INVERTER WITH CONVERTER REMOVAL

PROCEDURE


  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 battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  2. REMOVE LUGGAGE COMPARTMENT FLOOR MAT

    Click here

  3. REMOVE LUGGAGE COMPARTMENT TRIM COVER LH

    Click here

  4. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

  5. REMOVE SERVICE PLUG GRIP

    Click here

  6. REMOVE ENGINE ROOM SIDE COVER

    Click here

  7. REMOVE COOL AIR INTAKE DUCT SEAL

    Click here

  8. REMOVE NO. 1 AIR CLEANER INLET

    Click here

  9. REMOVE ENGINE UNDER COVER

    Click here

  10. REMOVE FRONT SUSPENSION MEMBER BRACE

    Click here

  11. REMOVE NO. 2 ENGINE UNDER COVER

    Click here

  12. DRAIN COOLANT (for Inverter)

    Click here

  13. REMOVE V-BANK COVER SUB-ASSEMBLY

    Click here

  14. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE (for LHD)

    Click here

  15. REMOVE INVERTER COVER


    1. B002BE8E02
      Text in Illustration
      *A for LHD
      *B for RHD

      Raise the front of the inverter cover to detach the clip. Then remove the 2 inverter cover clips from the bracket, and remove the inverter cover.

  16. REMOVE CONNECTOR COVER ASSEMBLY

    CAUTION:


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

    • Wear insulated gloves.

    Note

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


    1. B002BD6E02
      Text in Illustration
      *A for LHD
      *B for RHD

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

      Note


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

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

  17. CHECK TERMINAL VOLTAGE

    CAUTION:

    Wear insulated gloves.

    Note

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


    1. B002BFBE02
      Text in Illustration
      *A for LHD
      *B for RHD

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

      Standard voltage
      0 V

      Tech Tips

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

  18. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

    CAUTION:

    Wear insulated gloves.


    1. Temporarily install the connector cover assembly with the bolt to prevent any foreign objects or water from entering the inverter with converter assembly.

  19. REMOVE INVERTER MOTOR CABLE BRACKET ASSEMBLY


    1. B002BWWE02
      Text in Illustration
      *A for LHD
      *B for RHD

      Detach the 2 clamps from the inverter motor cable bracket assembly.

    2. Remove the 2 bolts and inverter motor cable bracket assembly.

  20. REMOVE INVERTER TERMINAL COVER

    CAUTION:

    Wear insulated gloves.


    1. for Type A:


      1. B002BJZE02
        Text in Illustration
        *A for LHD
        *B for RHD

        Using an insulated tool, remove the 2 bolts and inverter terminal cover.

        Note


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

        • Do not touch the inverter terminal cover waterproofing rubber.

    2. for Type B:


      1. B002BUQE03
        Text in Illustration
        *A for LHD
        *B for RHD

        Using an insulated tool, remove the 3 bolts and inverter terminal cover.

        Note


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

        • Do not touch the inverter terminal cover waterproofing rubber.

  21. DISCONNECT GENERATOR CABLE

    CAUTION:

    Wear insulated gloves.


    1. B002B77E02
      Text in Illustration
      *A for LHD
      *B for RHD

      Using an insulated tool, remove the 3 bolts labeled A in the illustration.

      Note


      • Do not damage the terminals, connector housings or inverter with converter assembly when disconnecting them.

      • Do not touch the connector waterproofing rubber or terminals.

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

    2. Using an insulated tool, remove the 2 bolts labeled B in the illustration.

      Note


      • Do not damage the terminals, connector housings or inverter with converter assembly when disconnecting them.

      • Do not touch the connector waterproofing rubber or terminals.

      • Insulate the removed terminals with insulating tape.

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

  22. DISCONNECT MOTOR CABLE

    CAUTION:

    Wear insulated gloves.


    1. B002B4CE02
      Text in Illustration
      *A for LHD
      *B for RHD

      Using an insulated tool, remove the 3 bolts labeled A in the illustration.

      Note


      • Do not damage the terminals, connector housings or inverter with converter assembly when disconnecting them.

      • Do not touch the connector waterproofing rubber or terminals.

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

    2. Using an insulated tool, remove the 2 bolts labeled B in the illustration.

      Note


      • Do not damage the terminals, connector housings or inverter with converter assembly when disconnecting them.

      • Do not touch the connector waterproofing rubber or terminals.

      • Insulate the removed terminals with insulating tape.

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

  23. REMOVE NO. 1 INVERTER COOLING OUTLET HOSE (for LHD)


    1. Release the retainer and disconnect the No. 1 inverter cooling outlet hose from the inverter with converter assembly.

    2. A000NXS

      Slide the clamp and remove the No. 1 inverter cooling outlet hose.

      Note

      Apply insulating tape to the pipes and in the disconnected hoses, or cover the pipes and hoses with plastic bags to prevent foreign matter from entering the cooling system and to prevent coolant from spilling near the inverter with converter assembly.

  24. DISCONNECT NO. 1 INVERTER COOLING INLET HOSE (for LHD)


    1. A000O9K

      Slide the clamp and disconnect the No. 1 inverter cooling inlet hose from the inverter with converter assembly.

      Note

      Apply insulating tape to the pipes and in the disconnected hoses, or cover the pipes and hoses with plastic bags to prevent foreign matter from entering the cooling system and to prevent coolant from spilling near the inverter with converter assembly.

  25. REMOVE INVERTER RESERVOIR TANK ASSEMBLY (for RHD)


    1. A000PVT

      Remove the 2 bolts and disconnect the inverter reservoir tank assembly from the No. 4 inverter cooling hose.

    2. A000Q7D

      Release the retainer and disconnect the No. 2 inverter cooling outlet hose from the inverter with converter assembly.

      Note

      Apply insulating tape to the pipes and in the disconnected hoses, or cover the pipes and hoses with plastic bags to prevent foreign matter from entering the cooling system and to prevent coolant from spilling near the inverter with converter assembly.

  26. DISCONNECT NO. 2 INVERTER COOLING INLET HOSE (for RHD)


    1. A000N3L

      Slide the clamp and disconnect the No. 2 inverter cooling inlet hose from the inverter with converter assembly.

      Note

      Apply insulating tape to the pipes and in the disconnected hoses, or cover the pipes and hoses with plastic bags to prevent foreign matter from entering the cooling system and to prevent coolant from spilling near the inverter with converter assembly.

  27. DISCONNECT INVERTER BUS-BAR PLATE SUB-ASSEMBLY


    1. for LHD:


      1. A000ORU

        Detach the 4 claws and disconnect the connector cover.

      2. Disconnect the connector.

      3. A000T0E

        Remove the 3 nuts and disconnect the wire harness and inverter bus-bar plate sub-assembly.

      4. A000QR8

        Remove the bolt and disconnect the wire harness bracket.

    2. for RHD:


      1. Remove the relay block cover.

      2. A000QYG

        Disconnect the connector and detach the clamp.

      3. Remove the nut, detach the 2 claws and disconnect the inverter bus-bar plate sub-assembly.

  28. REMOVE WIRE HARNESS CLAMP BRACKET A (for LHD)


    1. A000O4J

      Remove the 2 nuts and wire harness clamp bracket A.

  29. REMOVE INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Wear insulated gloves.


    1. Loosen the 6 bolts as shown in the illustration.

      B002BMCE02
      Text in Illustration
      *A for LHD *B for RHD

      Note


      • Since the inverter with converter is very heavy, 2 people are needed to remove the inverter with converter. 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. B002BYAE02
      Text in Illustration
      *A for LHD
      *B for RHD

      Raise the lock lever and disconnect the connector.

    3. Remove the bolt and connector cover assembly.

      Note


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

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

    4. B002BCZE02
      Text in Illustration
      *A for LHD
      *B for RHD

      Disconnect the air conditioning harness.

      Note


      • Do not damage the terminals, connector housings or inverter with converter assembly when disconnecting them.

      • Do not touch the connector waterproofing rubber or terminals.

      • Insulate the removed terminals with insulating tape.

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

    5. B002C1CE02
      Text in Illustration
      *A for LHD
      *B for RHD

      Using an insulated tool, remove the bolt and disconnect the No. 4 floor wire.

      Note


      • Do not damage the terminals, connector housings or inverter with converter assembly when disconnecting them.

      • Do not touch the connector waterproofing rubber or terminals.

      • Insulate the removed terminals with insulating tape.

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

    6. Temporarily install the connector cover assembly with the bolt to prevent any foreign objects or water from entering the inverter with converter assembly.

    7. Remove the 6 bolts, and inverter with converter assembly and No. 6 inverter bracket.

      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.

      • Insulate the removed terminals with insulating tape.

      • 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.

    8. Even after the coolant is drained, coolant remains in the inverter with converter due to its internal structure. Therefore, seal or cover the pipes when removing the inverter with converter assembly to prevent coolant from spilling out or foreign matter from entering the inverter with converter assembly.

    9. B002BF2E01
      Text in Illustration
      *a Cushion

      When removing and storing the inverter with converter assembly, make sure to install the inverter terminal cover assembly and place a cushion under the inverter with converter assembly to protect it.

      Note

      Do not place the inverter with converter assembly upside-down.

  30. REMOVE NO. 4 INVERTER BRACKET


    1. B002BEKE02
      Text in Illustration
      *A for LHD
      *B for RHD

      Remove the 2 bolts and No. 4 inverter bracket.

    2. A000SN7

      for RHD:

      Remove the bolt and wire harness bracket.

  31. REMOVE INVERTER BUS-BAR PLATE SUB-ASSEMBLY


    1. B002B6YE02
      Text in Illustration
      *A for LHD
      *B for RHD

      Detach the 2 wire harness clamps and remove the bolt.

    2. B002BURE02
      Text in Illustration
      *A for LHD
      *B for RHD

      Open the cover.

      Note

      Do not twist the cover excessively when opening it.

    3. Remove the nut and inverter bus-bar plate sub-assembly.

      Note


      • If the stud bolt becomes loose when removing the nut, tighten the stud bolt to a torque of 10N*m (107kgf*cm 7ft.*lbf).

      • If the inverter bus-bar plate sub-assembly is dropped or deformed, replace it with a new one.

  32. REMOVE HIGH VOLTAGE FUSE

    CAUTION:

    Wear insulated gloves.

    Tech Tips

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


    1. Remove the bolt and connector cover assembly.

      Note


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

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

    2. B002BZ1E02
      Text in Illustration
      *A for LHD
      *B for RHD

      Remove the 2 nuts and high voltage fuse.

    3. Temporarily install the connector cover assembly with the bolt to prevent any foreign objects or water from entering the inverter with converter assembly.