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HOMESERVICE MANUALSTOYOTA2004MATRIX XR, FWD, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 533 (HYBRID CONTROL SYSTEM)W/CONVERTER INVERTER ASSYREPLACEMENT
2004 Toyota Matrix XR, FWD, Standard

W/Converter Inverter ASSY: Replacement

2004 Toyota Matrix XR, FWD, StandardSECTION Replacement
WARNING: This page is about a different car, the 2004 Toyota Prius. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
  • When working on the high voltage systems, always wear insulating gloves.
  • After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU.
  • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle.
  • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes.
  1. PRECAUTION (See  PRECAUTION  ) 
  2. REMOVE ENGINE UNDER COVER LH 
  3. REMOVE ENGINE UNDER COVER RH 
  4. DRAIN HV COOLANT (See  REPLACEMENT  ) 
  5. REMOVE REAR FLOOR BOARD NO. 2 (See  SERVICE PLUG GRIP  ) 
  6. REMOVE DECK FLOOR BOX REAR (See  SERVICE PLUG GRIP  ) 
  7. REMOVE REAR FLOOR BOARD NO. 3 (See  SERVICE PLUG GRIP  ) 
  8. DISCONNECT BATTERY NEGATIVE TERMINAL (See  SERVICE PLUG GRIP  ) 
  9. REMOVE SERVICE PLUG GRIP (See  SERVICE PLUG GRIP  ) 
  10. REMOVE FRONT WIPER ARM HEAD CAP (See  WIPER & WASHER  ) 
  11. REMOVE FR WIPER ARM LH (See  WIPER & WASHER  ) 
  12. REMOVE FR WIPER ARM RH (See  WIPER & WASHER  ) 
  13. REMOVE HOOD TO COWL TOP SEAL (See  WIPER & WASHER  ) 
  14. REMOVE COWL TOP VENTILATOR LOUVER LH (See  WIPER & WASHER  ) 
  15. REMOVE COWL TOP VENTILATOR LOUVER RH (See  WIPER & WASHER  ) 
  16. REMOVE WINDSHIELD WIPER MOTOR & LINK ASSY (See  WIPER & WASHER  ) 
  17. REMOVE COWL TOP PANEL SUB-ASSY OUTER FRONT (See  WIPER & WASHER  ) 
  18. REMOVE RADIATOR SUPPORT OPENING COVER 
  19. REMOVE INVERTER COVER 
    1. Using a T30 Torx socket wrench, remove the Torx screw.
    2. Remove the 12 bolts and inverter cover.
      Fig 1: Locating Inverter Cover Torx Screw
      G00950357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. VERIFY THAT VOLTAGE OF W/CONVERTER INVERTER ASSY IS 0V 
    NOTE: Wear insulating gloves.
    1. Using a voltmeter, measure the voltage of the high voltage DC line.

      Standard: 0 V 

      HINT:

      Use measuring range of DC 400 V or more on the voltmeter.

      Fig 2: Measuring Voltage Of High Voltage DC Line Using Voltmeter
      G00950358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using the voltmeter, measure the voltage between the terminals of the three phase connector (U - V, V - W, U - W).

      Standard: 0 V 

      HINT:

      Use measuring range of DC 400 V or more on the voltmeter.

      Fig 3: Identifying Three Phase Terminals
      G00950359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. DISCONNECT INVERTER COOLING HOSE NO. 2 
    Fig 4: Disconnecting Inverter Cooling Hose No. 2
    G00950360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT INVERTER COOLING HOSE NO. 1 
    Fig 5: Disconnecting Inverter Cooling Hose No. 1
    G00950361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT INVERTER COOLING HOSE NO. 6 
    Fig 6: Disconnecting Inverter Cooling Hose No. 6
    G00950362Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. SEPARATE CIRCUIT BREAKER SENSOR NO. 1 
    1. Move the outer section to the wire harness side as illustrated, then disconnect the circuit breaker sensor No. 1.
      Fig 7: Moving Outer Section To Wire Harness Side
      G00950363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. DISCONNECT FRAME WIRE 
    NOTE:
    • Wear insulating gloves.
    • After removing the service plug grip, be sure to wait for at least 5 minutes before performing any work.
    • Insulate the electrode and connector parts with insulating tape.
    1. Remove the 2 frame wire connectors from the with converter inverter assembly.
      Fig 8: Removing Frame Wire Connectors From W/Converter Inverter Assembly
      G00950364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE W/CONVERTER INVERTER ASSY 
    1. Using a small screwdriver, lift up the lock pin (green) as illustrated to unlock.
      NOTE: Wear insulating gloves.
    2. Disconnect the connector for the air conditioner inverter.
      NOTE: Wear insulating gloves.
RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.