Toyota Avalon (XX50) 2019-2022 Service & Repair Manual: 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.

CAUTION:

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

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• 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. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

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PROCEDURE

1. REMOVE SERVICE PLUG GRIP

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2. DRAIN COOLANT (for Inverter)

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3. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

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4. REMOVE COOL AIR INTAKE DUCT SEAL

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5. REMOVE INLET AIR CLEANER ASSEMBLY

(a) Remove the 2 bolts and inlet air cleaner assembly.

6. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE

(a) Disconnect the mass air flow meter sub-assembly connector.

(b) Disengage the wire harness clamp.

(c) Slide the clip and disconnect the No. 2 ventilation hose from the cylinder head cover sub-assembly.

*a Grommet *b Pin

(d) Loosen the hose clamp and disconnect the air cleaner hose from the throttle body with motor assembly.

(e) Disengage the 2 grommets and pin to remove the air cleaner assembly with air cleaner hose.

7. REMOVE ECM

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8. 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 while pushing the lock on the connector, and disconnect the inverter with converter assembly connector. NOTICE: 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. Do not touch the waterproof seal or terminals of the connector.

(b) Remove the bolt.

(c) Disengage the clamp and disconnect the engine room main 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 HV FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the bolt.

*a Waterproof Seal

(b) Disengage the 2 clamps 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.

13. DISCONNECT HV AIR CONDITIONING WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the 2 bolts.

*a Waterproof Seal

(b) Disengage the clamp and disconnect the HV air conditioning wire 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.
• Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.

14. REMOVE WIRE HARNESS CLAMP BRACKET

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

15. 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) Move the lock lever while pushing the lock on the connector, and disconnect the inverter with converter assembly connector. NOTICE: 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. Do not touch the waterproof seal or terminals of the connector.

(b) Disengage the 3 clamps (A) and disconnect the No. 1 fuel vapor feed hose.

(c) Remove the bolt.

(d) Disengage the 2 clamps (B).

(e) Disengage the 2 clamps (A) and disconnect the No. 1 fuel vapor feed hose and No. 2 fuel vapor feed hose.

(f) Remove the bolt.

(g) Disengage the clamp (B).

(h) Disconnect the generator temperature sensor connector.

*a Generator Temperature Sensor Connector *b Resolver (Transmission Fluid Temperature Sensor) Connector *c Shift Lever Position Sensor Connector

(i) Disconnect the resolver (transmission fluid temperature sensor) connector.

(j) Disconnect the shift lever position sensor connector.

(k) Disengage the clamp.

(l) Disengage the 2 clamps.

(m) Remove the bolt.

(n) Remove the bolt.

(o) Disengage the 2 claws and open the engine wire terminal cover.

(p) Remove the nut.

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

16. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Remove the nut and disconnect the transmission control cable assembly from the control shaft lever.

(b) Using a screwdriver, disengage the 4 claws and disconnect the transmission control cable assembly with the clip from the No. 1 transmission control cable bracket.

(c) Using a screwdriver, disengage the 2 claws and remove the clip from the transmission control cable assembly.

(d) Remove the 3 bolts and disconnect the transmission control cable assembly from the inverter with converter assembly.

17. DISCONNECT NO. 1 INVERTER COOLING HOSE

(a) Slide the clip and disconnect the 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. DISCONNECT NO. 4 INVERTER COOLING HOSE

(a) Slide the clip and disconnect the No. 4 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.

19. 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.

20. 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 motor cable.

(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 motor cable.
• 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.

21. 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.

22. 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) 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.

23. REMOVE NO. 2 INVERTER BRACKET

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

*a Wooden Block

24. REMOVE WIRE HARNESS CLAMP BRACKET

(a) Remove the 2 bolts and 2 wire harness clamp brackets 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.

25. REMOVE INVERTER PROTECTOR

(a) Remove the bolt and inverter protector from the inverter with converter assembly.