2001 TOYOTA PRIUS Service Repair Manual

HV008±02
B12008
2 3 4
5 6 7 86 1
A BC
D
1 2 3
4 52
3 4
5 6 7 81
61 2 3
4 5
HV±14
± HYBRID VEHICLE CONTROLCONVERTER AND INVERTER ASSEMBLY
1344 Author: Date:
2001 PRIUS (RM778U)
CONVERTER AND INVERTER ASSEMBLY
ON±VEHICLE INSPECTION
1. INSPECT INVERTER
(a) Turn the IG switch OFF and disconnect the 4 connectors.
(b) Apply battery positive voltage to connector B terminal 5 (IGCT) on the inverter side through a fuse, and
battery negative voltage to connector B terminal 6 (GND).
(c) Measure the voltage and resistance between each terminal shown below and ground.
TerminalMeasuring ConditionSpecification
A, 5 (G ± INVT)
D, 5 (M±INVT)±Approx. 2 ± 4.5 V
C, 5 (VB)±Approx. 0.5 ± 4 V
A, 4 (G ± SDOWN)
D, 4 (M ± SDOWN)Apply battery positive voltage to terminal through the resistance of 1 kW.Approx. 5 ± 6 V
B, 8 (G ± FINV)
C, 8 (M ± FINV)
B, 7 (G ± SINV)
C, 7 (M ± SINV)
Connect the terminal to connector B terminal 6 through the resistance of 10 kW.7 ± 12 V approx. 0.2 sec.
A, 1 (G ± UU)
A, 2 (G ± VU)
A, 3 (G ± WU)
D, 1 (M ± UU)
D, 2 (M ± VU)
D, 3 (M ± WU)
Connect the terminal to connector B terminal 6 through the resistance of 1 kW.Approx. 6 ± 8 V
B, 1 (G ± IVA)
B, 2 (G ± IWA)
B, 3 (G ± IVB)
B, 4 (G ± IWB)
C, 1 (M ± IVA)
C, 2 (M ± IWA)
C, 3 (M ± IVB)
C, 4 (M ± IWB)
±Approx. 0 V
B, 6 (GND)
A, 6 (G ± GINV)
D, 6 (M ± GINV)
±Continuity
C, 6 (CVRSW)Install a cover for the connecting part of the power cable for the MG1 and MG2.Continuity

B12009
± HYBRID VEHICLE CONTROLCONVERTER AND INVERTER ASSEMBLY
HV±15
1345 Author: Date:
2001 PRIUS (RM778U)
2. INSPECT CONVERTER
(a) Function check
Measure the voltage of an auxiliary battery terminal when
the ºREADYº lamp is OFF and ON.
READY lamp is OFF: Approx. 12 V
READY lamp is ON: Approx. 14 V
(b) Output current check
(1) Disconnect the MG2 power cable from the inverter
(See page HV±18).
(2) Install AC/DC 400 A probe to the wire harness of the
IP connector of the converter.
(3) Connect the MG2 power cable to the inverter (See
page HV±22).
(4) With the READY lamp ON, operate electric devices
one by one and measure the output current.
Standard: 100 A or less
HINT:
If more than 100 A is shown momentarily, check for the follow-
ings.

Ground short of electric device.

Overload caused by installation of excessive device.

PTC heater operation.

HV009±01
B11975
Wiper Arm and Blade Assembly
Wiper Motor
w/ Wiper Link
Cowl Top Ventilator
Louver
N´m (kgf´cm, ft´lbf) : Specified torque
8.0 (82, 71 in.´lbf)
Hood to Cowl Top SealCowl Top Panel
Power Cable Connector
Converter
Connector
Inverter
Connector Inverter Terminal
Cover

Gasket
Converter & Inverter
Assembly
MG1 Power CableConnector CoverCircuit Breaker Sensor
Water HoseWater Hose
20 (204, 15)
21 (214, 15)8.0 (82, 71 in.´lbf)
7.0 (71, 62 in.´lbf)MG2 Power Cable
8.0 (82, 71 in.´lbf)
19.5 (199, 14)

Non±reusable part HV±16
± HYBRID VEHICLE CONTROLCONVERTER AND INVERTER ASSEMBLY
2001 PRIUS (RM778U)
COMPONENTS

B11976
Non±reusable part
8.0 (82, 71 in.´lbf)
N´m (kgf´cm, ft´lbf) : Specified torqueWater Hose
25 (255, 18)
25 (255, 18)
25 (255, 18)
BracketBracket
Bracket
O±ring Inverter Reservoir Tank
8.0 (82, 71 in.´lbf)

Gasket
2.5 (25, 22 in.´lbf)Upper Inverter Cover






± HYBRID VEHICLE CONTROLCONVERTER AND INVERTER ASSEMBLY
HV±17
2001 PRIUS (RM778U)

HV00A±01
B11977
B11979
B11980
HV±18
± HYBRID VEHICLE CONTROLCONVERTER AND INVERTER ASSEMBLY
2001 PRIUS (RM778U)
REMOVAL
1. REMOVE SERVICE PLUG (See page HV±1)
2. DRAIN HV COOLANT (See page HT±6)
3. REMOVE COWL TOP PANEL (See page BO±31)
4. VERIFY 0 V
NOTICE:

Before starting step (a), 5 minutes or more should be
passed after removing the service plug.

Be careful to prevent foreign matter from entering the
inside of connector cover.
(a) Disconnect the connector of the battery power cable and
insulate it with packaging tape.
(b) Using a torx socket wrench (T30), remove the 4 screws
and inverter terminal cover.
(c) Using a torx socket wrench (T40), remove the 2 screws,
circuit breaker sensor and connector cover.
HINT:
Slide the connector cover to disconnect the circuit breaker sen-
sor connector.
(d) Using a voltmeter, measure the voltage between termi-
nals of 3 phases (U±V, V±W, U±W) and each terminal and
body ground to verify them to be approx. 0 V.
5. REMOVE CONVERTER & INVERTER ASSEMBLY
(a) Remove the 6 bolts and 3 power cables for MG2.
NOTICE:
Be careful to prevent foreign matter from entering the in-
side of connector cover.
(b) Remove the 3 bolts and power cable for MG1.
NOTICE:

Remove the power cable for MG1 together with con-
verter & inverter assembly.

Be careful to prevent foreign matter from entering the
inside of connector cover.
(c) Remove the bolt and ground cable.