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Reassembly [08/2014 - ]: Procedure

  1. REMOVE SEAL PACKING (FROM HYBRID CONVERTER KIT CONTACT SURFACE) 
    NOTE:
    • Do not touch the circuit board.
    • 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 hybrid vehicle converter kit.
    • Do not bend the bus-bars.
    1. Put clean pieces of paper into the areas shown in the illustration to prevent any remaining seal packing from entering the hybrid vehicle converter kit.
      GTY651574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Paper
    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.
      GTY642250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Paper *2 Seeped Out or Uneven Seal Packing
      *3 Light Coat of Seal Packing Remaining on Contact Surface - -
      *a Minimum Requirement for Removal of Seal Packing - -
      NOTE:

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

  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.
      GTY654251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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. Remove the protective tape from the installation holes of the No. 1 and No. 2 inverter drain plugs.
      GTY628488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Protective Tape
    2. Apply protective tape to the No. 1 and No. 2 inverter drain plugs installation holes from the inside.
      GTY625178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Protective Tape
      NOTE:

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

    3. 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.

      GTY662203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Sealing Surface
    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. Apply protective tape to the installation holes of the No. 1 and No. 2 inverter drain plugs as shown in the illustration.
      GTY628488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Protective Tape
  4. REMOVE RESIDUE (FROM INVERTER SIGNAL CONNECTOR COVER SEALING SURFACE) 
    1. Apply protective tape to the area shown in the illustration to prevent removed residue from entering the inverter case with condenser.
      GTY663718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Protective Tape
    2. 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.
      GTY642125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove any adhesive particles using tape or equivalent.
    4. Remove the protective tape.
    5. Thoroughly wash hands after performing this step.

      HINT: 

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

  5. REMOVE RESIDUE (FROM GROMMET SEALING SURFACE) 

    HINT: 

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

    1. 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.
      GTY676995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Inverter Case with Condenser *2 Hybrid Vehicle Converter Kit
      *3 Protective Tape - -
    2. Using 600-grit sandpaper, remove the residue from each grommet sealing surface until it feels smooth.
      GTY685500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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. 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.

      GTY616593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Gasket
    2. Thoroughly wash hands after performing this step.
  7. 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.
      GTY628102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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. 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.
      Fig 1: Tightening Sequence Of MG Control Computer With Bracket Sub-Assembly Bolts
      GTY639327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    4. Engage the 2 wire harnesses to the 4 clamps.
      GTY662796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the 2 connectors to the MG control computer with bracket sub-assembly.
    6. Disengage the lock claws of the white resin connector and connect the flat cable to the power module intelligent transistor kit.
      GTY674576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Check that the flat cable is connected securely.
      NOTE:

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

      GTY621969Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. If the gasket of the inverter signal connector is protruding, fully push it in.
      GTY664494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Gasket

      HINT: 

      If the gasket is misaligned, set it so that each mark is at the center of each side.

      GTY676710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Gasket
      *2 Mark
  8. 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.

      Refer to COMPONENTS [08/2014 - ] 

    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.
      GTY634186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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. Temporarily tighten the 4 bolts evenly in several steps in the order shown in the illustration, then fully tighten them.
      Fig 2: Tightening Sequence Of Inverter Terminal With Sensor Sub-Assembly Bolts
      GTY666323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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. For inverter with converter assembly with part number G9200-76010 or G9200-76011:
        GTY685501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT: 

        If the MG control computer with bracket sub-assembly has been replaced, it is necessary to refer to the illustration for inverter with converter assemblies with part numbers other than those listed above to confirm the position of the connectors, even if an inverter with converter assembly with a part number listed above has been installed.

      2. For inverter with converter assembly with part number other than G9200-76010 or G9200-76011:
        GTY655645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
        GTY617071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 PEN Sheet - -
      2. 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.
        GTY639330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Guide Pin
        *2 Double-sided Tape
        *3 PEN Sheet
      3. Attach the double-sided tape of the pen sheet to the connector shown in the illustration.
    6. Install the 6 bolts to the bus-bars.
      GTY673267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

      NOTE:

      Do not touch the bus-bars.

    7. If the No. 2 engine room wire is installed, install the bolt (A) using SST as shown in the illustration.
      • SST: 09961-00950 
      GTY679789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 SST

      without SST 

      Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

      with SST 

      Torque: 3.3 N*m (34 kgf*cm, 29 in.*lbf) 

      NOTE:

      This torque value is effective when SST is parallel to the torque wrench.

      HINT: 

      • The "with SST" torque value is effective when using SST with a fulcrum length of 150 mm (5.91 in.).
        GTY626145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 SST
        *a Length of SST 150 mm (5.91 in.)
        *b Length of Torque Wrench 185 mm (7.28 in.)
      • The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 185 mm (7.28 in.)
      • If using a torque wrench with a different length, or connecting the torque wrench and SST at an angle, refer to the alternate torque values.

        Refer to PRECAUTION [08/2014 - ]

      • Loosen the nut of the No. 2 engine room wire to secure enough space to perform work.
  9. 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.
      GTY639169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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. Peel back the protective tape to the extent that the following steps can be performed.
        GTY633014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Protective Tape
        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).
        GTY634232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Guide Pins - -
        NOTE:
        • Make sure to align the guide pins correctly.
        • Check that the bus-bars of the hybrid converter kit overlap the bus-bars of the inverter case with condenser.
          GTY671485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • 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.
          GTY669869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
          *1 Bus-bar (A)
    3. Temporarily install the inverter case with condenser with the 11 bolts.
      GTY671327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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. Install the 5 bolts to the bus-bars.
      GTY671290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

      NOTE:

      Do not touch the bus-bars.

    6. Install the nut to the No. 2 engine room wire.
      GTY636570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:

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

    7. Engage the 2 claws and close the terminal cover.
      GTY674580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL INVERTER UNION GROMMET 
    1. Apply a light coat of seal packing to 2 new inverter union grommets.
      GTY640763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Seal Packing

      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. Push in the inverter union grommet until it passes over the flange of the coolant pipe.
      GTY645815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Coolant Pipe
      *2 Inverter Union Grommet
      *a Flange
      NOTE:

      Do not damage the coolant pipes.

    3. Using a 30 mm socket, install the inverter union grommet.
      GTY645713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 30 mm Socket

      HINT: 

      Make sure that the clearance between the inverter union grommet and inverter case with condenser is 2.0 mm (0.0787 in.) or less.

      GTY665168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 2.0 mm (0.0787 in.) or less
    4. Perform the same procedure to install the other inverter union grommet.
  11. INSTALL NO. 1 AND NO. 2 INVERTER DRAIN PLUG 
    NOTE:

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

    1. Make sure that the sealing surfaces of the No. 1 and No. 2 inverter drain plugs are covered with aluminum tape.
      GTY657641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 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. Remove the release film from the No. 1 and No. 2 inverter drain plugs.
      GTY675221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Release Film
    3. Apply seal packing (diameter: 3.0 mm (0.118 in.)) to new No. 1 and No. 2 inverter drain plugs.
      GTY670277Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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.)

      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. Install the No. 1 and No. 2 inverter drain plugs to the inverter with converter assembly.
      GTY671704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Inverter Drain Plug
      *2 No. 2 Inverter Drain Plug
  12. INSTALL INVERTER SIGNAL CONNECTOR COVER 
    1. Install the gasket to the inverter signal connector cover.

      HINT: 

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

      GTY673387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Gasket
    2. Clean the installation surface.
    3. Install the inverter signal connector cover with the 4 bolts.

      Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

      GTY620325Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Inverter Signal Connector Cover
  13. INSTALL INVERTER TERMINAL COVER 
    1. Remove the protective tape.
      GTY667813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Protective Tape
    2. Temporarily install the inverter terminal cover with the 9 bolts to prevent any foreign objects or water from entering the inverter with converter assembly.
      GTY530738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL INVERTER WITH CONVERTER ASSEMBLY 

    Refer to INSTALLATION [08/2014 - ] 

  15. CHECK FOR COOLANT LEAK (for Inverter) 
    1. Remove the reserve tank cap.
      WARNING:

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

    2. 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.

      HINT: 

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

      GTY356676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Reinstall the reserve tank cap.
  16. OPERATION CHECK 

    HINT: 

    • 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. Connect the AC/DC 400 A probe to the positive (+) auxiliary battery cable.
      GTY194202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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. Change the orientation of the AC/DC400A probe.
      GTY194203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
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