INVERTER WITH CONVERTER REMOVAL

PROCEDURE


  1. PRECAUTION

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  2. REMOVE SERVICE PLUG GRIP

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  3. REMOVE NO. 1 ENGINE UNDER COVER

  4. DRAIN COOLANT (for Inverter)

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  5. REMOVE RADIATOR SUPPORT OPENING COVER

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  6. REMOVE NO. 1 INVERTER BRACKET


    1. A005EF5

      Remove the 3 bolts and No. 1 inverter bracket.

  7. DISCONNECT ENGINE ROOM MAIN WIRE

    Note


    • Insulate the disconnected terminals with insulating tape.

    • Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter.

    • To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.


    1. A005COC

      Raise the lock lever and disconnect the inverter with converter connector.

    2. A005AL5

      Disconnect the engine wire from the engine room main wire.

    3. A0059WF

      Remove the bolt.

    4. A005CIT

      Remove the bolt from the engine room main wire.

    5. Disconnect the clamp and clip, and separate the engine room main wire.

  8. REMOVE INVERTER COVER

    CAUTION:

    Wear insulated gloves.


    1. A005C4K

      Remove the 9 bolts and inverter cover.

      Note

      Make sure to pull the inverter cover straight up, as a connector is connected to the bottom of the cover.

  9. CHECK TERMINAL VOLTAGE

    CAUTION:

    Wear insulated gloves.

    Note

    Do not allow any foreign matter or water to enter the inverter with converter assembly.


    1. A005AMG

      Using a voltmeter, measure the voltage between the terminals of the 2 phase connectors.

      Standard voltage
      0 V

      Tech Tips

      Use measuring range of DC 750 V or more on the voltmeter.

  10. DISCONNECT FRAME WIRE

    CAUTION:

    Wear insulated gloves.

    Note


    • Insulate the disconnected terminals with insulating tape.

    • Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter.


    1. A005EM1

      Disconnect the harness clamp.

    2. A005EL4

      Remove the 4 bolts, and disconnect the frame wire (high voltage cables of the hybrid battery) from the inverter with converter assembly.

  11. DISCONNECT GENERATOR CABLE

    CAUTION:

    Wear insulated gloves.

    Note


    • Insulate the disconnected terminals with insulating tape.

    • Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter.


    1. A005BBL

      Turn back the wire harness cover and release the generator cable.

    2. A0059S2

      Remove the 5 bolts, and disconnect the high voltage cables of the generator cable (MG1) from the inverter with converter assembly.

  12. DISCONNECT MOTOR CABLE

    CAUTION:

    Wear insulated gloves.

    Note


    • Insulate the disconnected terminals with insulating tape.

    • Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter.


    1. A005BML

      Disconnect the harness clamp.

    2. A005DHA

      Remove the 5 bolts, and disconnect the high voltage cables of the motor cable (MG2) from the inverter with converter assembly.

  13. DISCONNECT NO. 2 ENGINE WIRE

    CAUTION:

    Wear insulated gloves.

    Note


    • Insulate the disconnected terminals with insulating tape.

    • Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter.


    1. A005B6X

      Remove the 4 bolts, and disconnect the No. 2 engine wire (high voltage cables for the air conditioning compressor) from the inverter with converter assembly.

    2. A005CD5

      Disconnect the harness clamp.

  14. INSTALL INVERTER COVER

    CAUTION:

    Wear insulated gloves.


    1. A005ALGE05
      Text in Illustration
      *1 Interlock

      Temporarily install the inverter cover with the 9 bolts to prevent any foreign or water from entering the inverter with converter assembly.

      Note


      • Make sure that the interlock is fully engaged.

      • Do not allow any foreign or water to enter the inverter with converter assembly.

  15. DISCONNECT NO. 2 ENGINE ROOM WIRE


    1. Remove the relay block cover.

    2. A005BFH

      Release the 2 clamps, and remove the No. 1 relay block cover.

    3. A005D6Y

      Remove the bolt from the No. 2 engine room wire.

    4. Release the 2 claws, and disconnect the No. 2 engine room wire.

    5. A005EI0

      Connect the No. 2 engine room wire to the protector.

  16. DISCONNECT WATER HOSE


    1. A005C7TE05
      Text in Illustration
      *1 Retainer

      Release the retainer and disconnect the water hose from the inverter with converter assembly.

    2. A005DRBE05
      Text in Illustration
      *1 Retainer

      Release the retainer and disconnect the water hose from the inverter with converter assembly.

    3. A005C3P

      Put pieces of cloth into the pipes and in the disconnected hoses, or cover the pipes and hoses with plastic bags as shown in the illustration to prevent foreign matter from entering the cooling system and to prevent coolant from spilling near the inverter with converter assembly.

  17. REMOVE INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Wear insulated gloves.


    1. A005DYG

      Remove the 3 bolts and inverter with converter assembly.

      Note


      • Since the inverter with converter assembly is very heavy, 2 people are needed to remove the inverter with converter assembly. When removing the inverter with converter assembly, do not damage the parts around it.

      • To prevent damage, do not hold the inverter with converter assembly by the connectors.

      • To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.

    2. A005A37

      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 so that coolant does not spill out.

  18. REMOVE MOTOR CABLE BRACKET


    1. A005ECH

      Remove the 2 bolts and motor cable bracket.

  19. REMOVE HIGH VOLTAGE FUSE

    CAUTION:

    Wear insulated gloves.

    Tech Tips

    Perform this procedure only when replacement of the high voltage fuse is necessary.


    1. A005C4K

      Remove the 9 bolts and inverter cover.

      Note

      Make sure to pull the inverter cover straight up, as a connector is connected to the bottom of the cover.

    2. A005ERA

      Remove the 2 bolts and high voltage fuse from the inverter with converter assembly.

      Note

      Do not allow any foreign or water to enter the inverter with converter assembly.

    3. A005ALGE05
      Text in Illustration
      *1 Interlock

      Temporarily install the inverter cover with the 9 bolts to prevent any foreign or water from entering the inverter with converter assembly.

      Note


      • Make sure that the interlock is fully engaged.

      • Do not allow any foreign or water to enter the inverter with converter assembly.

  20. REMOVE NO. 2 ENGINE ROOM WIRE

    Tech Tips

    Perform this procedure only when replacement of the No. 2 engine room wire is necessary.


    1. A005A41

      Disengage the 2 claws and open the terminal cover.

    2. A005AZZ

      Remove the nut from the No. 2 engine room wire.

    3. Disengage the clamp and remove the No. 2 engine room wire from the inverter with converter assembly.