ELECTRIC VEHICLE CONVERTER REASSEMBLY

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.


  • for Europe : 08887-83080

  • except Europe : 08887-02809


  1. REMOVE THERMAL GREASE


    1. A003TLQE01
      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.

      A003ULVE01
      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. A003S6OE01
      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. A003S7KE01
      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. A003SE5E01
      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. A003S6OE01
      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. A003RQKE01
      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. A003SDB

      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. A003T01E01
      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.

      A003U13E01
      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. A003TKEE01
      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. A003U6XE01
      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. A003SZRE01
      Text in Illustration
      *1 Protective Tape

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

    3. A003SAYE01
      Text in Illustration
      *1 Protective Tape

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

    4. A003TCY

      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.

      A003TLZE01
      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.

      A003TEY

      Note


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

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

    7. A003SYJ

      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.

      A003S3OE01
      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. A003TQ9E01
      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)

      A003T8ZE01
      Text in Illustration
      *1 SST - -
      *a 45° - -
    11. A003SYKE01
      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. A003U3P

      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. A003SWI

      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. A003SOZE01
      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.

      A003RJ8E01
      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. A003RZTE01

      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. A003TY9

      Connect the connector to the power module intelligent transistor kit.

    25. A003S8N

      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.

      A003UEGE01
      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. A003U8PE01

      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.

      A003UIA

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

    6. A003SXK

      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.

      A003SZZ
    8. A003TC2E01
      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 G9200-47140 or G9200-47141: 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.

      A003RRHE01
      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. A003RXQE01

      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. A003TMZ

        For inverter with converter assembly with part number G9200-47140 or G9200-47141:

      2. A003T8J

        For inverter with converter assembly with part number other than G9200-47140 or G9200-47141:

    5. 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.

        A003S7OE01
        Text in Illustration
        *1 PEN Sheet - -
      2. A003S32E01
        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.

    6. A003U81

      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.

      A003T4GE01
      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. A003SV1E01
        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).

        A003TKNE01
        Text in Illustration
        *1 Guide Pins - -

        Note


        • Make sure to align the guide pins correctly.

        • A003T5Y

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

        • A003SM0E01

          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. A003SP9

      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. A003UNL

      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. A003T6PE01
      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. A003RV2E01
      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. A003TLUE01
      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. A003TMVE01
      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. A003TS1E01
      Text in Illustration
      *1 Release Film

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

    3. A003SB7E01
      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. A003T0KE01
      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. A003TKEE03
      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. A003TBLE02
      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. A003TZX

      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. A003UFU

      Engage the 2 claws and close the terminal cover.

  15. INSTALL INVERTER TERMINAL COVER


    1. A003UW6E01
      Text in Illustration
      *1 Protective Tape

      Remove the protective tape.

    2. A003UIY

      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. A003UG5

      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. A003UWPE02

      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. A003V01E02

      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.