Camry 2007

High Voltage Vehicle Converter

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Removal & Installation




CAUTION
Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions, such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. Make sure to turn the power switch off before removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system. After disconnecting the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals.

  1. Check for any present DTCs and record them.
    NOTE
    Confirm that P0AA6 (High voltage insulation is unusual) is not output before doing removal or installation work inside the battery. If the DTC is output, perform troubleshooting procedures first.

  2.  
  3. Release the 2 claws and remove the luggage trim service hole cover.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the service plug grip.
  8.  
  9. Remove the left engine room side cover as follows:
    1. Pull the A part upward to disengage the clip.
    2.  
    3. Pull the B parts upward by hand to disengage the 2 clips, and remove the No. 2 engine room side cover.

      Click image to see an enlarged view

      Fig. Remove the left engine room side cover

    4.  

  10.  
  11. Remove the 2 bolts and connector cover assembly.
    CAUTION
    Do not touch the high voltage connectors and terminals for 10 minutes after the service plug grip is removed. Wear insulating gloves.


    WARNING
    Do not start the engine with the service plug grip removed because it may cause a malfunction.

  12.  
  13. Using the voltmeter, measure the voltage between the terminals of the 2 phase connectors (N-P).
  14.  
  15. Use measuring range of DC 750 V or more on the voltmeter. Standard voltage: should read 0 volts.
  16.  
  17. Install the connector cover assembly.
  18.  
  19. Install the left engine room side cover.
  20.  
  21. Remove the luggage compartment floor mat.
  22.  
  23. Remove the spare wheel cover clamp.
  24.  
  25. Remove the spare wheel cover.
  26.  
  27. Remove the 2 screws and the 2 luggage compartment trim hooks.
  28.  
  29. Remove the rear floor finish plate.
  30.  
  31. Remove the luggage compartment rear trim cover.
  32.  
  33. Remove the luggage compartment left inner trim cover.
  34.  
  35. Remove the 2 rear seat headrest assemblies.
  36.  
  37. Remove the rear center seat headrest assembly.
  38.  
  39. Detach the 2 front hooks of the seat cushion from the vehicle body.
  40.  
  41. Remove the seat cushion.

    Click image to see an enlarged view

    Fig. Remove the rear seat cushion as shown

  42.  
  43. Remove the bolts and the left and right separate type rear seatback assemblies.
  44.  
  45. Remove the right and left rear side seat back assemblies.
  46.  
  47. Remove the No. 5 HV battery intake duct.
  48.  
  49. Remove the wiring harness clamp bracket.
  50.  
  51. Remove the upper battery sub-assembly.
  52.  
  53. Remove the battery cover lid.
  54.  
  55. Remove the No.5 battery carrier panel.
  56.  
  57. Remove the No.2 HV Battery exhaust duct.
  58.  
  59. Remove the clip and No. 1 HV battery exhaust duct.
  60.  
  61. Remove the nut and disconnect the ground cable.
  62.  
  63. Disconnect the 5 connectors from the HV relay assembly.
  64.  
  65. Remove the HV converter as follows:
    1. Remove the 2 nuts and 3 clamps and disconnect the wire harness from the hybrid vehicle converter.
    2.  
    3. Remove the 3 bolts, nut, and hybrid vehicle converter.
    4.  
    5. Disconnect the connector from the hybrid vehicle converter.
    6.  

  66.  
  67. Remove the 2 clips and ventilator inner duct.

    Click image to see an enlarged view

    Fig. HV Converter view

  68.  

To install:

  1. Install the ventilator inner duct with the 2 clips.
  2.  
  3. Install the HV converter as follows:
    1. Install the hybrid vehicle converter with the 3 bolts and nut. Tighten the bolt and nut to 71 inch. lbs. (8 Nm)
    2.  
    3. Connect the wire harness with the 3 clamps.
    4.  
    5. Connect the AMD cable with the nut. Tighten the nut to 71 inch. lbs.
    6.  
    7. Connect the high voltage cable with the nut. Tighten the nut to 71 inch. lbs.
    8.  

  4.  
  5. Connect the 5 connectors to the HV relay assembly.
  6.  
  7. Connect the ground cable with the nut. Tighten the nut to 71 inch. lbs.
  8.  
  9. Install the No. 1 HV battery exhaust duct with the clip.
  10.  
  11. Install the No. 2 HV battery exhaust duct with the bolt and 2 clips. Tighten the bolt to 71 inch. lbs.
  12.  
  13. Install the battery panel.
  14.  
  15. Install the battery cover lid.
  16.  
  17. Install the upper battery carrier sub-assembly
  18.  
  19. Install the wiring harness bracket.
  20.  
  21. Install the No. 5 HV battery intake duct with the clamp
  22.  
  23. Install the front luggage compartment trim cover with the 3 clips.
  24.  
  25. Install the left and right rear side seat back assemblies.
  26.  
  27. Install the left and right separate type rear seat back assemblies.
  28.  
  29. Install the rear seat cushion by attaching the front hooks of the bench type rear seat cushion assembly to the vehicle body.
  30.  
  31. Confirm that the seat cushion is firmly installed.
  32.  
  33. Install the rear seat headrest assemblies.
  34.  
  35. Install the service plug grip.
  36.  
  37. Connect the negative battery cable.
  38.  
  39. Install the luggage trim hole cover.
  40.  
  41. Perform the initialization procedure.
    NOTE
    Some vehicle systems require initialization after reconnecting the cable to the negative battery terminal.

  42.  

 
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