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

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  4. DRAIN COOLANT (for Inverter)

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  5. REMOVE NO. 1 INVERTER BRACKET


    1. A01KS2F

      Remove the 3 bolts and No. 1 inverter bracket.

  6. REMOVE INVERTER COVER

    CAUTION:

    Wear insulated gloves.


    1. A01KSPL

      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 inverter cover.

  7. CHECK TERMINAL VOLTAGE

    CAUTION:

    Wear insulated gloves.

    Note

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


    1. A01KTWP

      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.

  8. DISCONNECT ENGINE ROOM MAIN WIRE

    CAUTION:

    Wear insulated gloves.

    Note


    • Insulate the disconnected connectors 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. A01KTT8

      Remove the bolt.

    2. A01KSHS

      Remove the bolt, clamp and clip, and disconnect the engine room main wire.

    3. A01KTX1

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

    4. A01KRS0

      Disconnect the engine wire from the engine room main wire.

  9. DISCONNECT FRAME WIRE

    CAUTION:

    Wear insulated gloves.

    Note


    • Insulate the removed 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. A01KS16

      Disconnect the harness clamp.

    2. A01KTKH

      Using an insulated tool, remove the 4 bolts, and disconnect the frame wire (high voltage cables of the hybrid battery) from the inverter with converter assembly.

  10. DISCONNECT GENERATOR CABLE

    CAUTION:

    Wear insulated gloves.

    Note


    • Insulate the removed 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. A01KS75

      Turn back the wire harness cover and release the cable.

    2. A01KSQK

      Using an insulated tool, remove the 5 bolts, and disconnect the high voltage cables of the generator cable (MG1) from the inverter with converter assembly.

  11. DISCONNECT MOTOR CABLE

    CAUTION:

    Wear insulated gloves.

    Note


    • Insulate the removed 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. A01KSX5

      Disconnect the harness clamp.

    2. A01KT2P

      Using an insulated tool, remove the 5 bolts, and disconnect the high voltage cables of the motor cable (MG2) from the inverter with converter assembly.

  12. DISCONNECT NO. 2 ENGINE WIRE

    CAUTION:

    Wear insulated gloves.

    Note


    • Insulate the removed 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. A01KTNF

      Using an insulated tool, 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. A01KTH6

      Disconnect the harness clamp.

  13. INSTALL INVERTER COVER

    CAUTION:

    Wear insulated gloves.


    1. A01KSDRC01
      *a Interlock

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

      Note


      • Make sure that the interlock is fully engaged.

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

  14. DISCONNECT NO. 2 ENGINE ROOM WIRE


    1. Remove the relay block cover.

    2. A01KSXX

      Release the 2 claws and remove the No. 1 relay block cover.

    3. A01KR84

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

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

    5. A01KTMT

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

  15. DISCONNECT NO. 1 INVERTER COOLING HOSE


    1. A01KTQFC01
      *a Retainer

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

    2. A01KTP4

      Put pieces of cloth into the pipe and disconnected hose, 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.

  16. DISCONNECT NO. 6 INVERTER COOLING HOSE


    1. A01KRN9C01
      *a Retainer

      Release the retainer and disconnect the No. 6 inverter cooling hose from the inverter with converter assembly.

    2. A01KTP4

      Put pieces of cloth into the pipe and disconnected hose, 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. A01KSJ5

      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.

      • If removing and storing the inverter with converter assembly, make sure to install the inverter cover to prevent any foreign matter or water from entering the inverter with converter assembly.

      • Cover the connectors with insulating tape to prevent foreign matter or water from entering.

    2. A01KSQS

      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. A01KRU2

      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. A01KSA3

      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 inverter cover.

    2. A01KRL5

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

      Note

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

    3. A01KS8VC01
      *a Interlock

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

      Note


      • Make sure that the interlock is fully engaged.


      • Do not allow any foreign matter 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. A01KSIN

      Disengage the 2 claws and open the terminal cover.

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

    3. A01KRID

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