Last Modified: 07-31-2024 6.11:8.1.0 Doc ID: RM100000001O2PU
Model Year Start: 2021 Model: Corolla Prod Date Range: [04/2020 - 09/2022]
Title: HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER: REMOVAL; 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]

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

Auxiliary battery terminal is disconnected/reconnected

Perform steering sensor zero point calibration

Lane Control System

2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; PRE-COLLISION: PRE-COLLISION SYSTEM (for HV Model): INITIALIZATION

Pre-collision System

Replacement of inverter with converter assembly

Resolver learning
  • DTCs are stored
  • Slight vibration at a vehicle speed of 5 km/h (3 mph) or less
  • Shock or vibration during acceleration

2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; HYBRID / BATTERY CONTROL: MOTOR GENERATOR CONTROL SYSTEM (for NICKEL METAL HYDRIDE BATTERY): UTILITY for Nickel Metal Hydride Battery

2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; HYBRID / BATTERY CONTROL: MOTOR GENERATOR CONTROL SYSTEM (for LITHIUM-ION BATTERY with P610): UTILITY for Lithium-ion Battery

Replacement of ECM

Vehicle Identification Number (VIN) registration

MIL comes on

2020 - 2025 MY Corolla Corolla HV [01/2019 -        ]; 2ZR-FXE (ENGINE CONTROL): SFI SYSTEM: REGISTRATION

CAUTION:

  • Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.

    for NICKEL METAL HYDRIDE BATTERY: Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for NICKEL METAL HYDRIDE BATTERY): PRECAUTION

    for LITHIUM-ION BATTERY: Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for LITHIUM-ION BATTERY with P610): PRECAUTION

  • To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.

NOTICE:

After the power switch is turned off, the radio and display receiver assembly records various types of memory and settings. As a result, after turning the power switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal. (for Audio and Visual System (for HV Model))

PROCEDURE

1. DISCONNECT ENGINE WIRE

(a) Disengage the 2 claws and disconnect the engine wire from the battery current sensor holder.

(b) Disconnect the battery state sensor assembly connector.

2. REMOVE AUXILIARY BATTERY

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; MAINTENANCE: 2ZR-FXE AUXILIARY BATTERY: REMOVAL

3. REMOVE SERVICE PLUG GRIP

Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; HYBRID / BATTERY CONTROL: SERVICE PLUG GRIP: REMOVAL

4. DRAIN COOLANT (for Inverter)

Click here 2020 - 2022 MY Corolla Corolla Hatchback Corolla HV GR Corolla [01/2019 - 09/2022]; MAINTENANCE: COOLANT (for Inverter): REPLACEMENT+

5. REMOVE ECM

Click here 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]; 2ZR-FXE (ENGINE CONTROL): ECM: REMOVAL

6. REMOVE BATTERY CLAMP SUB-ASSEMBLY

(a) Remove the 3 bolts and battery clamp sub-assembly from the vehicle.

7. SEPARATE FLOOR SHIFT TRANSMISSION CONTROL SELECT CABLE

(a) Disengage the clamp to separate the floor shift transmission control select cable.

8. 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.

(a) Remove the No. 1 relay block cover from the No. 1 engine room relay block.

(b) Disconnect the 3 No. 1 engine room relay block connectors.

(c) Disengage the 2 claws to separate the engine wire from the No. 1 engine room relay block.

(d) Move each lock lever as shown in the illustration and disconnect the 2 inverter with converter assembly connectors.

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.
  • Insulate the disconnected terminals with insulating tape.

(e) Remove the bolt.

(f) Disengage the clamp (A) and remove the inverter protector.

(g) Disengage the clamp (B).

(h) Remove the 2 bolts.

(i) Disengage the clamp and disconnect the engine wire.

9. REMOVE CONNECTOR COVER ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the bolt (B).

*a

Bolt (A)

*b

Bolt (B)

(b) Using a T25 "TORX" socket wrench, remove the bolt (A) and connector cover assembly from the inverter with converter assembly.

NOTICE:

  • Do not touch the connector cover assembly waterproof seal.
  • Do not allow any foreign matter or water to enter the inverter with converter assembly.

10. CHECK TERMINAL VOLTAGE

CAUTION:

Be sure to wear insulated gloves.

(a) 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.

HINT:

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

11. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Temporarily install the connector cover assembly to the inverter with converter assembly.

(b) Using a T25 "TORX" socket wrench, install the bolt.

Torque:

4.5 N·m {46 kgf·cm, 40 in·lbf}

NOTICE:

  • 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. DISCONNECT FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the bolt and disconnect the HV floor under wire from the inverter with converter assembly.

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

(b) Disengage the 2 clamps.

13. DISCONNECT HV AIR CONDITIONING WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the 2 bolts and disconnect the HV air conditioning wire from the inverter with converter assembly.

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

(b) Disengage the clamp.

14. REMOVE WIRE HARNESS CLAMP BRACKET

(a) Remove the nut and wire harness clamp bracket.

15. DISCONNECT NO. 3 ENGINE WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the bolt and disconnect the No. 3 engine wire from the inverter with converter assembly.

(b) Remove the bolt and disconnect the No. 3 engine wire from the inverter with converter assembly.

(c) Disengage the 2 claws and open the No. 3 engine wire terminal cover.

(d) Remove the nut.

(e) Disengage the clamp and disconnect the No. 3 engine wire from the inverter with converter assembly.

16. DISCONNECT OUTLET NO. 1 INVERTER COOLING HOSE

(a) Slide the clip and disconnect the outlet No. 1 inverter cooling hose from the inverter with converter assembly.

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.

17. DISCONNECT INLET NO. 1 INVERTER COOLING HOSE

(a) Slide the clip and disconnect the inlet No. 1 inverter cooling hose from the inverter with converter assembly.

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.

18. REMOVE INVERTER COVER

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the 2 bolts and inverter cover from the inverter with converter assembly.

NOTICE:

  • 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.

    *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.

*a

Protective Tape

*a

Interlock

*b

Waterproof Seal

19. DISCONNECT MOTOR CABLE

CAUTION:

Be sure to wear insulated gloves.

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

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.

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

*a

Waterproof Seal

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.
  • 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.

20. REMOVE INVERTER WITH CONVERTER ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the 5 bolts, 2 nuts and inverter with converter assembly.

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.

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.

21. 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

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

*a

Wooden Block

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

22. REMOVE NO. 2 INVERTER BRACKET

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

*a

Wooden Block

23. REMOVE TRANSMISSION CONTROL CABLE SUPPORT

(a) Remove the bolt and transmission control cable support from the inverter with converter assembly.

24. REMOVE WIRE HARNESS CLAMP BRACKET

(a) Remove the bolt and wire harness clamp bracket from the inverter with converter assembly.

(b) Remove the bolt and wire harness clamp bracket from the inverter with converter assembly.

(c) Remove the bolt and wire harness clamp bracket from the inverter with converter assembly.