ARTICLE BEGINNING SERVICE PRECAUTIONSww2.justanswer.com/uploads/...173710_2002_estima-6.pdf ·...

ARTICLE BEGINNING

SERVICE PRECAUTIONS

WARNING: When performing any inspection or service procedure on thisvehicle, ensure following service precautions are followed to preventpersonal injury or death due to extremely high voltage.

WARNING: Read ALL service precautions before proceeding with serviceprocedure. Vehicle is equipped with air bag supplemental restraintsystem. Before attempting ANY repairs involving steering column,instrument panel or related components, see SERVICEPRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM inAIR BAG RESTRAINT SYSTEMS article.

CAUTION: When battery is disconnected, vehicle computer and memorysystems may lose memory data. Driveability problems may existuntil computer systems have completed a relearn cycle. Seeappropriate COMPUTER RELEARN PROCEDURES article inGENERAL INFORMATION before disconnecting battery.

The Following Service Precautions Must Be Followed:

Ensure ignition is off and ignition key is removed from ignition before performing anyinspection or service procedure in engine compartment, as engine may automatically startand shut off when ignition is on and READY light is illuminated. READY light is displayedjust above shift lever position indicator on instrument cluster at center of instrument panel.

•

Read all service and warning labels in engine compartment before performing anyprocedures.

•

All high-voltage wiring harnesses contain Orange connectors. DO NOT touch any wiringharness that contains Orange connectors.

•

High-voltage battery and other high-voltage components may be identified by HIGHVOLTAGE caution labels on them. DO NOT touch these components.

•

If necessary to inspect or service high-voltage system, ensure ignition is off. Remove serviceplug and wait at least 5 minutes to ensure high voltage is fully discharged before touchingany high-voltage wiring harness, connectors or components. Service plug is located onservice plug assembly at driver's side front corner of luggage compartment, near high-voltage battery. See Fig. 1 . Ensure service plug is stored in a location in which no one mayinstall service plug while technician is working on vehicle.

•

If necessary to touch any high-voltage wiring harness, connectors or components, ensureservice plug is removed and battery voltage or less exists at electrical connector. Use Toyotainsulated gloves when touching any high-voltage wiring harness, connectors or components.Ensure insulated gloves are dry and in good condition and that no holes exist in insulatedgloves by applying air to insulated glove before touching any high-voltage wiring harness,connectors or components.

•

Page 1 of 96HYBRID VEHICLE CONTROL -2002 Toyota Prius

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DO NOT wear any metal objects while working on vehicle which may accidently drop andcause a short circuit.

•

If any high-voltage wiring harness connector is disconnected, ensure terminal on wiringharness connector is wrapped with tape to prevent wiring harness connector from contactingany surface.

•

If servicing high-voltage system, place sign on roof of vehicle to indicate to othertechnicians that high-voltage system is being serviced.

•





Fig. 1: Locating Service Plug & Service Plug AssemblyCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

HYBRID VEHICLE CONTROL SYSTEM

PRECAUTION

CAUTION: A repair operation incorrectly performed on the hybrid vehicle (HV)could cause an electrical shock, leakage or explosion. Be sure toperform repair operations correctly.

Remove key from ignition switch .1.

Ensure that charge connector is disconnected .2.

Wear insulating gloves always .3.

Disconnect negative (-) terminal cable from auxiliary battery .4.

Remove service plug and do not start any repair operation before 5 minutes havepassed .

5.



Fig. 2: Removing Service PlugCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

WARNING: Due to the discharge resistance, it takes at least 5 minutesbefore the 273.6 V electricity is sufficiently dischargedfrom the condenser in the inverter circuit.

•

Even after the 5 minutes have passed, the followingprecaution should be observed. Before touching a 273.6 Vcable or any other cable which you cannot identify, usethe tester to confirm that the voltage through the cable is12 V or less.

•

After removing the service plug, cover the plug connector using rubber or vinyl tape.6.

After removing 273.6 V cable, be sure to cover terminal using vinyl tape .7.

Use insulated tools .8.

Do not leave tools or parts (bolts, nuts, etc.) inside cabin .9.

WARNING: A metallic object may drop and cause a short-circuit.

Do not wear metallic objects such as mechanical pencils or scales .10.

HV BATTERY

HV BATTERY COMPONENTS



Fig. 3: Locating Hybrid Vehicle Battery & Related Components (1 Of 2)Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.



Fig. 4: Locating Hybrid Vehicle Battery & Related Components (2 Of 2)Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.



HV BATTERY REMOVAL

Remove service plug . See PRECAUTION .1.

Remove LUGGAGE TRIM .2.

Remove REAR SEAT .3.

Remove power cable :4.

Using the service plug, turn the interlock counterclockwise to unlock.a.

NOTE: When the interlock is damaged, be sure to replace it withnew one.

Fig. 5: Identifying Battery Carrier Catch Bracket Mounting NutsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Remove the 3 nuts and battery carrier catch bracket.b.

Remove the 2 bolts and power cables.c.



Fig. 6: Identifying Power Cable Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Remove the earth terminal.d.

Remove battery bracket .5.

Remove the 13 bolts and nut, RH and LH battery brackets.



Fig. 7: Identifying Right & Left Side Battery BracketsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Disconnect connector :6.

Disconnect the 2 connectors from the battery ECU.a.

Disconnect the connector from the SMR.b.

Disconnect the connector from the service plug assembly.c.

Remove duct . See 3 -6 .7.

Remove HV battery :8.

WARNING: Since alkaline electrolyte may be on the hose end, carryout the operation with considerable care.

Disconnect the battery hose from the body.a.

Remove the 5 bolts and HV battery.b.



Fig. 8: Identifying HV Battery Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

HV BATTERY DISASSEMBLY

Remove battery module set bolt .1.

Turn the battery assembly upside down, remove the 76 battery module bolts.

NOTE: When turning it over, prevent the flange from being deformed.When not removing a battery module, skip the operation of step(1 .

Remove battery cover .2.

Remove the 12 bolts, screw and battery cover.

Remove service plug :3.



Remove the rear RH and LH busbar module protectors.a.

Remove the 2 nuts for busbar module.b.

Fig. 9: Identifying Busbar Terminal Mounting NutsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Remove the nut and wire harness protector.c.



Fig. 10: Identifying Wire Harness Protector NutCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Remove the 3 bolts and service plug assembly.d.



Fig. 11: Identifying Service Plug Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Remove power cable for SMR :4.

Remove the front RH and LH busbar module protectors.a.

Remove the 2 nuts, and disconnect the power cable from the front busbar module.b.



Fig. 12: Identifying Power Cable To Front Busbar Module Mounting NutsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Remove the SMR cover from the SMR.c.

Remove 2 bolts, and disconnect the power cable for SMR.d.

Remove SMR :5.

NOTE: When the interlock is damaged, be sure to replace it withnew one.

Using the service plug, turn the interlock counterclockwise to unlock.a.

Remove the 3 bolts and SMR.b.



Fig. 13: Identifying SMR Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Remove HV battery thermistor .6.



Fig. 14: Identifying Battery ThermistorCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Remove battery ECU :7.

Disconnect the connector.a.

Remove the 2 bolts and battery ECU.b.



Fig. 15: Identifying Battery ECU Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Remove battery hose .8.

Remove busbar module :9.

Remove the 36 nuts, RH and LH rear busbar modules.a.

Remove the 36 nuts, RH and LH front busbar modules.b.

Remove battery clamp bolt .10.



Fig. 16: Identifying Battery ClampCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Remove the 4 bolts and battery clamp bolt.

WARNING: Never remove the battery clamp bolt until 4 hours has passedafter the ignition switch is turned OFF. An explosion due toexpansion could occur.

Remove RH battery bracket .11.

Remove the 2 bolts and RH battery bracket.



Fig. 17: Identifying Battery Bracket To Battery Carrier Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

WARNING: Never remove the RH battery bracket until 4 hours has passedafter the ignition switch is turned OFF. An explosion due toexpansion could occur.

Remove 38 HV battery modules .12.

HV BATTERY INSPECTION

Inspect HV Battery Thermistor

Using an ohmmeter, measure the resistance between terminals.



Fig. 18: Identifying HV Battery Thermistor TerminalsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Standard resistance:

1 To 2: 9-11 kohm at 25 °C (77 °F) .

3 To 4: 9 -11 kohm at 25 °C (77 °F) .

5 To 6: 9 -11 kohm at 25 °C (77 °F) .

7 To 8: 9 -11 kohm at 25 °C (77 °F) .

7 To 10: 9 -11 kohm at 25 °C (77 °F) .

IF resistance is not specified, replace the HV battery thermistor.

HV BATTERY REASSEMBLY

Install battery module .1.



Install the 38 battery modules to the battery carrier.

NOTE: Packs containing 2 battery module each are arranged inthe order of 1 to 19 from the ECU side.

•

Starting from the positive terminal of the battery moduleon the battery ECU side, install 38 battery modules byalternately connecting the positive and negative terminalsto the vehicle front side.

•

Install battery clamp bolt .2.

Install the battery clamp bolt with the 2 bolts.

Torque: 23 N.m (230 kgf.cm, 16 ft.lbf) .



Fig. 19: Identifying Battery Clamp To Battery Carrier Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Install RH battery bracket .3.

Install the RH battery bracket with the 4 bolts.


Fig. 20: Identifying Battery Bracket To Battery Carrier & Clamp Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Install battery hose4.



Fig. 21: Identifying Battery HosesCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Install HV battery thermistor .5.



Fig. 22: Identifying Battery ThermistorCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Install battery ECU :6.

Install the battery ECU with the 2 bolts.a.

Torque: 3.3 N.m (33 kgf.cm, 29 in.lbf) .

Connect the connector for HV battery thermistor.b.

Install busbar module :7.

Install the front busbar module with the 74 nuts.a.


Install the rear RH and LH busbar modules with the 74 nuts.b.




Fig. 23: Identifying Battery ECU Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Install SMR :8.

Install the SMR with the 3 bolts.a.


Connect the power cable for SMR with the 2 bolts.b.


Install the SMR cover to the SMR.c.

Connect the connector to the cover for external uniform charger and lock the cover.d.



Fig. 24: Identifying SMR Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Connect the power cable for SMR with 2 new nuts.e.


Install the front RH and LH busbar module protectors.f.



Fig. 25: Identifying Power Cable To Front Busbar Module Mounting NutsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Install service plug :9.

Install the service plug with the 3 bolts.a.



Fig. 26: Identifying Service Plug Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.


Install the wire harness protector with the nut.b.



Fig. 27: Identifying Wire Harness Protector NutCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Install the busbar module with 2 new nutsc.



Fig. 28: Identifying Busbar Terminal Mounting NutsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.


Install rear RH and LH busbar module protector .10.

Install battery cover .11.

Install the battery cover with the 12 bolts and screw.



Fig. 29: Identifying Battery Cover Mounting Bolts "A"-"C" & ScrewCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Torque:

Bolt A: 18 N.m (185 kgf.cm, 13 ft.lbf) .

Bolt B: 8.0 N.m (80 kgf.cm, 71 in.lbf) .

Bolt C: 7.0 N.m (70 kgf.cm, 62 in.lbf) .

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

Install battery module set bolt .12.

Turn the battery assembly upside down, install the 76 battery module set bolts.


HV BATTERY INSTALLATION

Install HV battery .1.



Set the HV battery to the body.a.

WARNING: Since alkaline electrolyte may be on the hose end, carryout the operation with considerable care.

Connect the battery hose to the body.b.

Install battery bracket .2.

Install the RH and LH battery bracket with the 13 bolts and nut.a.


Fig. 30: Identifying Right & Left Side Battery BracketsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Install and tighten the 5 bolts for HV battery.b.




Fig. 31: Identifying HV Battery Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Install high tension cable :3.

Install the earth terminal.a.

Install the high tension cable with the 2 bolts.b.




Fig. 32: Identifying High Tension Cable Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE: When installing a cover, never fail to pass the interlockbutton.



Fig. 33: Identifying Battery Carrier Catch Bracket Mounting NutsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Install the battery carrier catch bracket with the 3 nuts.c.


Install duct . See 2 -5 .4.

Connect connector :5.

Connect the 2 connectors to the battery ECU.a.

Connect the connector to the SMR,b.

Connect the connector to the service plug assembly.c.

Install REAR SEAT .6.

Install LUGGAGE TRIM .7.

Install service plug . See PRECAUTION .8.



CONVERTER AND INVERTER ASSEMBLY

ON-VEHICLE INSPECTION OF CONVERTER & INVERTER ASSEMBLY

Inspect inverter :1.

Turn the IG switch OFF and disconnect the 4 connectors.a.

Apply battery positive voltage to connector B terminal 5 (IGCT) on the inverter sidethrough a fuse, and battery negative voltage to connector B terminal 6 (GND).

b.

Measure the voltage and resistance between each terminal shown in Fig. 34 and Fig.35 and ground.

c.

Fig. 34: Identifying Inverter Terminals Of Connectors A-DCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.



Fig. 35: Identifying Inverter Connector Terminal SpecificationsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Inspect converter :2.

Function checka.

Measure the voltage of an auxiliary battery terminal when the "READY" lamp is OFFand ON.



Fig. 36: Locating The Driving Ready LightCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

READY lamp is OFF: Approximately 12 V .

READY lamp is ON: Approximately 14 V .

Output current checkb.

Disconnect the MG2 power cable from the inverter. See (a .1.

Install AC/DC 400 A probe to the wire harness of the IP connector of theconverter.

2.

Connect the MG2 power cable to the inverter. See ( i .3.

With the READY lamp ON, operate electric devices one by one and measurethe output current.

4.

Standard: 100 A or less .

NOTE:If more than 100 A is shown momentarily, check for the following:



Ground short of electric device.•

Overload caused by installation of excessive device.•

PTC heater operation.•

CONVERTER & INVERTER ASSEMBLY COMPONENTS



Fig. 37: Locating Converter & Inverter Related Components (1 Of 2)Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.



Fig. 38: Locating Converter & Inverter Related Components (2 Of 2)Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

CONVERTER & INVERTER ASSEMBLY REMOVAL



Remove service plug . See PRECAUTION .1.

Drain HV coolant . See Step 2) in Replace Coolant in HYBRID TRANSAXLE ON-VEHICLE REPAIR .

2.

Remove COWL TOP PANEL .3.

Verify "ZERO" V .4.

CAUTION: Before starting step (a ), 5 minutes or more should bepassed after removing the service plug.

•

Be careful to prevent foreign matter from entering theinside of connector cover.

•

Disconnect the connector of the battery power cable and insulate it with packagingtape.

a.

Using a torx socket wrench (T30), remove the 4 screws and inverter terminal cover.b.

NOTE: Slide the connector cover to disconnect the circuitbreaker sensor connector.

Using a torx socket wrench (T40), remove the 2 screws, circuit breaker sensor andconnector cover.

c.

Using a voltmeter, measure the voltage between terminals of 3 phases (U-V, V-W, U-W) and each terminal and body ground to verify them to be approximately 0 V.

d.







Fig. 39: Identifying Converter & Inverter AssemblyCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Remove converter & inverter assembly :5.

CAUTION: Be careful to prevent foreign matter from entering theinside of connector cover.

Fig. 40: Identifying MG2 Power Cable Securing & Terminal BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Remove the 6 bolts and 3 power cables for MG2.a.

CAUTION: Remove the power cables for MG1 together withconverter & inverter assembly.

•



Be careful to prevent foreign matter from enteringthe inside of connector cover.

•

Fig. 41: Identifying MG1 Power Cable Terminal BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Remove the 3 bolts and power cables for MG1.b.

Remove the bolt and ground cable.c.

Disconnect the 3 water hoses from the converter & inverter assembly.d.

Remove the 4 bolts and converter & inverter assembly.e.



Fig. 42: Locating Converter & Inverter Assembly Mounting Bolts & Water HoseConnectionsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

DISASSEMBLY OF CONVERTER & INVERTER

Remove inverter reservoir tank :1.

Remove the 2 bolts, nuts and inverter reservoir tank.a.

Remove the O-ring from the inverter reservoir tank.b.



Fig. 43: Identifying Inverter Reservoir TankCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

CAUTION: Do not remove the inverter cover unless necessary. Doingso may result in vehicle breakdown or electric shock.

•

When replacing the inverter cover, quickly replace it toprevent water, dirt or dust from entering into the inverter.

•

Remove inverter cover :2.

Remove the 12 bolts and inverter cover.a.



Fig. 44: Identifying Inverter Cover BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Remove the gasket from the inverter cover.b.

Remove bracket :3.

Remove the 6 bolts and 4 brackets.

Remove water hose .4.

REASSEMBLY OF CONVERTER & INVERTER

Install water hose .1.



Install bracket .2.

Install the 4 brackets with the 6 bolts.


Install inverter cover :3.

Install a new gasket to the inverter cover.a.

Install the inverter cover with the 12 bolts.b.


Fig. 45: Identifying Inverter Cover Bolts & Gasket OrientationCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Install inverter reservoir tank :4.

Install a new O-ring to the inverter reservoir tank.a.



Install the inverter reservoir tank with the 2 bolts and nuts.b.


Fig. 46: Identifying Inverter Reservoir TankCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALLATION OF CONVERTER & INVERTER

Install converter & inverter assembly :1.

Install the converter & inverter assembly with the 4 bolts.a.



Fig. 47: Identifying Inverter Cover & Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.


Connect the 3 water hoses to the converter & inverter assembly.b.

Connect the 4 connectors.c.

Connect the 2 power cable connectors.d.

Install the ground cable to the radiator upper support.e.


Install the power cables for MG1 with the 3 bolts.f.





Fig. 48: Identifying MG1 Power Cable Terminal BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Install the connector cover and circuit breaker sensor with the 2 screws.g.



Fig. 49: Identifying Circuit Breaker Sensor Mounting ScrewsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.


Connect the connector for circuit breaker sensor.h.

Install the 3 power cables for MG2 with the 6 bolts.i.

Torque:

Bolt A: 19.5 N.m (199 kgf.cm, 14 ft.lbf) .

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




Fig. 50: Identifying MG2 Power Cable Securing Bolts "B" & Terminal Bolts "A"Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Install the gasket and inverter terminal cover with the 4 screws.j.



Fig. 51: Identifying Inverter Terminal Cover ScrewsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.


Install COWL TOP PANEL .2.

Install service plug . See PRECAUTION .3.

Fill with HV coolant . See Step 2) in Replace Coolant in HYBRID TRANSAXLE ON-VEHICLE REPAIR .

4.

Operation after replacing converter & inverter assembly :5.

Even if the master warning light is not lit, clear DTC using a TOYOTA hand-held tester.When replacing a converter & inverter assembly of the vehicle in which no error occurs,also clear DTC using a TOYOTA hand held tester.

NOTE: When a TOYOTA hand-held tester cannot be used, disconnectthe auxiliary battery for 1 minute or more and connect it again.



Checking after replacing converter & inverter assembly .6.

Depressing the accelerator pedal to a degree of 50 %, increase the speed up to approximately15 km/h 3 or 4 times to check that there is no problem in the inverter operation.

HV WATER PUMP

HV WATER PUMP COMPONENTS



Fig. 52: Locating Hybrid Vehicle Water Pump Mounting Related ComponentsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

HV WATER PUMP REMOVAL



Drain HV coolant . See Step 2) Replace Coolant in HYBRID TRANSAXLE ON-VEHICLE REPAIR .

1.

Remove FRONT BUMPER COVER .2.

Remove LH heat light .3.

Remove HV water pump :4.

Disconnect the connector for HV water pump.a.

Disconnect the 2 water hoses from the HV water pump.b.

Remove the 2 bolts and HV water pump.c.

Fig. 53: Identifying Hybrid Vehicle (Heater) Water Pump Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECTION OF HV WATER PUMP

Check HV Water Pump Operation

Apply battery voltage to the HV water pump setting terminal 1 as negative pole and terminal 2 aspositive and check that the pump operates.



CAUTION:Pay special attention to the poles and never make a mistake.•

This check should be done for a short time (10 second or less).•

Fig. 54: Identifying Hybrid Vehicle (Heater) Water Pump TerminalsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALLATION OF HV WATER PUMP

Install HV water pump :1.

Install the HV water pump with the 2 bolts.a.

Torque: 7.0 N.m (70 kgf.cm, 62 in.lbf)

Connect the 2 water hoses.b.



Connect the connector for HV water pump.c.

Install LH head light .2.

Install FRONT BUMPER COVER .3.

Fill with HV coolant .4.

Fig. 55: Identifying Hybrid Vehicle (Heater) Water Pump Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INVERTER RADIATOR

INVERTER RADIATOR COMPONENTS



Fig. 56: Identifying Inverter Radiator Related ComponentsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INVERTER RADIATOR REMOVAL



Drain HV coolant . See Step 2) Replace Coolant in HYBRID TRANSAXLE ON-VEHICLE REPAIR .

1.

Remove FRONT BUMPER COVER .2.

Disconnect ambient temperature sensor .3.

Disconnect water temperature switch connector .4.

Remove water temperature switch .5.

Disconnect 2 water hoses .6.

Remove inverter radiator :7.

Remove the 3 nuts and inverter radiator.

Fig. 57: Identifying Inverter Radiator Mounting NutsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECTION OF INVERTER RADIATOR

Inspect Water Temperature Switch

Using a ohmmeter and thermometer, check continuity between terminals.

Standard:



No continuity at 48 °C (118.4 °F) or less .

Continuity at more than 55 °C (131 °F) .

Fig. 58: Testing Water Temperature SwitchCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSTALLATION OF INVERTER RADIATOR

Install inverter radiator :1.

Install the inverter radiator with the 3 nuts.



Fig. 59: Identifying Inverter Radiator Mounting NutsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.


Connect 2 water hoses .2.

Install water temperature switch .3.


Connect water temperature switch connector .4.

Connect ambient temperature sensor .5.

Install FRONT BUMPER COVER .6.

Fill with HV coolant . See Step 2) Replace Coolant in HYBRID TRANSAXLE ON-VEHICLE REPAIR .

7.

HV BATTERY COOLING

COMPONENTS



Fig. 60: Locating Hybrid Vehicle Battery Cooling System Related ComponentsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL

Remove REAR SEAT .1.

Remove LUGGAGE TRIM .2.



Remove inner ventilator duct .3.

Remove the 4 bolts and inner ventilator duct.

Remove lower quarter ventilator duct .4.

Remove the 2 bolts and lower quarter ventilator duct.

Fig. 61: Identifying Lower Quarter & Inner Ventilator Duct Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Remove quarter ventilator duct :5.

Disconnect the connector for blower motor control.a.

Remove the 6 screws and quarter ventilator duct.b.



Fig. 62: Identifying Quarter Ventilator Duct Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Remove quarter inner No. 2 duct .6.

Remove the 2 screws and quarter inner No. 2 duct.



Fig. 63: Identifying Quarter Inner No. 2 Duct Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Remove blower assembly :7.

Remove the quarter ventilation inner duct.a.

Disconnect the connector for blower motor.b.

Remove the bolt, 2 nuts and blower assembly.c.



Fig. 64: Identifying Blower Assembly Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

DISASSEMBLY

Remove Blower Motor Control

Using a drill, drill out the 2 rivet heads and remove the blower motor control.a.

Gently and vertically put the drill to the rivet, and cut the rivet flanges.b.

NOTE: Prizing the hole with a drill can lead to damage to the rivethole or breaking the drill.

•

Take care as the cut rivet is hot.•

Using a vacuum cleaner, remove the drilled rivet and their dust.c.



Fig. 65: Identifying Blower Motor Control Mounting RivetsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

INSPECTION

Inspect blower motor operation . See DTC P3077: BATTERY COOLING FANMOTOR CIRCUIT MALFUNCTION .

1.

Inspect battery fan relay :2.

Remove the battery fan relay.a.



Fig. 66: Locating Battery Fan RelayCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Inspect the battery fan relay continuity.b.

Using an ohmmeter, check that there is continuity between terminals 1 and 2.1.



Fig. 67: Testing Battery Fan Relay ContinuityCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

If there is no continuity, replace the relay.

Check that there is no continuity between terminals 3 and 5.2.

If there is continuity, replace the relay.

Inspect the battery fan relay operation.c.

Apply battery voltage across terminals 1 and 2.1.



Fig. 68: Testing Battery Fan Relay OperationCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Using an ohmmeter, check that there is continuity between terminals 3 and 5.2.

If there is no continuity, replace the relay.

Install the battery fan relay.d.

REASSEMBLY

Install Blower Motor Control

Using an air riveter or hand riveter, install the blower motor control.



Fig. 69: Identifying Blower Motor Control Mounting RivetsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

NOTE:Do not prize a riveter, as riveter is damaged, it is not tightened and the mandrel isbent.

•



Fig. 70: Causes Of Improper Rivet Installation (1 Of 3)Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Do not tilt the riveter and disconnect the rivet from the material while handling ariveter, as the materials are not tightened firmly.

•




Install the rivet while attaching materials, as they are not tightened firmly.•




INSTALLATION

Install blower assembly :1.

Connect the connector for blower motor.a.

Install the blower assembly with the bolt and 2 nuts.b.


install the quarter ventilation inner duct.c.



Fig. 73: Identifying Blower Assembly Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Install quarter inner No. 2 duct .2.

Install the quarter inner No. 2 duct with the 2 screws.



Fig. 74: Identifying Quarter Inner No. 2 Duct Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Install quarter ventilator duct .3.

Install the quarter ventilator duct with the 6 screws.a.

Connect the connector for blower motor control.b.



Fig. 75: Identifying Quarter Ventilator Duct Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Install lower quarter ventilator .4.

Install the lower quarter ventilator duct with the 2 bolts.


Install inner ventilator duct .5.

Install the inner ventilator duct with the 4 bolts.


Install LUGGAGE TRIM .6.

Install . REAR SEAT .7.



Fig. 76: Identifying Lower Quarter & Inner Ventilator Duct Mounting BoltsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

SERVICE PLUG

INSPECTION

Check Continuity

Using an ohmmeter, check continuity between the terminals.







Fig. 77: Testing Service PlugCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 78: Service Plug SpecificationsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

AUXILIARY BATTERY

INSPECTION

CAUTION:Check that the battery cables are connected to the correctterminals.

•

Disconnect the battery cables when the battery is given a quickcharge.

•

Do not perform tests with a high voltage insulation resistancetester.

•

Never disconnect the battery while the engine is running.•

Check battery electrolyte level .1.

Check the electrolyte quantity of each cell.

If under the lower level, replace the battery (or add distilled water if possible). Check thecharging system.

Check battery voltage :2.

After having driven the vehicle and in the case that 20 minutes have not passed afterhaving stopped the engine, turn the ignition switch ON and turn on the electrical

a.



system (headlight, blower motor, rear defogger etc.) for 60 seconds to remove thesurface charge.

Turn the ignition switch OFF and turn off the electrical systems.b.

Measure the battery voltage between the negative (-) and positive (+) terminals of thebattery.

c.

Standard voltage: 12.5 -12.9 V at 20°C (68°F) .

If the voltage is less than specification, charge the battery.

Check battery terminals, fusible link and fuses :3.

Check that the battery terminals are not loose or corroded.a.

If the terminals are corroded, clean the terminals.

Check the fusible link, H-fuses, M-fuse and fuses for continuity.b.

SPEED SENSOR (RESOLVER) AND TEMPERATURE SENSOR

INSPECTION

Inspect Speed Sensor (Resolver) And Temperature Sensor

NOTE: The range of standard values for the temperature sensor is shown inFig. 80 .

Using an ohmmeter, measure resistance at each terminals.



Fig. 79: Speed Sensor (Resolver) & Temperature Sensor SpecificationsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.



Fig. 80: Determining Temperature Sensor Resistance ValuesCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.







Fig. 81: Identifying Speed Sensor (Resolver) & Temperature Sensor TerminalsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

POWER CABLE

COMPONENTS



Fig. 82: Identifying Power Cable Related ComponentsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.



INSPECTION

Inspect Power Cable

If any damage mentioned below is identified at visual inspection, replace the power cable.

Area covered by protector:1.

When the protector is so damaged that the corrugated tube for the power cable inside theprotector is exposed.

Fig. 83: Identifying Types Of Power Cable Damage (1 Of 2)Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Other area:2.

When the corrugated tube is so damaged that the coating inside the power cable is exposed.



Fig. 84: Identifying Types Of Power Cable Damage (2 Of 2)Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

HV ECU

COMPONENTS



Fig. 85: Identifying Hybrid Vehicle ECU Related ComponentsCourtesy of TOYOTA MOTOR SALES, U.S.A., INC.

© 2008 Mitchell Repair Information Co., LLC.



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