Inverter DIY Replacement

[Iget100mpg]

Hey All,

Im new to the forums. I bought an 05 with 40k miles off eBay motors a few months ago (yeah I know but it was a really was a good deal at the time!!). I knew the car was hit in the front, but after inspection it seemed pretty sound... until about 2 weeks ago.

HV Light, ABS, light Coil4 DTC, etc, and the car would stall after about 10 secs. Restarting produced exaclty the same behavior. Replaced a coil (hoping it was that) and fully cjharged the aux battery to eliminate squirrly 12v possibilities. Still the same Times Square lights adorning my lovely dash.

Had her towed to the dealer, who after a one hour inspection informed me that the "very dangerous" HV connector to the inverter was broken and that b/c the inverter is a non-servicable part, the whole inverter would have to be replaced at a cost cost upwards of 5k.

I have since located a used inverter from AutobeYours.com, and will be going the DIY install route. I have done alot of HV EV work but have as of yet had the opportunity to tackle removing the Inverter from a Pruis.

I have looked around to no avail for some DIY inverter removal and replace info and have found nothing of value. Basically looking for anyone's step-by-step or guide to replacing the inverter. (I did find the info for and will be replacing the inverter pump since now I am aware of the hacky job done on the front end repair and since ill have the car half apart anyway - thanks for the info).

has anyone seen an info on removing and replacing the inverter? Id rather not reinvent the wheel if it exists, but will document the process if no one has done it yet.

TIA

[vertex]

Originally Posted by Iget100mpg

Hey All,

Im new to the forums. I bought an 05 with 40k miles off eBay motors a few months ago (yeah I know but it was a really was a good deal at the time!!). I knew the car was hit in the front, but after inspection it seemed pretty sound... until about 2 weeks ago.

HV Light, ABS, light Coil4 DTC, etc, and the car would stall after about 10 secs. Restarting produced exaclty the same behavior. Replaced a coil (hoping it was that) and fully cjharged the aux battery to eliminate squirrly 12v possibilities. Still the same Times Square lights adorning my lovely dash.

Had her towed to the dealer, who after a one hour inspection informed me that the "very dangerous" HV connector to the inverter was broken and that b/c the inverter is a non-servicable part, the whole inverter would have to be replaced at a cost cost upwards of 5k.

I have since located a used inverter from AutobeYours.com, and will be going the DIY install route. I have done alot of HV EV work but have as of yet had the opportunity to tackle removing the Inverter from a Pruis.

I have looked around to no avail for some DIY inverter removal and replace info and have found nothing of value. Basically looking for anyone's step-by-step or guide to replacing the inverter. (I did find the info for and will be replacing the inverter pump since now I am aware of the hacky job done on the front end repair and since ill have the car half apart anyway - thanks for the info).

has anyone seen an info on removing and replacing the inverter? Id rather not reinvent the wheel if it exists, but will document the process if no one has done it yet.

TIA

I did the one in my car last fall. Had no problems. I did not document it. I don't have time to detail it now. If you have any particular questions, or need the manual pages, send me a message, and I will try to get back to you within 24 hours.

[efusco]

I think Jelloslug had to remove and replace an inverter on his project vehicle.
I just acquired a new project vehicle

[efusco]

here are some pix
I just acquired a new project vehicle

[Iget100mpg]

Thanks much. Jelloslug's thread is awesome and helpful. With the info from his thread and the Bentley manual I was able to pull the Inverter in about two hours.

After a thorough inspection with the inverter out I noticed that whoever repaired the front end of the car before I got it reversed the coolant lines at the inverter (according to the manual). Had the front of the reservoir going into the top of the pump (instead of into the radiator) which is the opposite flow direction. I'm amazed the inverter lasted as long as it did assuming there's a check valve or some sort of back flow prevention in the system. If so, there would have been zero coolant flow.

Removed the inverter pump today (which is cake with the inverter out) and will be replacing that as well.