Last Modified: 07-31-2024 6.11:8.1.0 Doc ID: RM10000000277T4
Model Year Start: 2023 Model: Corolla Prod Date Range: [09/2022 -           ]
Title: HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER: REMOVAL; 2023 - 2025 MY Corolla Corolla HV [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

Replacement of inverter with converter assembly

ECU configuration

-

2023 - 2025 MY Corolla Corolla Hatchback Corolla HV GR Corolla [09/2022 -        ]; SETUP: WHEN REPLACING OR REMOVING/INSTALLING PARTS: ECU CONFIGURATION

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

2023 - 2025 MY Corolla HV [09/2022 -        ]; HYBRID / BATTERY CONTROL: MOTOR GENERATOR CONTROL SYSTEM (for LITHIUM-ION BATTERY with PA10): UTILITY

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

ECU configuration

-

2023 - 2025 MY Corolla Corolla Hatchback Corolla HV GR Corolla [09/2022 -        ]; SETUP: WHEN REPLACING OR REMOVING/INSTALLING PARTS: ECU CONFIGURATION

Update ECU security key

Vehicle Control History (RoB) are stored

2023 - 2025 MY Corolla Corolla Hatchback Corolla HV GR Corolla [09/2022 -        ]; SETUP: WHEN REPLACING OR REMOVING/INSTALLING PARTS: UPDATE ECU SECURITY KEY

CAUTION:

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

    Click here 2023 - 2025 MY Corolla HV [09/2022 -        ]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for LITHIUM-ION BATTERY with PA10): PRECAUTION

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

NOTICE:

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

    Click here 2023 - 2025 MY Corolla Corolla Hatchback Corolla HV GR Corolla [09/2022 -        ]; SETUP: WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL: BEFORE DISCONNECTING BATTERY

  • After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

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.

Learning completes when vehicle is driven

Effect/Inoperative Function when Necessary Procedure not Performed

Necessary Procedure

Link

Front Camera System (for TMC Made)

Drive the vehicle straight ahead at 15 km/h (9 mph) or more for 1 second or more.

2023 MY Corolla Corolla Hatchback Corolla HV GR Corolla [09/2022 - 11/2022]; ADVANCED DRIVER ASSISTANCE SYSTEM: FRONT CAMERA SYSTEM (for TMC Made): INITIALIZATION 2023 - 2025 MY Corolla Corolla Hatchback Corolla HV GR Corolla [11/2022 -        ]; ADVANCED DRIVER ASSISTANCE SYSTEM: FRONT CAMERA SYSTEM: INITIALIZATION

PROCEDURE

1. REMOVE ECM

Click here 2023 MY Corolla Corolla HV [09/2022 - 11/2022]; 2ZR-FXE (ENGINE CONTROL): ECM: REMOVAL 2023 - 2025 MY Corolla Corolla HV [11/2022 -        ]; 2ZR-FXE (ENGINE CONTROL): ECM: REMOVAL

2. REMOVE SERVICE PLUG GRIP

Click here 2023 - 2025 MY Corolla Corolla HV [09/2022 -        ]; HYBRID / BATTERY CONTROL: SERVICE PLUG GRIP: REMOVAL

3. DRAIN COOLANT (for Inverter)

Click here 2023 - 2025 MY Corolla Corolla Hatchback Corolla HV GR Corolla [09/2022 -        ]; MAINTENANCE: COOLANT (for Inverter): REPLACEMENT+

4. REMOVE BATTERY CLAMP SUB-ASSEMBLY

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

5. REMOVE CONNECTOR COVER ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the bolt (A).

*a

Bolt (A)

*b

Bolt (B)

(b) Using a T20 "TORX" socket wrench, remove the bolt (B) 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.

6. 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.

*a

Terminal

-

-

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.
  • Perform the measurement while holding the tips of the tester probes against the terminals as shown in the illustration.

7. 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 T20 "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.

8. SEPARATE FLOOR SHIFT TRANSMISSION CONTROL SELECT CABLE

(a) Remove the nut to separate the floor shift transmission control select cable.

9. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

Click here 2023 - 2025 MY Corolla Corolla HV [09/2022 -        ]; 2ZR-FXE (ENGINE CONTROL): THROTTLE BODY: REMOVAL+

10. REMOVE AIR CLEANER HOSE ASSEMBLY

Click here 2023 - 2025 MY Corolla Corolla HV [09/2022 -        ]; 2ZR-FXE (ENGINE CONTROL): THROTTLE BODY: REMOVAL+

11. REMOVE RADIATOR SUPPORT OPENING COVER

Click here 2023 MY Corolla Corolla Hatchback Corolla HV GR Corolla [09/2022 - 11/2022]; EXTERIOR PANELS / TRIM: FRONT BUMPER (for Sedan without Illumination): REMOVAL+ 2023 - 2025 MY Corolla Corolla Hatchback Corolla HV GR Corolla [11/2022 -        ]; EXTERIOR PANELS / TRIM: FRONT BUMPER (for Sedan without Illumination): REMOVAL+

12. REMOVE NO. 2 AIR CLEANER INLET

Click here 2023 - 2025 MY Corolla Corolla HV [09/2022 -        ]; 2ZR-FXE (INTAKE / EXHAUST): INTAKE MANIFOLD: REMOVAL+

13. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

Click here 2023 - 2025 MY Corolla Corolla HV [09/2022 -        ]; 2ZR-FXE (INTAKE / EXHAUST): INTAKE MANIFOLD: REMOVAL+

14. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

Click here 2023 - 2025 MY Corolla Corolla HV [09/2022 -        ]; 2ZR-FXE (INTAKE / EXHAUST): INTAKE MANIFOLD: REMOVAL+

15. REMOVE AIR CLEANER BRACKET

Click here 2023 - 2025 MY Corolla Corolla HV [09/2022 -        ]; 2ZR-FXE (INTAKE / EXHAUST): INTAKE MANIFOLD: REMOVAL+

16. REMOVE NO. 1 AIR CLEANER INLET

Click here 2023 - 2025 MY Corolla Corolla HV [09/2022 -        ]; 2ZR-FXE (INTAKE / EXHAUST): INTAKE MANIFOLD: REMOVAL+

17. DISCONNECT HV AIR CONDITIONING WIRE

CAUTION:

Be sure to wear insulated gloves.

*a

Green-colored Lock

Slide

(a) Disengage the 2 clamps.

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

NOTICE:

Insulate the disconnected terminals with insulating tape.

18. 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 2 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 the lock lever as shown in the illustration and disconnect the inverter with converter assembly connector.

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 3 nuts.

(f) Disengage the clamp.

(g) Disengage the 2 clamps and disconnect the engine wire from the inverter with converter assembly.

19. 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.

(a) Move the lock lever as shown in the illustration and disconnect the inverter with converter assembly connector.

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.

(b) Disengage the 3 clamps.

(c) Disconnect the connector and disconnect the engine room main wire from the inverter with converter assembly.

20. DISCONNECT FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Disengage the clamp.

*a

Waterproof Seal

(b) Remove the bolt, 2 nuts 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.

(c) for 4WD

Remove the 2 bolts 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

21. DISCONNECT NO. 3 ENGINE WIRE

(a) Remove the nut.

(b) Disengage the 2 claws.

(c) Disengage the clamp.

22. DISCONNECT NO. 7 ENGINE WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the 2 bolts and disconnect the No. 3 engine wire from the inverter with converter assembly.

(b) Disengage the clamp.

23. 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.

24. 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.

25. DISCONNECT ENGINE WIRE

CAUTION:

Be sure to wear insulated gloves.

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

26. DISCONNECT INVERTER WITH CONVERTER ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the 4 bolts, 2 nuts to disconnect inverter with converter assembly.

NOTICE:

To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.

27. REMOVE INVERTER COVER

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the bolt and inverter cover from the hybrid vehicle transaxle assembly.

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

(c) 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.

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

(e) Using the 2 bolts as guides, remove the upper 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.

    *a

    Screw
  • Although the inverter cover may feel loose, this is not due to a malfunction.
  • Hold the upper inverter cover horizontal while removing it.

HINT:

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

*a

Interlock

*b

Waterproof Seal

(f) Remove the 2 bolts.

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

NOTICE:

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

(h) Remove the bolt.

28. DISCONNECT MOTOR CABLE

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the 6 bolts.

CAUTION:

Insulate the tool with insulating tape.

NOTICE:

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

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

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.

*a

Waterproof Seal

29. REMOVE INVERTER WITH CONVERTER ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the 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.