Toyota Prius: Inverter With Converter (for Hev Model)

• Precaution
• Removal
• Disassembly
• Reassembly
• Installation

Precaution

PRECAUTION

1.PRECAUTION WHEN REMOVING/INSTALLING INVERTER WITH CONVERTER ASSEMBLY

NOTICE:

Observe the following in order to prevent entry of foreign matter:

NOTICE:

PRECAUTION WHEN HANDLING ELECTRONIC COMPONENTS

NOTICE:

PRECAUTION WHEN HANDLING PARTS

NOTICE:

PRECAUTION WHEN SUSPENDING WORK

Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during inverter with converter assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Replacement of inverter with converter assembly	ECU configuration	-
	Resolver learning	DTCs are stored Slight vibration at a Toyota Prius vehicle speed of 5 km/h (3 mph) or less Shock or vibration during acceleration	2ZR-FXE: M20A-FXS:

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal.

Click here

HINT:

When the cable is disconnected / reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

Items for which learning is completed by driving the Toyota Prius vehicle

Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
Front Camera System	Drive the Toyota Prius vehicle straight ahead at 35 km/h (22 mph) or more for 5 seconds or more.

Items for which learning is completed by operating the vehicle normally

Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
*1: w/o Power Back Door System *2: w/ Power Back Door System
Power Door Lock Control System*1 Back door opener	Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch.
Power Back Door System*2	Reset back door close position
Air Conditioning System	After the ignition switch is turned to ON, the servo motor standard position is recognized.	-

CAUTION / NOTICE / HINT

COMPONENTS (REMOVAL)

Procedure		Part Name Code
1	PRECAUTION	-		-	-
2	SERVICE PLUG GRIP	G3834	-	-	-
3	DRAIN COOLANT	-	-		-

Procedure		Part Name Code
4	FRONT WIPER ARM HEAD CAP	85292B		-	-
5	SHIELD CAP	85247		-	-
6	FRONT WIPER ARM AND BLADE ASSEMBLY LH	-		-	-
7	FRONT WIPER ARM AND BLADE ASSEMBLY RH	-		-	-
8	WINDSHIELD LOWER OUTSIDE MOULDING LH	75536D		-	-
9	WINDSHIELD LOWER OUTSIDE MOULDING RH	75535F	-	-	-
10	COWL WATER EXTRACT SHIELD LH	55754F	-	-	-
11	COWL WATER EXTRACT SHIELD RH	55753D	-	-	-
12	COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY	55708		-	-
13	CHECK TERMINAL VOLTAGE	-		-	-

*A	for M20A-FXS	*B	for 2ZR-FXE
*1	Connector Cover Assembly	-	-
	N*m (kgf*cm, ft.*lbf): Specified torque	-	-

Procedure		Part Name Code
14	ECM	89661	-	-	-

Procedure		Part Name Code
15	BATTERY CLAMP SUB-ASSEMBLY	74404A	-	-	-
16	RADIATOR SUPPORT OPENING COVER	53289A	-	-	-
17	AIR CLEANER CAP SUB-ASSEMBLY	17705	-	-	-
18	AIR CLEANER HOSE ASSEMBLY	-	-	-	-
19	AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY	17801	-	-	-
20	AIR CLEANER CASE SUB-ASSEMBLY	17701	-	-	-
21	INLET NO. 2 AIR CLEANER	17752	-	-	-
22	AIR CLEANER BRACKET	17771A	-	-	-
23	INLET NO. 1 AIR CLEANER	17751	-	-	-

*A

for 2ZR-FXE

-

-

Procedure		Part Name Code
24	NO. 2 VENTILATION HOSE	12262	-	-	-
25	AIR CLEANER CAP WITH AIR CLEANER HOSE	-	-	-	-
26	AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY	17801	-	-	-
27	AIR CLEANER CASE SUB-ASSEMBLY	17701	-	-	-
28	AIR CLEANER BRACKET	17771A	-	-	-
29	HV AIR CONDITIONING WIRE	821H2		-	-
30	NO. 2 RELAY BLOCK COVER	82662B	-	-	-
31	NO. 3 ENGINE WIRE	82123	-	-	-
32	VACUUM SWITCHING VALVE ASSEMBLY	25860	-	-	-

*A

for M20A-FXS

-

-

Procedure		Part Name Code
33	ENGINE WIRE	82121		-	-
34	ENGINE ROOM MAIN WIRE	82111		-	-
35	FLOOR UNDER WIRE	821H1		-	-
36	NO. 7 ENGINE WIRE	82127D		-	-
37	OUTLET NO. 1 INVERTER COOLING HOSE	G922C		-	-
38	INLET NO. 1 INVERTER COOLING HOSE	G922AA		-	-
39	ENGINE WIRE	82121		-	-

*A

for 2WD

*B

for 4WD

Procedure		Part Name Code
40	SEPARATE INVERTER WITH CONVERTER ASSEMBLY	G9200		-	-
41	UPPER INVERTER COVER	G9221		-	-
42	MOTOR CABLE	G1148		-	-
43	REMOVE INVERTER WITH CONVERTER ASSEMBLY	G9200		-	-

PROCEDURE

1. PRECAUTION

Click here

2. REMOVE SERVICE PLUG GRIP

Click here

3. DRAIN COOLANT (for Inverter)

Click here

4. REMOVE FRONT WIPER ARM HEAD CAP

Click here

5. REMOVE SHIELD CAP (for M20A-FXS)

Click here

6. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH

Click here

7. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH

Click here

8. REMOVE WINDSHIELD LOWER OUTSIDE MOULDING LH

Click here

9. REMOVE WINDSHIELD LOWER OUTSIDE MOULDING RH

(a) Use the same procedure as for the LH side.

10. REMOVE COWL WATER EXTRACT SHIELD LH

Click here

11. REMOVE COWL WATER EXTRACT SHIELD RH

(a) Use the same procedure as for the LH side.

12. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

Click here

13. CHECK TERMINAL VOLTAGE

CAUTION: Be sure to wear insulated gloves.

(1) Remove the bolt (A).

(2) Using a T20 "TORX" socket wrench, remove the bolt (B) and connector cover assembly from the inverter with converter assembly.

*a

Terminal

-

-

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

Standard Voltage:

0 V

NOTICE:

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

(1) Using a T20 "TORX" socket wrench, install the connector cover assembly to the inverter with converter assembly with the bolt (B).

Torque:

4.5 N·m {46 kgf·cm, 40 in·lbf}

NOTICE:

Do not touch the waterproof seal of the connector cover assembly.

(2) Install the bolt (A).

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

HINT:

It is not necessary to install the bolt (B) if it is to be removed in the next step or later, such as when removing the inverter with converter assembly.

14. REMOVE ECM

15. REMOVE BATTERY CLAMP SUB-ASSEMBLY (for 2ZR-FXE)

16. REMOVE RADIATOR SUPPORT OPENING COVER (for 2ZR-FXE)

Click here

17. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 2ZR-FXE)

Click here

18. REMOVE AIR CLEANER HOSE ASSEMBLY (for 2ZR-FXE)

Click here

19. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY (for 2ZR-FXE)

Click here

20. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (for 2ZR-FXE)

Click here

21. REMOVE INLET NO. 2 AIR CLEANER (for 2ZR-FXE)

Click here

22. REMOVE AIR CLEANER BRACKET (for 2ZR-FXE)

Click here

23. REMOVE INLET NO. 1 AIR CLEANER (for 2ZR-FXE)

Click here

24. DISCONNECT NO. 2 VENTILATION HOSE (for M20A-FXS)

Click here

25. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE (for M20A-FXS)

Click here

26. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY (for M20A-FXS)

Click here

27. REMOVE AIR CLEANER CASE SUB-ASSEMBLY (for M20A-FXS)

28. REMOVE AIR CLEANER BRACKET (for M20A-FXS)

29. DISCONNECT HV AIR CONDITIONING WIRE

CAUTION: Be sure to wear insulated gloves. NOTICE: Do not damage the terminals, connector housing or inverter with converter assembly during disconnection. Insulate the disconnected terminals with insulating tape.

(a) for 2ZR-FXE:

*a	Green-colored Lock	-	-
	Slide	-	-

(1) Slide the green-colored lock of the connector as shown in the illustration to release it and disconnect the HV air conditioning wire.

(b) for M20A-FXS:

*a	Green-colored Lock	-	-
	Slide	-	-

(1) Disengage the 2 clamps.

(2) Slide the green-colored lock of the connector as shown in the illustration to release it and disconnect the HV air conditioning wire.

30. REMOVE NO. 2 RELAY BLOCK COVER

31. DISCONNECT NO. 3 ENGINE WIRE

32. DISCONNECT VACUUM SWITCHING VALVE ASSEMBLY NO.1

33. DISCONNECT ENGINE WIRE

CAUTION: Be sure to wear insulated gloves. NOTICE: 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.

34. DISCONNECT ENGINE ROOM MAIN WIRE

CAUTION: Be sure to wear insulated gloves. NOTICE: 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.

35. DISCONNECT FLOOR UNDER WIRE

CAUTION: Be sure to wear insulated gloves. NOTICE: 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. 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.

*a

Waterproof Seal

-

-

(b) for 4WD:

*a

Waterproof Seal

-

-

36. DISCONNECT NO. 7 ENGINE WIRE

CAUTION: Be sure to wear insulated gloves.

37. DISCONNECT OUTLET NO. 1 INVERTER COOLING HOSE

NOTICE: 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.

38. DISCONNECT INLET NO. 1 INVERTER COOLING HOSE

NOTICE: 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.

39. DISCONNECT ENGINE WIRE

CAUTION: Be sure to wear insulated gloves. NOTICE: Do not allow any foreign matter or water to enter the inverter with converter assembly.

40. SEPARATE INVERTER WITH CONVERTER ASSEMBLY

CAUTION: Be sure to wear insulated gloves. NOTICE: To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.

41. REMOVE UPPER INVERTER COVER

CAUTION: Be sure to wear insulated gloves.

(1) Remove the bolt and inverter cover from the hybrid Toyota Prius vehicle transaxle assembly.

(2) To prevent the inverter with converter assembly from falling, temporarily install the bolt in the location shown in the illustration.

(3) Shift the position of the inverter with converter assembly and temporarily set it on top of the stud bolts as shown in the illustration.

NOTICE:

When lifting, make sure not to apply force to the motor cable.

(4) Loosen the 2 bolts, leaving 2 to 3 threads at the tip of the bolt still engaged.

*a

Interlock

*b

Waterproof Seal

(1) Using the 2 bolts as guides, remove the upper inverter cover from the inverter with converter assembly.

HINT:

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

(2) Remove the 2 bolts.

(1) Shift the position of the inverter with converter assembly and temporarily set it on the hybrid Toyota Prius vehicle transaxle assembly as shown in the illustration.

NOTICE:

When lifting, make sure not to apply force to the motor cable.

(2) Remove the bolt.

42. DISCONNECT MOTOR CABLE

CAUTION: Be sure to wear insulated gloves.

*a

Waterproof Seal

-

-

(1) Using an insulated tool, remove the 6 bolts.

(2) Remove the 4 bolts and disconnect the motor cable from the inverter with converter assembly.

43. REMOVE INVERTER WITH CONVERTER ASSEMBLY

CAUTION: Be sure to wear insulated gloves. NOTICE: 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.

(1) 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.

Disassembly

DISASSEMBLY

CAUTION / NOTICE / HINT

COMPONENTS (DISASSEMBLY)

Procedure		Part Name Code
1	NO. 1 INVERTER BRACKET	G9214		-	-
2	NO. 2 INVERTER BRACKET	G9215		-	-
3	NO. 3 ENGINE WIRE	82123		-	-
4	HV AIR CONDITIONING WIRE	821H2		-	-
5	FUEL HOSE BRACKET	23881B	-	-	-
6	WIRE HARNESS CLAMP BRACKET	-	-	-	-

*A

for M20A-FXS

*B

for 2ZR-FXE

PROCEDURE

1. REMOVE NO. 1 INVERTER BRACKET

NOTICE: Make sure to support the inverter with converter assembly at the positions shown in the illustration, otherwise it may be damaged. *a: Bottom of Inverter with Converter Assembly *b: Support

(1) Set the inverter with converter assembly on wooden blocks.

(2) Remove the 2 bolts and No. 1 inverter bracket from the inverter with converter assembly.

NOTICE:

Do not touch portion (A) of the No. 1 inverter bracket.

2. REMOVE NO. 2 INVERTER BRACKET

(1) Remove the 2 bolts and No. 2 inverter bracket from the inverter with converter assembly.

NOTICE:

Do not touch portion (A) of the No. 2 inverter bracket.

3. REMOVE NO. 3 ENGINE WIRE

CAUTION: Be sure to wear insulated gloves. NOTICE: Do not allow any foreign matter or water to enter the inverter with converter assembly. Perform this procedure when it is necessary to replace the inverter with converter assembly or the No. 3 engine wire.

(1) Disengage the 2 claws and open the cover.

(2) Remove the bolt, nut, clamp and disconnect the No. 3 engine wire from the inverter with converter assembly.

NOTICE:

Move the tool in the downward direction to loosen the nut as shown in the illustration.

4. REMOVE HV AIR CONDITIONING WIRE

CAUTION: Be sure to wear insulated gloves. NOTICE: 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.

*a

Waterproof Seal

-

-

5. REMOVE FUEL HOSE BRACKET (for M20A-FXS)

*A

for 2WD

*B

for 4WD

6. REMOVE WIRE HARNESS CLAMP BRACKET

(a) for M20A-FXS:

*A

for 2WD

*B

for 4WD

(b) for 2ZR-FXE:

*A

for 2WD

*B

for 4WD

Reassembly

REASSEMBLY

CAUTION / NOTICE / HINT

COMPONENTS (REASSEMBLY)

Procedure		Part Name Code
1	WIRE HARNESS CLAMP BRACKET	-	-	-	-
2	FUEL HOSE BRACKET	23881B	-	-	-
3	HV AIR CONDITIONING WIRE	821H2		-	-
4	NO. 3 ENGINE WIRE	82123		-	-
5	NO. 2 INVERTER BRACKET	G9215		-	-
6	NO. 1 INVERTER BRACKET	G9214		-	-

*A	for M20A-FXS	*B	for 2ZR-FXE
	Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)		N*m (kgf*cm, ft.*lbf): Specified torque

PROCEDURE

1. INSTALL WIRE HARNESS CLAMP BRACKET

(a) for M20A-FXS:

*A

for 2WD

*B

for 4WD

Torque:

Bolt A :

10 N·m {102 kgf·cm, 7 ft·lbf}

Bolt B :

8.0 N·m {82 kgf·cm, 71 in·lbf}

(b) for 2ZR-FXE:

*A

for 2WD

*B

for 4WD

Torque:

Bolt A :

10 N·m {102 kgf·cm, 7 ft·lbf}

Bolt B :

8.0 N·m {82 kgf·cm, 71 in·lbf}

2. INSTALL FUEL HOSE BRACKET (for M20A-FXS)

Torque:

13 N·m {133 kgf·cm, 10 ft·lbf}

3. INSTALL HV AIR CONDITIONING WIRE

CAUTION: Be sure to wear insulated gloves. NOTICE: 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 when connecting the connector.

*a

Waterproof Seal

-

-

Torque:

Bolt A :

8.0 N·m {82 kgf·cm, 71 in·lbf}

Bolt B :

10 N·m {102 kgf·cm, 7 ft·lbf}

4. INSTALL NO. 3 ENGINE WIRE

CAUTION: Be sure to wear insulated gloves. NOTICE: Do not allow any foreign matter or water to enter the inverter with converter assembly. Perform this procedure when it is necessary to replace the inverter with converter assembly and the No. 3 engine wire.

(1) Engage the clamp and connect the engine wire to the inverter with converter assembly with the bolt and nut.

Torque:

Bolt :

10 N·m {102 kgf·cm, 7 ft·lbf}

Nut :

16 N·m {163 kgf·cm, 12 ft·lbf}

(2) Engage the 2 claws.

5. INSTALL NO. 2 INVERTER BRACKET

NOTICE: Make sure to support the inverter with converter assembly at the positions shown in the illustration, otherwise it may be damaged. *a: Bottom of Inverter with Converter Assembly *b: Support

(1) Set the inverter with converter assembly on wooden blocks.

(2) Temporarily install the No. 2 inverter bracket to the inverter with converter assembly with the 2 bolts.

NOTICE:

Do not touch portion (A) of the No. 2 inverter bracket.

(3) Fully tighten the 2 bolts in the order shown in the illustration.

Torque:

15 N·m {153 kgf·cm, 11 ft·lbf}

6. INSTALL NO. 1 INVERTER BRACKET

(1) Temporarily install the No. 1 inverter bracket to the inverter with converter assembly with the 2 bolts.

NOTICE:

Do not touch portion (A) of the No. 1 inverter bracket.

(2) Fully tighten the 2 bolts in the order shown in the illustration.

Torque:

15 N·m {153 kgf·cm, 11 ft·lbf}

Installation

INSTALLATION

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure		Part Name Code
1	SET INVERTER WITH CONVERTER ASSEMBLY	G9200		-	-
2	MOTOR CABLE	G1148		-	-
3	UPPER INVERTER COVER	G9221		-	-
4	INSTALL INVERTER WITH CONVERTER ASSEMBLY	G9200		-	-

*	For use with a union nut wrench	-	-
	Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)		N*m (kgf*cm, ft.*lbf): Specified torque

Procedure		Part Name Code
5	ENGINE WIRE	82121		-	-
6	INLET NO. 1 INVERTER COOLING HOSE	G922AA		-	-
7	OUTLET NO. 1 INVERTER COOLING HOSE	G922C		-	-
8	NO. 7 ENGINE WIRE	82127D		-	-
9	FLOOR UNDER WIRE	821H1		-	-
10	ENGINE ROOM MAIN WIRE	82111		-	-
11	ENGINE WIRE	82121		-	-

*A	for 2WD	*B	for 4WD
	Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)		N*m (kgf*cm, ft.*lbf): Specified torque

Procedure		Part Name Code
12	VACUUM SWITCHING VALVE ASSEMBLY	25860	-	-	-
13	NO. 3 ENGINE WIRE	82123	-	-	-
14	NO. 2 RELAY BLOCK COVER	82662B	-	-	-
15	HV AIR CONDITIONING WIRE	821H2		-	-
16	AIR CLEANER BRACKET	17771A	-	-	-
17	AIR CLEANER CASE SUB-ASSEMBLY	17701	-	-	-
18	AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY	17801	-	-	-
19	AIR CLEANER CAP WITH AIR CLEANER HOSE	-	-	-	-
20	NO. 2 VENTILATION HOSE	12262	-	-	-

*A	for M20A-FXS	-	-
	Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)		N*m (kgf*cm, ft.*lbf): Specified torque

Procedure		Part Name Code
21	INLET NO. 1 AIR CLEANER	17751	-	-	-
22	AIR CLEANER BRACKET	17771A	-	-	-
23	INLET NO. 2 AIR CLEANER	17752	-	-	-
24	AIR CLEANER CASE SUB-ASSEMBLY	17701	-	-	-
25	AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY	17801	-	-	-
26	AIR CLEANER HOSE ASSEMBLY	-	-	-	-
27	AIR CLEANER CAP SUB-ASSEMBLY	17705	-	-	-
28	RADIATOR SUPPORT OPENING COVER	53289A	-	-	-
29	BATTERY CLAMP SUB-ASSEMBLY	74404A	-	-	-

*A	for 2ZR-FXE	-	-
	N*m (kgf*cm, ft.*lbf): Specified torque	-	-

Procedure		Part Name Code
30	ECM	89661	-	-	-

Procedure		Part Name Code
31	COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY	55708		-	-
32	COWL WATER EXTRACT SHIELD LH	55754F	-	-	-
33	COWL WATER EXTRACT SHIELD RH	55753D	-	-	-
34	WINDSHIELD LOWER OUTSIDE MOULDING LH	75536D	-	-	-
35	WINDSHIELD LOWER OUTSIDE MOULDING RH	75535F	-	-	-
36	FRONT WIPER ARM AND BLADE ASSEMBLY LH	-		-	-
37	FRONT WIPER ARM AND BLADE ASSEMBLY RH	-		-	-
38	SHIELD CAP	85247		-	-
39	FRONT WIPER ARM HEAD CAP	85292B		-	-

*A	for M20A-FXS	*B	for 2ZR-FXE
	N*m (kgf*cm, ft.*lbf): Specified torque	-	-

Procedure		Part Name Code
40	SERVICE PLUG GRIP	G3834	-	-	-
41	ADD COOLANT (for Inverter)	-	-		-
42	INSPECT FOR COOLANT LEAK (for Inverter)	-	-		-
43	ECU CONFIGURATION	-	-	-
44	RESOLVER LEARNING	-	-	-

PROCEDURE

1. SET INVERTER WITH CONVERTER ASSEMBLY

CAUTION: Be sure to wear insulated gloves. NOTICE: When installing 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. Make sure that the inverter with converter assembly is positioned so that the stud bolts are in contact with the base of the U-shaped portions of the No. 1 inverter bracket. *a: Correct *b: Incorrect

2. CONNECT MOTOR CABLE

CAUTION: Be sure to wear insulated gloves. NOTICE: Do not allow any foreign matter or water to enter the inverter with converter assembly.

*a

Waterproof Seal

-

-

(1) Temporarily install the motor cable to the inverter with converter assembly with the 4 bolts,

(2) Fully tighten the 3 bolts in the order shown in the illustration.

Torque:

8.0 N·m {82 kgf·cm}

(3) Using a 10 mm union nut wrench, fully tighten the bolt(A).

Torque:

Specified Tightening Torque :

8.0 N·m {82 kgf·cm, 71 in·lbf}

(4) Temporarily install the 6 bolts.

CAUTION:

Insulate the tool with insulating tape.

(5) Fully tighten the 6 bolts.

Torque:

8.0 N·m {82 kgf·cm}

CAUTION:

Insulate the tool with insulating tape.

3. INSTALL UPPER INVERTER COVER

CAUTION: Be sure to wear insulated gloves.

*a

Interlock

*b

Waterproof Seal

(1) To prevent the inverter with converter assembly from falling, temporarily install the bolt in the location shown in the illustration.

(2) Shift the position of the inverter with converter assembly and temporarily set it on top of the stud bolts as shown in the illustration.

NOTICE:

When lifting, make sure not to apply force to the motor cable.

(3) Install the inverter cover to the inverter with converter assembly with the 2 bolts.

Torque:

8.0 N·m {82 kgf·cm}

(1) Shift the position of the inverter with converter assembly and temporarily set it on the hybrid Toyota Prius vehicle transaxle assembly as shown in the illustration.

NOTICE:

When lifting, make sure not to apply force to the motor cable.

(2) Install the inverter cover with the bolt to the hybrid vehicle transaxle assembly.

Torque:

8.0 N·m {82 kgf·cm}

4. INSTALL INVERTER WITH CONVERTER ASSEMBLY

CAUTION: Be sure to wear insulated gloves.

(1) Temporarily install the inverter with converter assembly with the 5 bolts and 2 nuts.

HINT:

If the bolts and nuts are not tightened appropriately, the inverter with converter assembly may make an abnormal noise.

(2) Fully tighten the 4 bolts in the order shown in the illustration.

Torque:

55 N·m {561 kgf·cm, 41 ft·lbf}

(3) Fully tighten the 2 nuts.

Torque:

55 N·m {561 kgf·cm, 41 ft·lbf}

5. CONNECT ENGINE WIRE

CAUTION: Be sure to wear insulated gloves.

6. CONNECT INLET NO. 1 INVERTER COOLING HOSE

(a) for 2ZR-FXE:

*a	Alignment Mark	*b	Rib
*c	2 to 11 mm (0.0787 to 0.4331 in.)	*d	Up
*e	LH Side	-	-

(1) Connect the inlet No. 1 inverter cooling hose to the inverter with converter assembly and slide the clip to secure it.

(b) for M20A-FXS:

*a	Alignment Mark	*b	Rib
*c	2 to 11 mm (0.0787 to 0.4331 in.)	*d	Up
*e	LH Side	-	-

(1) Connect the inlet No. 1 inverter cooling hose to the inverter with converter assembly and slide the clip to secure it.

7. CONNECT OUTLET NO. 1 INVERTER COOLING HOSE

(a) for 2ZR-FXE:

*a	Alignment Mark	*b	Rib
*c	2 to 11 mm (0.0787 to 0.4331 in.)	*d	Up
*e	LH Side	-	-

(1) Connect the outlet No. 1 inverter cooling hose to the inverter with converter assembly and slide the clip to secure it.

(b) for M20A-FXS:

*a	Alignment Mark	*b	Rib
*c	2 to 11 mm (0.0787 to 0.4331 in.)	-	-

(1) Connect the outlet No. 1 inverter cooling hose to the inverter with converter assembly and slide the clip to secure it.

8. CONNECT NO. 7 ENGINE WIRE

CAUTION: Be sure to wear insulated gloves.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

9. CONNECT FLOOR UNDER WIRE

CAUTION: Be sure to wear insulated gloves. NOTICE: 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 when connecting the connector.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

10. CONNECT ENGINE ROOM MAIN WIRE

CAUTION: Be sure to wear insulated gloves. NOTICE: To prevent the threads from being damaged, temporarily tighten the nut by hand. Do not touch the waterproof seal or terminals of the connectors. To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors. Do not damage the terminals, connector housing or inverter with converter assembly when connecting the connectors.

11. CONNECT ENGINE WIRE

CAUTION: Be sure to wear insulated gloves. NOTICE: To prevent the threads from being damaged, temporarily tighten the nut by hand. Do not touch the waterproof seal or terminals of the connectors. To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors. Do not damage the terminals, connector housing or inverter with converter assembly when connecting the connectors.

Torque:

10 N·m {102 kgf·cm, 89 in·lbf}

12. CONNECT NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (for M20A-FXS)

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

13. CONNECT NO. 3 ENGINE WIRE

Torque:

8.35 N·m {85 kgf·cm, 74 in·lbf}

14. INSTALL NO. 2 RELAY BLOCK COVER

15. CONNECT HV AIR CONDITIONING WIRE

CAUTION: Be sure to wear insulated gloves. NOTICE: 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 when connecting the connector.

(a) for 2ZR-FXE

*a	Green-colored Lock	-	-
	Slide	-	-

(1) Connect the connector and slide the green-colored lock as shown in the illustration to securely lock it.

(b) for M20A-FXS

*a	Green-colored Lock	-	-
	Slide	-	-

(1) Connect the connector and slide the green-colored lock as shown in the illustration to securely lock it.

(2) Engage the 2 clamps.

16. INSTALL AIR CLEANER BRACKET (for M20A-FXS)

Torque:

7.0 N·m {71 kgf·cm, 62 in·lbf}

17. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for M20A-FXS)

Torque:

4.0 N·m {41 kgf·cm, 35 in·lbf}

18. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY (for M20A-FXS)

19. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE (for M20A-FXS)

20. CONNECT NO. 2 VENTILATION HOSE (for M20A-FXS)

21. INSTALL INLET NO. 1 AIR CLEANER (for 2ZR-FXE)

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22. INSTALL AIR CLEANER BRACKET (for 2ZR-FXE)

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23. INSTALL INLET NO. 2 AIR CLEANER (for 2ZR-FXE)

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24. INSTALL AIR CLEANER CASE SUB-ASSEMBLY (for 2ZR-FXE)

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25. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY (for 2ZR-FXE)

26. INSTALL AIR CLEANER HOSE ASSEMBLY (for 2ZR-FXE)

27. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 2ZR-FXE)

28. INSTALL RADIATOR SUPPORT OPENING COVER (for 2ZR-FXE)

29. INSTALL BATTERY CLAMP SUB-ASSEMBLY (for 2ZR-FXE)

Torque:

15.4 N·m {157 kgf·cm, 11 ft·lbf}

30. INSTALL ECM

31. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

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32. INSTALL COWL WATER EXTRACT SHIELD RH

33. INSTALL COWL WATER EXTRACT SHIELD LH

34. INSTALL WINDSHIELD LOWER OUTSIDE MOULDING LH

35. INSTALL WINDSHIELD LOWER OUTSIDE MOULDING RH

36. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH

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37. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH

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38. INSTALL SHIELD CAP (for M20A-FXS)

39. INSTALL FRONT WIPER ARM HEAD CAP

40. INSTALL SERVICE PLUG GRIP

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41. ADD COOLANT (for Inverter)

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42. INSPECT FOR COOLANT LEAK (for Inverter)

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43. PERFORM ECU CONFIGURATION

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44. PERFORM RESOLVER LEARNING