Reassembly [08/2014 - ]: Procedure

REMOVE THERMAL GREASE

Using a scraper with its tip wrapped with protective tape, remove any remaining thermal grease from the hybrid vehicle converter kit as shown in the illustration.

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NOTE:

To prevent thermal grease from entering the hybrid vehicle converter kit, remove it by moving the scraper from the sides toward the center as shown in the illustration.
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.

Using a piece of cloth, remove the thermal grease.
HINT:

It is acceptable to leave a small amount of thermal grease in the grooves.

REMOVE SEAL PACKING (FROM HYBRID CONVERTER KIT 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 hybrid vehicle converter kit.
Do not bend the bus-bars.

Install the 2 stud bolts and set the hybrid vehicle converter kit on its side as shown in the illustration.

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Stud Bolt

NOTE:

To prevent the hybrid vehicle converter kit from falling over, hold it with a hand or place an object behind it.

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.

NOTE:

Do not bend the bus-bars.

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*1	Seeped Out or Uneven Seal Packing	*2	Light Coat of Seal Packing Remaining on Contact Surface
*a	Contact Surface	*b	Minimum Requirement for Removal of Seal Packing

While supporting the hybrid vehicle converter kit by hand, 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.

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Contact Surface

Remove the 2 stud bolts.

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.

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.

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*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	-	-

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

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

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*1	Protective Tape

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

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*1	Protective Tape

NOTE:

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

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.

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*1	Sealing Surface

Remove any adhesive shavings particles using tape or equivalent.
Remove the protective tape from the inside of the inverter case with condenser.

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

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*1	Protective Tape

REMOVE RESIDUE (FROM INVERTER SIGNAL CONNECTOR COVER SEALING SURFACE)

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

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*1	Protective Tape

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

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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.

Remove any adhesive particles using tape or equivalent.
Remove the protective tape.
Thoroughly wash hands after performing this step.
HINT:

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

REMOVE RESIDUE (FROM GROMMET SEALING SURFACE)

HINT:

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

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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Inverter Case with Condenser	*2	Hybrid Vehicle Converter Kit
*3	Protective Tape	-	-

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

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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.

Remove any adhesive shavings particles using tape or equivalent.
Remove the protective tape.
Thoroughly wash hands after performing this step.

CLEAN INVERTER SIGNAL CONNECTOR COVER

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.

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Gasket

Thoroughly wash hands after performing this step.

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.

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.

HINT:

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

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*1	Guide Pins
*a	Thermal Grease Contacting Area

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

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*1	Protective Tape

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

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*1	Protective Tape

Remove the protective paper from the masking seal.

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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.

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*1	Masking Seal	*2	Guide Pins
*3	Guide Hole	-	-

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

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NOTE:

Securely attach the masking seal without leaving any air bubbles.
Do not touch the bus-bars when attaching the masking seal.

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

HINT:

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

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

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*a	Reference Line	*b	Almost equally spaced
*c	Approximately 6.0 mm (0.236 in.)	*d	Approximately 2.0 mm (0.0787 in.)

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

SST: 09891-47010

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*1	SST
*a	45°

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.

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

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*1	SST	-	-
*a	45°	-	-

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

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*1	SST
*a	45°

Repeat steps A through C until the thermal grease is smooth and even.
Check that the thermal grease has been applied smoothly and evenly.

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

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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.

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.

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

Remove the masking seal from the hybrid vehicle converter kit.

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*1	Bus-bar
*a	Remove

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.

Remove the protective tape.

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.

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*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.

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

Fig 1: Tightening Sequence Of Power Module Intelligent Transistor Kit Bolts
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Connect the 2 connectors to the power module intelligent transistor kit.

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Install the 5 bolts to the bus-bars.

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

NOTE:

Do not touch the bus-bars.

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.

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.

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Guide Pins

NOTE:

Make sure to align the guide pins correctly.

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

Fig 2: Tightening Sequence Of MG Control Computer With Bracket Sub-Assembly Bolts
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Engage the 2 wire harnesses to the 4 clamps.

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

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

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Check that the flat cable is connected securely.

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NOTE:

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

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

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Gasket

HINT:

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

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*1	Gasket
*2	Mark

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 - ]

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.

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Guide Pins

NOTE:

Make sure to align the guide pins correctly.

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

Fig 3: Tightening Sequence Of Inverter Terminal With Sensor Sub-Assembly Bolts
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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.

For inverter with converter assembly with part number G9200-47140, G9200-47141, G9200-47180 or G9200-47181:

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For inverter with converter assembly with part number other than G9200-47140, G9200-47141, G9200-47180 or G9200-47181:

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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.

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.

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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.

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*1	Guide Pin
*2	Double-sided Tape
*3	PEN Sheet

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

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.

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If the No. 2 engine room wire is installed, install the bolt (A) using SST as shown in the illustration.

SST: 09961-00950

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)

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SST

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.).

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*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.

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.

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.

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*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.

Install the inverter case with condenser.

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

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*1	Protective Tape

NOTE:

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

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).

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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.

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.

*1	Bus-bar (A)

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

Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)

Fully tighten the 11 bolts.
Torque: 9.2 N*m (94 kgf*cm, 81 in.*lbf)

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.

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

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.

Engage the 2 claws and close the terminal cover.

INSTALL INVERTER UNION GROMMET

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

*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.

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

*1	Coolant Pipe
*2	Inverter Union Grommet
*a	Flange

NOTE:

Do not damage the coolant pipes.

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

*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.

*a	2.0 mm (0.0787 in.) or less

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

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.

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

*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.

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

*1	Release Film

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

*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.

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

*1	No. 1 Inverter Drain Plug
*2	No. 2 Inverter Drain Plug

INSTALL INVERTER SIGNAL CONNECTOR COVER

Install the gasket to the inverter signal connector cover.

Gasket

HINT:

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

Clean the installation surface.

Install the inverter signal connector cover with the 4 bolts.

*1	Inverter Signal Connector Cover

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

INSTALL INVERTER TERMINAL COVER

Remove the protective tape.

*1	Protective Tape

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

INSTALL INVERTER WITH CONVERTER ASSEMBLY
Refer to INSTALLATION [08/2014 - ]

CHECK FOR COOLANT LEAK (for Inverter)

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.

Install the radiator cap tester.

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.
Reinstall the reserve tank cap.

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.

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

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.

Change the orientation of the AC/DC400A probe.

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)

Turn the power switch off.