Disassembly [11/2015 - ]: Procedure

REMOVE INVERTER WITH CONVERTER ASSEMBLY
Refer to REMOVAL [11/2015 - ]

DRAIN COOLANT (for Inverter)

WARNING:

Wear insulating gloves.

Apply protective tape to the areas shown in the illustration without leaving any gaps between the tape and part.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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*1	Protective Tape

NOTE:

Use non-residue type tape.

Tilt the inverter with converter assembly back and forth to drain the coolant (for inverter).

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*1	Coolant (for inverter) Passage

NOTE:

Do not hold the inverter with converter assembly by the coolant pipes or inverter signal connector.

HINT:

The coolant (for inverter) passage is designed as shown in the illustration. Tilt the inverter with converter assembly back and forth repeatedly to drain the coolant (for inverter) completely.

Blow compressed air into the inverter with converter assembly until most all of the coolant (for inverter) is blown out.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Do not damage the coolant pipes.

HINT:

Use a piece of cloth as shown in the illustration to prevent the coolant (for inverter) from spraying.
Cover the air inlet port with a piece of cloth to minimize air leakage.

CLEAN INVERTER WITH CONVERTER ASSEMBLY
WARNING:
Wear insulating gloves.
1. Using a piece of cloth, clean the outside of the inverter with converter assembly and around the bolts.
  NOTE:
  To prevent foreign matter from entering the inverter with converter assembly, make sure that the protective tape is not partially removed.
2. Turn the inverter with converter assembly over and clean around the bolts.
  NOTE:
  Do not hold the inverter with converter assembly by the coolant pipes.

REMOVE INVERTER TERMINAL COVER

WARNING:

Wear insulated gloves.

Remove the 2 bolts and inverter terminal cover.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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*1	Interlock Connector

WARNING:

An interlock connector is installed to the inverter terminal cover. Make sure to remove the inverter terminal cover before removing the inverter cover.

NOTE:

Make sure to pull the inverter terminal cover straight up, as a connector is connected to the bottom of the cover.

REMOVE INVERTER COVER

WARNING:

Wear insulating gloves.

Remove the 7 bolts and inverter cover.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

WARNING:

An interlock connector is installed to the inverter terminal cover. Make sure to remove the inverter terminal cover before removing the inverter cover.

REMOVE INVERTER SIGNAL CONNECTOR COVER

WARNING:

Wear insulating gloves.

Apply protective tape to the area that was exposed when the inverter terminal cover was removed.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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*1	Protective Tape

NOTE:

Use non-residue type tape.

Remove the protective tape from the inverter signal connector.

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*1	Protective Tape

Remove the 4 bolts and inverter signal connector cover.

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*1	Inverter Signal Connector Cover

HINT:

As there will be dust and dirt around the inverter signal connector cover gasket, before removing the inverter signal connector cover, clean the area around the inverter signal connector cover with a piece of cloth to prevent foreign matter from entering the inverter with converter assembly.

REMOVE NO. 1 AND NO. 2 INVERTER DRAIN PLUG

WARNING:

Wear insulating gloves.
Wear protective goggles.

Using a screwdriver with its tip wrapped with protective tape, remove the No. 1 and No. 2 inverter drain plugs.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

NOTE:

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

VERIFY THAT VOLTAGE OF INVERTER WITH CONVERTER IS 0 V

WARNING:

Wear insulating gloves.

NOTE:

Do not allow any foreign matter or water to enter the inverter with converter assembly.

Using a voltmeter, measure the voltage between the high voltage cable connector terminals.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard voltage

HINT:

Use measuring range of DC 750 V or more on the voltmeter.

REMOVE INVERTER UNION GROMMET

Using a screwdriver with its tip wrapped with protective tape, remove the 2 inverter union grommets from the inverter with converter assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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*1	Inverter Union Grommet
*2	Coolant Pipe

NOTE:

Pull the grommet straight out without applying any force to the coolant pipes.

REMOVE INVERTER CASE WITH CONDENSER

Disengage the 2 claws and open the terminal cover.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Loosen the nut of the No. 2 engine room wire to secure enough space to perform work.

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Remove the 5 bolts.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Do not touch the bus-bars.

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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*1	Protective Tape

NOTE:

Use non-residue type tape.
Do not touch or allow grease or oil to contact the sealing surfaces of the inverter case with condenser.

Remove the 11 bolts.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Apply protective tape to the coolant pipe as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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Protective Tape

Coolant Pipe

NOTE:

Do not apply excessive force to the coolant pipe.
Do not damage the coolant pipe.
Use non-residue type tape.

Install SST to the inverter with converter assembly. (Step A)

SST: 09891-47020

Apply protective tape to SST as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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*1	SST
*2	Protective Tape

Insert SST into the inverter union grommet installation hole and tighten the bolt (A) of SST to install SST to the inverter with converter assembly as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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*1	SST	*2	Inverter Case with Condenser
*3	Hybrid Vehicle Converter Kit	-	-
*a	Tip	-	-

NOTE:

Do not damage the grommet sealing surface of the inverter with converter assembly.
Do not apply excessive force to the coolant pipe.

Check that the tips of SST are not in contact with the grommet sealing surface of the inverter with converter assembly.

While supporting SST by hand, tighten the bolt A of SST to separate the inverter case with condenser and hybrid vehicle converter kit as shown in the illustration. (Step B)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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SST

NOTE:

Do not use air tools.

Remove SST from the inverter with converter assembly, and then insert SST into the inverter union grommet installation hole on the opposite side of the inverter with converter assembly and tighten the bolt (A) of SST to install SST to the inverter with converter assembly as shown in the illustration. (Step C)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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*1	SST	*2	Inverter Case with Condenser
*3	Hybrid Vehicle Converter Kit	-	-
*a	Tips	-	-

While supporting SST by hand, tighten the bolt A of SST to separate the inverter case with condenser and hybrid vehicle converter kit as shown in the illustration. (Step D)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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SST

NOTE:

Do not use air tools.

Perform steps A, B, C and D on the opposite side of the inverter with converter assembly and remove the inverter case with condenser from the hybrid vehicle converter kit.

Place the inverter case with condenser on a clean piece of cloth.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

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

HOW TO PREVENT STATIC ELECTRICITY

SST: 09890-47010

NOTE:

Static electricity should be eliminated when removing/installing the inverter with converter assembly.
Do not touch the electronic components of a circuit board.
Keep clothes away from electronic components.
Place parts removed from the inverter with converter assembly on an antistatic mat.

Wear an antistatic wrist strap.

Connect the ground clip of the antistatic mat securely to a ground point provided in the workshop or on a workbench (anchor bolt).
HINT:

If the ground clip cable is too short, use an extension cable.
Connect the ground clip of the antistatic wrist strap securely to the specified point of the antistatic mat.
After removing the inverter case with condenser, perform work with bare hands to prevent damage from static electricity and entry of foreign matter.

REMOVE INVERTER TERMINAL WITH SENSOR SUB-ASSEMBLY

NOTE:

If metal shavings are created, remove them using tape or equivalent.
Do not touch the circuit board.
Do not allow any moisture to come into contact with the inverter terminal with sensor sub-assembly.
Do not touch or allow grease or oil to contact the sealing surfaces of the inverter case with condenser.

Disconnect the 3 connectors from the MG control computer with bracket sub-assembly.

NOTE:

Do not move a pen sheet out of position when disconnecting the connectors.

HINT:

If the pen sheet is moved out of position, return it to its original position when connecting the connectors

Remove the 6 bolts.

NOTE:

Do not touch the bus-bars.

Remove the 4 bolts and inverter terminal with sensor sub-assembly.

REMOVE MG CONTROL COMPUTER WITH BRACKET SUB-ASSEMBLY

NOTE:

If metal shavings are created, remove them using tape or equivalent.
Do not touch the circuit board.
Do not allow any moisture to come into contact with the MG control computer with bracket sub-assembly.

While disengaging the white resin lock claws of the connector, disconnect the flat cable from the power module intelligent transistor kit.

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*a	Do not disconnect

NOTE:

Do not disconnect the flat cable from the MG control computer with bracket sub-assembly.
Do not use any tools.

Disconnect the 2 connectors.

NOTE:

Do not move a pen sheet out of position when disconnecting the connectors.

Disconnect the connector.

Disengage the 2 wire harnesses from the 4 clamps.

Remove the 4 bolts and MG control computer with bracket sub-assembly.

REMOVE POWER MODULE INTELLIGENT TRANSISTOR KIT

NOTE:

If metal shavings are created, remove them using tape or equivalent.
Do not touch the circuit board.
Do not allow any moisture to come into contact with the power module intelligent transistor kit.

Remove the 3 bolts.

NOTE:

Do not touch the bus-bars.

Remove the 4 bolts.

Using a screwdriver with its tip wrapped with protective tape, lift the power module intelligent transistor kit.

While holding the base of the coolant pipes, remove the power module intelligent transistor kit.

NOTE:

Do not touch the circuit board.

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*1	Base of the coolant pipe