INVERTER WITH CONVERTER (for RHD) REMOVAL


  1. PRECAUTION

    CAUTION:

    Be sure to read Precaution thoroughly before servicing Click here.

    Note

    After turning the power switch off, waiting time may be required before disconnecting the cable from the auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the auxiliary battery terminal notice before proceeding with work Click here.

  2. CHECK FOR DTCS

    Note

    Confirm that P0AA6 (Hybrid Battery Voltage System Isolation Fault) is not output before doing removal or installation work inside the battery. If the DTC is output, perform troubleshooting procedures first Click here.

  3. REMOVE LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY (w/ Spare Tire)

    A01GWKI

  4. REMOVE DECK BOARD ASSEMBLY (w/o Spare Tire)

    A01GZ3P

  5. REMOVE DECK TRIM SIDE BOARD LH (w/o Spare Tire)


    1. A01GXQQ

      Detach the 2 clips and remove the deck trim side board LH.

  6. REMOVE BATTERY SERVICE HOLE COVER LH


    1. A01GZIME02
      Text in Illustration
      *A for Standard
      *B for Ottoman
      *1 Fastening Tape

      Detach the clip, fastening tape and remove the battery service hole cover LH.

  7. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the auxiliary negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  8. REMOVE SERVICE PLUG GRIP

    Click here

  9. REMOVE V-BANK COVER SUB-ASSEMBLY


    1. A01GZ6XE01

      While using both hands, lift the rear side of the V-bank cover sub-assembly upwards to detach the 4 clips labeled B. Slide the V-bank cover sub-assembly towards the front of the vehicle to detach the 2 clips labeled A, and remove the V-bank cover sub-assembly.

      Note

      The V-bank cover sub-assembly may be damaged if its front and rear are lifted at the same time.

  10. REMOVE ENGINE ROOM SIDE COVER RH


    1. A01GWGRE01

      for LHD:

      Remove the 5 clips and engine room side cover RH.

      Note

      Remove the clip labeled A by turning it to prevent the engine room side cover RH and bracket from being damaged.

      Tech Tips

      The clip labeled A cannot be removed from the engine room side cover RH.

    2. A01H09J

      for RHD:

      Remove the 5 clips and engine room side cover RH.

  11. REMOVE ENGINE ROOM SIDE COVER LH


    1. A01GWZN

      for LHD:

      Remove the 5 clips and engine room side cover LH.

    2. A01GXEIE01

      for RHD:

      Remove the 5 clips and engine room side cover LH.

      Note

      Remove the clip labeled A by turning it to prevent the engine room side cover LH and bracket from being damaged.

      Tech Tips

      The clip labeled A cannot be removed from the engine room side cover LH.

  12. REMOVE FRONT UPPER FENDER PROTECTOR LH


    1. A01H2BK

      Using a clip remover, detach the 3 clips and remove the upper fender protector.

  13. REMOVE COWL TOP VENTILATOR LOUVER LH


    1. A01GZEK

      Remove the 4 clips and hood to cowl top seal.

    2. Remove the 6 clips and cowl top ventilator louver LH.

  14. REMOVE MOTOR CABLE COVER LH


    1. A01H1LZ

      Remove the 2 clips and motor cable cover LH.

  15. REMOVE INVERTER COVER ASSEMBLY LH


    1. A01GZOK

      Remove the 2 clips and inverter cover assembly LH.

  16. REMOVE FRONT CENTER FLOOR COVER


    1. A01GYNV

      Remove the 3 screws, 2 bolts, clip and front center floor cover.

  17. DRAIN COOLANT (for Inverter)

    Note


    • Do not reuse the drained coolant because it may contain foreign objects.

    • Collect the drained coolant and measure its volume to establish a benchmark. When adding coolant, make sure to add more coolant than the measured amount.


    1. Remove the inverter reserve tank cap.

      CAUTION:

      To avoid the danger of being burned, do not remove the inverter reserve tank cap while the coolant for the inverter is still hot.

      Note

      Do not remove the plug from the tube.

    2. A01GZ5N

      Using a hexagon wrench 10 mm, remove the drain plug indicated in the illustration and drain the coolant.

      CAUTION:

      Use caution when handling coolant immediately after driving or in summer because it may be hot.

    3. Using a hexagon wrench 10 mm, install the drain plug with a new gasket.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

    4. Measure the volume of the drained coolant.

  18. REMOVE CONNECTOR COVER ASSEMBLY

    CAUTION:

    Wear insulating gloves.


    1. A01GX3O

      Using an insulated tool, remove the 2 bolts and connector cover assembly.

      Note


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

      • Do not touch the high voltage connectors or terminals for 10 minutes after the service plug grip is removed.

  19. CHECK TERMINAL VOLTAGE

    CAUTION:

    Wear insulating gloves.


    1. A01GX6G

      Using the 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.

  20. REMOVE INVERTER TERMINAL COVER

    CAUTION:

    Wear insulating gloves.

    Note

    Lift the inverter terminal cover horizontally so that it will not tilt. Failure to do so may break the inverter cover guide pins.


    1. A01GWMTE01

      Using an insulated tool, remove the 2 bolts.

    2. Insert and gradually rotate a screwdriver between the inverter terminal cover and inverter case near bolt hole A to raise the terminal cover by approximately 2 mm (0.08 in.). (*1)

      Note

      Tape the screwdriver tip before use.

    3. Insert and gradually rotate a screwdriver between the inverter terminal cover and inverter case near bolt hole B to raise the terminal cover by approximately 2 mm (0.08 in.). (*2)

      Note

      Tape the screwdriver tip before use.

      Tech Tips

      Repeat the preceding steps (*1) and (*2) until the inverter cover can be easily removed by hand.

    4. Remove the inverter terminal cover by hand.

      Note


      • Do not allow any foreign objects to enter the waterproofed parts of the removed inverter terminal cover.

      • Do not touch the waterproofed parts.

      • When removing the inverter terminal cover, do not bend the connector terminals around the interlock part.

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

  21. DISCONNECT MOTOR CABLE

    CAUTION:

    Wear insulating gloves.


    1. A01H281

      Remove the 3 bolts and separate the motor cable bracket.

    2. A01H1MQ

      Using an insulated tool, remove the 5 bolts and pull out the motor cable from the inverter with converter assembly.

      Note


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

      • When removing the bolts that secure the cable, do not damage anything inside the inverter with converter assembly.

  22. DISCONNECT GENERATOR CABLE

    CAUTION:

    Wear insulating gloves.


    1. A01H0UQ

      Using an insulated tool, remove the 5 bolts and pull out the generator cable from the inverter with converter assembly.

      Note


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

      • When removing the bolts that secure the cable, do not damage anything inside the inverter with converter assembly.

  23. DISCONNECT FRAME WIRE

    CAUTION:

    Wear insulating gloves.


    1. A01GX3Z

      Using an insulated tool, remove the bolt and separate the frame wire from the inverter with converter assembly.

      Note

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

  24. DISCONNECT AIR CONDITIONING HARNESS

    CAUTION:

    Wear insulating gloves.


    1. A01GZ7T

      Disconnect the air conditioning harness from the inverter with converter assembly.

      Note

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

  25. REMOVE INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Wear insulating gloves.


    1. A01GWFY

      Remove the 2 clips and clamp and separate the 2 inverter hoses.

      Note


      • Do not deform, bend or scratch the pipes of the inverter with converter assembly. The pipes are made of aluminum and must remain undamaged to maintain proper seal with the rubber hoses.

      • The inverter hose is connected to the cooling system built into the inverter. Do not apply excessive force to the inverter hose, or the inverter cooling system may be damaged.

    2. A01GXE6E01

      Disconnect the coolant hose from the inverter with converter assembly. Put a piece of cloth in the pipe and in the disconnected hose or cover the pipe and hose with plastic bags as shown in the illustration, in order to prevent coolant from spilling around the inverter with converter assembly.

    3. A01GY93

      Raise the lock lever and disconnect the low voltage connector of the inverter with converter assembly.

      Note

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

    4. Disconnect the wire harness clamp.

    5. A01GZTD

      Disconnect the 2 wire harness clamps.

    6. A01GYDN

      Remove the bolt, 3 nuts, inverter bracket 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.

  26. REMOVE NO. 2 INVERTER COOLING INLET HOSE


    1. A01GXBJ

      Remove the clip and No. 2 inverter cooling inlet hose from the inverter with converter assembly.

      Note


      • Do not deform, bend or scratch the pipes of the inverter with converter assembly. The pipes are made of aluminum and must remain undamaged to maintain proper seal with the rubber hoses.

      • The inverter hose is connected to the cooling system built into the inverter. Do not apply excessive force to the inverter hose, or the inverter cooling system may be damaged.

  27. REMOVE NO. 2 INVERTER BRACKET


    1. A01GW8T

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

  28. REMOVE NO. 3 INVERTER BRACKET


    1. A01GYCJ

      Remove the 2 bolts and No. 3 inverter bracket from the inverter with converter assembly.

  29. REMOVE NO. 6 INVERTER BRACKET


    1. A01GZGS

      Remove the bolt and No. 6 inverter bracket from the inverter with converter assembly.

  30. REMOVE INVERTER COOLING PIPE BRACKET


    1. A01GZCP

      Remove the bolt and inverter cooling pipe bracket from the inverter with converter assembly.

  31. REMOVE HIGH VOLTAGE FUSE


    1. A01GWHH

      Remove the 2 nuts and high voltage fuse.

      Tech Tips

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