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W/Converter Inverter ASSY: Replacement

WARNING: This page is about a different car, the 2004 Toyota Prius. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
  • When working on the high voltage systems, always wear insulating gloves.
  • After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU.
  • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle.
  • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes.
  1. PRECAUTION (See  PRECAUTION  ) 
  2. REMOVE ENGINE UNDER COVER LH 
  3. REMOVE ENGINE UNDER COVER RH 
  4. DRAIN HV COOLANT (See  REPLACEMENT  ) 
  5. REMOVE REAR FLOOR BOARD NO. 2 (See  SERVICE PLUG GRIP  ) 
  6. REMOVE DECK FLOOR BOX REAR (See  SERVICE PLUG GRIP  ) 
  7. REMOVE REAR FLOOR BOARD NO. 3 (See  SERVICE PLUG GRIP  ) 
  8. DISCONNECT BATTERY NEGATIVE TERMINAL (See  SERVICE PLUG GRIP  ) 
  9. REMOVE SERVICE PLUG GRIP (See  SERVICE PLUG GRIP  ) 
  10. REMOVE FRONT WIPER ARM HEAD CAP (See  WIPER & WASHER  ) 
  11. REMOVE FR WIPER ARM LH (See  WIPER & WASHER  ) 
  12. REMOVE FR WIPER ARM RH (See  WIPER & WASHER  ) 
  13. REMOVE HOOD TO COWL TOP SEAL (See  WIPER & WASHER  ) 
  14. REMOVE COWL TOP VENTILATOR LOUVER LH (See  WIPER & WASHER  ) 
  15. REMOVE COWL TOP VENTILATOR LOUVER RH (See  WIPER & WASHER  ) 
  16. REMOVE WINDSHIELD WIPER MOTOR & LINK ASSY (See  WIPER & WASHER  ) 
  17. REMOVE COWL TOP PANEL SUB-ASSY OUTER FRONT (See  WIPER & WASHER  ) 
  18. REMOVE RADIATOR SUPPORT OPENING COVER 
  19. REMOVE INVERTER COVER 
    1. Using a T30 Torx socket wrench, remove the Torx screw.
    2. Remove the 12 bolts and inverter cover.
      Fig 1: Locating Inverter Cover Torx Screw
      G00950357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. VERIFY THAT VOLTAGE OF W/CONVERTER INVERTER ASSY IS 0V 
    NOTE: Wear insulating gloves.
    1. Using a voltmeter, measure the voltage of the high voltage DC line.

      Standard: 0 V 

      HINT:

      Use measuring range of DC 400 V or more on the voltmeter.

      Fig 2: Measuring Voltage Of High Voltage DC Line Using Voltmeter
      G00950358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using the voltmeter, measure the voltage between the terminals of the three phase connector (U - V, V - W, U - W).

      Standard: 0 V 

      HINT:

      Use measuring range of DC 400 V or more on the voltmeter.

      Fig 3: Identifying Three Phase Terminals
      G00950359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. DISCONNECT INVERTER COOLING HOSE NO. 2 
    Fig 4: Disconnecting Inverter Cooling Hose No. 2
    G00950360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT INVERTER COOLING HOSE NO. 1 
    Fig 5: Disconnecting Inverter Cooling Hose No. 1
    G00950361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT INVERTER COOLING HOSE NO. 6 
    Fig 6: Disconnecting Inverter Cooling Hose No. 6
    G00950362Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. SEPARATE CIRCUIT BREAKER SENSOR NO. 1 
    1. Move the outer section to the wire harness side as illustrated, then disconnect the circuit breaker sensor No. 1.
      Fig 7: Moving Outer Section To Wire Harness Side
      G00950363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. DISCONNECT FRAME WIRE 
    NOTE:
    • Wear insulating gloves.
    • After removing the service plug grip, be sure to wait for at least 5 minutes before performing any work.
    • Insulate the electrode and connector parts with insulating tape.
    1. Remove the 2 frame wire connectors from the with converter inverter assembly.
      Fig 8: Removing Frame Wire Connectors From W/Converter Inverter Assembly
      G00950364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE W/CONVERTER INVERTER ASSY 
    1. Using a small screwdriver, lift up the lock pin (green) as illustrated to unlock.
      NOTE: Wear insulating gloves.
    2. Disconnect the connector for the air conditioner inverter.
      NOTE: Wear insulating gloves.
      Fig 9: Disconnecting Connector For Air Conditioner Inverter
      G00950365Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the 3 connectors shown in the illustration.
      Fig 10: Disconnecting 3 Connectors
      G00950366Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the 3 connectors shown in the illustration and the engine main wire harness.
      Fig 11: Disconnecting Connectors And Engine Main Wire Harness
      G00950367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 5 bolts, then disconnect the MG2 power cable.
      NOTE:
      • Wear insulating gloves.
      • Insulate the connector parts with insulating tape.
      Fig 12: Locating MG2 Power Cable Bolts
      G00950368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 5 bolts, then disconnect the MG1 power cable.
      NOTE:
      • Wear insulating gloves.
      • Insulate the connector parts with insulating tape.
      Fig 13: Removing Bolts For Disconnecting MG1 Power Cable
      G00950369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 3 bolts and the with converter inverter assembly.
      Fig 14: Removing Bolts And W/Converter Inverter Assembly
      G00950370Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Disconnect the connector for the air conditioner inverter from the bracket.
    9. Remove the bolt and connector bracket for the air conditioner inverter.
      Fig 15: Removing Bolt And Connector Bracket For Air Conditioner Inverter
      G00950371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE INVERTER BRACKET NO. 1 
    1. Remove the 2 bolts and inverter bracket No. 1.
      Fig 16: Removing Bolts And Inverter Bracket No. 1
      G00950372Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE INVERTER BRACKET NO. 2 
    1. Remove the 2 bolts and inverter bracket No. 2.
      Fig 17: Removing Bolts And Inverter Bracket No. 2
      G00950373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE CIRCUIT BREAKER SENSOR NO. 1 
    1. Remove the 2 bolts and circuit breaker sensor No. 1.
      Fig 18: Removing Bolts And Circuit Breaker Sensor No. 1
      G00950374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL CIRCUIT BREAKER SENSOR NO. 1 
    1. Install the circuit breaker sensor No. 1 with the 2 bolts.

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

      Fig 19: Installing Circuit Breaker Sensor No. 1 With Bolts
      G00950375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL INVERTER BRACKET NO. 2 
    1. Install the inverter bracket No. 2 with the 2 bolts.

      Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) 

      Fig 20: Installing Inverter Bracket No. 2 With Bolts
      G00950376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL INVERTER BRACKET NO. 1 
    1. Install the inverter bracket No. 1 with the 2 bolts.

      Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) 

      Fig 21: Installing Inverter Bracket No. 1 With Bolts
      G00950377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL W/CONVERTER INVERTER ASSY 
    1. Install the connector bracket for the air conditioner inverter with the bolt.

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

    2. Install the connector for the air conditioner inverter on the bracket.
      Fig 22: Installing Connector Bracket For Air Conditioner Inverter
      G00950378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the with converter inverter assembly with the 3 bolts.
      NOTE: Wear insulating gloves.

      Torque: 21 N.m (214 kgf.cm, 16 ft.lbf) 

      Fig 23: Installing Converter Inverter Assembly
      G00950379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the MG1 power cable to the MG1 power cable terminal with the 5 bolts.
      NOTE: Wear insulating gloves.

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

      Fig 24: Installing MG1 Power Cable To MG1 Power Cable Terminal
      G00950380Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the MG2 power cable to the MG2 power cable terminal with the 3 bolts.
      NOTE: Wear insulating gloves.

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

      Fig 25: Installing MG2 Power Cable To MG2 Power Cable Terminal
      G00950381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the 3 connectors shown in the illustration.
      NOTE: Wear insulating gloves.
    7. Insert the grommet of the engine main wire harness into the U-shaped groove of the inverter case.
      NOTE: Wear insulating gloves.
      Fig 26: Connecting 3 Connectors
      G00950382Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Connect the 3 connectors shown in the illustration.
      NOTE: Wear insulating gloves.
    9. Connect the connector for the air conditioner inverter, then lock the connector with the lock pin.
      NOTE: Wear insulating gloves.
      Fig 27: Connecting Connector For Air Conditioner Inverter
      G00950383Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. CONNECT FRAME WIRE 
    NOTE: Wear insulating gloves.
  35. CONNECT CIRCUIT BREAKER SENSOR NO. 1 
    NOTE: Wear insulating gloves.
  36. CONNECT INVERTER COOLING HOSE NO. 6 
  37. CONNECT INVERTER COOLING HOSE NO. 1 
  38. CONNECT INVERTER COOLING HOSE NO. 2 
  39. INSTALL INVERTER COVER 
    1. Temporarily fasten the inverter cover with the 12 bolts and Torx screw.
    2. Tighten the 12 bolts.

      Torque: 11 N.m (112 kgf.cm, 8.1 ft.lbf) 

    3. Using a T30 Torx socket wrench, tighten the Torx screw.

      Torque: 11 N.m (112 kgf.cm, 8.1 ft.lbf) 

      Fig 28: Locating Inverter Cover Torx Screw
      G00950384Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL RADIATOR SUPPORT OPENING COVER 
  41. INSTALL COWL TOP PANEL SUB-ASSY OUTER FRONT 
  42. INSTALL WINDSHIELD WIPER MOTOR & LINK ASSY 
  43. INSTALL COWL TOP VENTILATOR LOUVER RH 
  44. INSTALL COWL TOP VENTILATOR LOUVER LH 
  45. INSTALL HOOD TO COWL TOP SEAL 
  46. INSTALL FR WIPER ARM RH (See  WIPER & WASHER  ) 
  47. INSTALL FR WIPER ARM LH (See  WIPER & WASHER  ) 
  48. INSTALL FRONT WIPER ARM HEAD CAP 
  49. INSTALL SERVICE PLUG GRIP (See  SERVICE PLUG GRIP  ) 
    NOTE: Wear insulating gloves.
  50. CONNECT BATTERY NEGATIVE TERMINAL 

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

  51. INSTALL REAR FLOOR BOARD NO. 3 
  52. INSTALL DECK FLOOR BOX REAR 
  53. INSTALL REAR FLOOR BOARD NO. 2 
  54. ADD HV COOLANT (See  REPLACEMENT  ) 
  55. CHECK FOR ENGINE COOLANT LEAKS (See  ON-VEHICLE INSPECTION  ) 
  56. INSTALL ENGINE UNDER COVER RH 
  57. INSTALL ENGINE UNDER COVER LH 
  58. POWER WINDOW CONTROL SYSTEM INITIALIZE (See  INITIALIZATION  ) 
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