DSD Information System
Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 10 (Hybrid Battery Control System - Service Information (1 Of 2)) >> Inverter With Converter >> Removal [11/2023 - ] >> Procedure

Removal [11/2023 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. PRECAUTION 

    Refer to PRECAUTION [11/2023 - ]

  2. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [11/2023 - ]

  3. DRAIN COOLANT (for Inverter) 

    See step  1

  4. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 19

  5. REMOVE COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 1

  6. REMOVE INLET AIR CLEANER ASSEMBLY 
    1. Remove the 2 bolts and inlet air cleaner assembly.
      GTY877755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE 
    1. Disconnect the mass air flow meter sub-assembly connector.
      GTY934879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the wire harness clamp.
    3. Slide the clip and disconnect the No. 2 ventilation hose from the cylinder head cover sub-assembly.
      GTY875792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Grommet
      *b Pin
    4. Loosen the hose clamp and disconnect the air cleaner hose from the throttle body with motor assembly.
    5. Disengage the 2 grommets and pin to remove the air cleaner assembly with air cleaner hose.
  8. REMOVE ECM 

    Refer to REMOVAL [11/2023 - ]

  9. REMOVE NO. 2 INVERTER PROTECTOR 
    1. Remove the 2 nuts and No. 2 inverter protector from the inverter with converter assembly.
      GTY877752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. DISCONNECT ENGINE ROOM MAIN WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    NOTE:

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

    1. Move the lock lever while pushing the lock on the connector, and disconnect the inverter with converter assembly connector.
      NOTE:
      • Do not touch the waterproof seal or terminals of the connector.
      • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
      • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
      • Insulate the disconnected terminals with insulating tape.
      GTY877747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt.
      GTY877746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the clamp and disconnect the engine room main wire.
  11. REMOVE CONNECTOR COVER ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    1. Remove the bolt (B).
      GTY900150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt (A)
      *b Bolt (B)
    2. Using a T25 "TORX" socket wrench, remove the bolt (A) and connector cover assembly from the inverter with converter assembly.
      NOTE:
      • Do not touch the connector cover assembly waterproof seal.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
  12. CHECK TERMINAL VOLTAGE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Using a voltmeter, measure the voltage between the terminals of the 2 phase connectors.

      Standard Voltage

      0 V

      NOTE:

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

      HINT: 

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

      GTY877741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    1. Temporarily install the connector cover assembly to the inverter with converter assembly.
      GTY934876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a T25 "TORX" socket wrench, install the bolt.

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

      NOTE:
      • Do not touch the connector cover assembly waterproof seal.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
  14. DISCONNECT FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. for AWD:
      1. Remove the 2 bolts and disconnect the HV floor under wire from the inverter with converter assembly.
        GTY842821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Waterproof Seal
        NOTE:
        • Do not damage the terminals, interlock connector or inverter with converter assembly during disconnection.
        • Do not touch the waterproof seal or terminals of the connector.
        • Do not allow any foreign matter or water to enter the inverter with converter assembly.
        • Although the connector may feel loose, this is not due to a malfunction.
    2. Remove the 2 nuts and disconnect the HV floor under wire from the inverter with converter assembly.
      GTY877739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and disconnect the HV floor under wire from the inverter with converter assembly.
      NOTE:
      • Do not touch the waterproof seal or terminals of the connector.
      • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
      • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Insulate the disconnected terminals with insulating tape.
      GTY854632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
  15. DISCONNECT HV AIR CONDITIONING WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Remove the 2 bolts.
      GTY860075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
    2. Disengage the clamp and disconnect the HV air conditioning wire from the inverter with converter assembly.
      NOTE:
      • Do not touch the waterproof seal or terminals of the connector.
      • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
      • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Insulate the disconnected terminals with insulating tape.
  16. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. Remove the nut and wire harness clamp bracket.
      GTY877743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT ENGINE WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    NOTE:

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

    1. Move the lock lever while pushing the lock on the connector, and disconnect the inverter with converter assembly connector.
      NOTE:
      • Do not touch the waterproof seal or terminals of the connector.
      • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
      • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
      • Insulate the disconnected terminals with insulating tape.
      GTY877742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. GTY874646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Disengage the 3 clamps (A) and disconnect the No. 1 fuel vapor feed hose.

    3. Remove the bolt.
    4. Disengage the 2 clamps (B).
    5. GTY872572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Generator Temperature Sensor Connector
      *b Resolver (Transmission Fluid Temperature Sensor) Connector
      *c Shift Lever Position Sensor Connector

      Disconnect the generator temperature sensor connector, resolver (transmission fluid temperature sensor) connector and shift lever position sensor connector and disengage the clamp.

      NOTE:

      After disconnecting the engine wire, cover the connector of the generator temperature sensor, resolver (transmission fluid temperature sensor) and shift lever position sensor with tape (non-residue type) or equivalent to prevent the entry of foreign matter or water.

      GTY958443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disengage the 2 clamps.
      GTY880215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the bolt.
      GTY880208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the bolt.
      GTY880205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Disengage the 2 claws and open the engine wire terminal cover.
      GTY880207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Remove the nut.
      GTY880197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Disengage the 2 clamps and disconnect the engine wire from the inverter with converter assembly.
  18. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Remove the nut and disconnect the transmission control cable assembly from the control shaft lever.
      GTY922122Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, disengage the 4 claws and disconnect the transmission control cable assembly with the clip from the No. 1 transmission control cable bracket.
      GTY922121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, disengage the 2 claws and remove the clip from the transmission control cable assembly.
      GTY745662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 bolts and disconnect the transmission control cable assembly from the inverter with converter assembly.
      GTY880198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. DISCONNECT NO. 1 INVERTER COOLING HOSE 
    1. Slide the clip and disconnect the No. 1 inverter cooling hose from the inverter with converter assembly.
      NOTE:

      Put pieces of cloth into the pipe and disconnected hose or cover the pipe and hose with plastic bags to prevent entry of foreign matter.

      GTY880200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. DISCONNECT NO. 4 INVERTER COOLING HOSE 
    1. Slide the clip and disconnect the No. 4 inverter cooling hose from the inverter with converter assembly.
      NOTE:

      Put pieces of cloth into the pipe and disconnected hose or cover the pipe and hose with plastic bags to prevent entry of foreign matter.

      GTY880202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE INVERTER COVER 
    WARNING:

    Be sure to wear insulated gloves.

    1. Remove the 2 bolts and inverter cover from the inverter with converter assembly.
      NOTE:
      • Make sure to pull the inverter cover straight out, as a connector is connected to the inside of the inverter cover.
      • Do not touch the waterproof seal of the inverter cover.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • When removing the inverter cover, do not pull the areas (A) as they may deform.
      • Make sure that the interlock is installed to the inverter cover.
      • Do not remove or excessively tighten the screw of the inverter cover.
        GTY596587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Inverter Cover
        *a Screw
      • Although the inverter cover may feel loose, this is not due to a malfunction.

      HINT: 

      If necessary, use a screwdriver with its tip wrapped with protective tape as shown in the illustration to remove the inverter cover.

      GTY866747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      GTY928959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Interlock
      *b Waterproof Seal
  22. DISCONNECT MOTOR CABLE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Using an insulated tool, remove the 6 bolts.
      GTY880269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Do not touch the waterproof seal or terminals of the connector.
    2. Remove the 4 bolts and disconnect the motor cable from the inverter with converter assembly.
      GTY883349Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
      NOTE:
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Do not touch the waterproof seal or terminals of the connector.
      • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
      • Insulate the disconnected terminals with insulating tape.
      • After disconnecting the motor cable, wrap it with a plastic bag or equivalent to protect it.
      • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
      • To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.
        GTY880262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. Remove the 2 bolts and wire harness clamp bracket from the inverter with converter assembly.
      GTY880267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE INVERTER WITH CONVERTER ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    1. Remove the 5 bolts, 2 nuts and inverter with converter assembly.
      GTY880264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • When removing the inverter with converter assembly, be careful not to damage the parts around it.
      • To prevent damage, do not hold the inverter with converter assembly by the connectors, brackets or cooling pipes.
      • To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.

      HINT: 

      Even after the coolant is drained, coolant remains in the inverter due to its internal structure. Therefore, seal or cover the pipes when removing the inverter with converter assembly so that coolant does not spill out.

  25. REMOVE NO. 1 INVERTER BRACKET 
    NOTE:
    GTY912955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Bottom of Inverter with Converter Assembly
    *b Support

    Make sure to support the inverter with converter assembly at the positions shown in the illustration, otherwise it may be damaged.

    1. Set the inverter with converter assembly on wooden blocks.
      GTY907971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
    2. Remove the 2 bolts and No. 1 inverter bracket from the inverter with converter assembly.
  26. REMOVE NO. 2 INVERTER BRACKET 
    1. Remove the 2 bolts and No. 2 inverter bracket from the inverter with converter assembly.
      GTY924662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
  27. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. Remove the bolt and wire harness clamp bracket from the inverter with converter assembly.
      GTY880246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and wire harness clamp bracket from the inverter with converter assembly.
      GTY880247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and wire harness clamp bracket from the inverter with converter assembly.
      GTY880248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE HYBRID INVERTER PROTECTOR ASSEMBLY 
    1. Remove the 4 bolts and hybrid inverter protector assembly from the inverter with converter assembly.
      GTY880237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Diesel-Data.com