction
      *2 Current Flowing into Auxiliary Battery

      Connect the AC/DC 400 A probe to the positive (+) auxiliary battery cable.

    2. Turn the power switch on (READY) and leave the vehicle as is until the electric current flowing into the auxiliary battery becomes 10 A or less.

    3. B001N9EE02
      *1 Probe Direction
      *2 Current Flowing from Auxiliary Battery

      Change the orientation of the AC/DC400A probe.

    4. Measure the current flowing from the auxiliary battery with the power switch on (READY), headlight position switch and blower motor switch in the HI position, and rear window defogger turned on.

      Standard Current
      Item Switch Condition Specified Condition
      Current flowing from auxiliary battery

      Power switch on (READY)

      (Headlight position switch and blower motor switch in HI position, rear window defogger on)

      0 A or less

      (No current from auxiliary battery)

    5. Turn the power switch off.