INVERTER WITH CONVERTER INSTALLATION

PROCEDURE


  1. INSTALL NO. 2 ENGINE ROOM WIRE

    Tech Tips

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


    1. A01KRID

      Engage the clamp to Install the No. 2 engine room wire to the inverter with converter assembly.

    2. Install the nut to the No. 2 engine room wire.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    3. A01KSIN

      Engage the 2 claws and close the terminal cover.

  2. INSTALL 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. A01KRBSC01
      *a Correct
      *b Incorrect

      Install the high voltage fuse with the 2 bolts.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

      Note

      Be sure to use a torque wrench to tighten the bolts.

      Note


      • Be sure to use a torque wrench to tighten the bolts.


      • The high voltage fuse should be installed with its orientation as shown in the illustration.

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

  3. INSTALL MOTOR CABLE BRACKET


    1. Temporarily install the motor cable bracket with the 2 bolts.

    2. A01KRU2N02

      Tighten the 2 bolts in the order shown in the illustration.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  4. INSTALL INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Wear insulated gloves.


    1. A01KSJ5N02

      Temporarily install the inverter with converter assembly with the 3 bolts.

      Note


      • Since the inverter with converter assembly is very heavy, 2 people are needed to install the inverter with converter assembly. When installing 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. Tighten bolt (A).

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    3. Tighten the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  5. CONNECT NO. 6 INVERTER COOLING HOSE


    1. A01KSJBC01
      *a Retainer

      Connect the No. 6 inverter cooling hose to the inverter with converter assembly and lock the hose with the retainer.

      Note


      • Insert the retainer until a click sound is heard.

      • Pull on the hose to confirm that the hose is securely connected.

      • If there is foreign matter on the union or the O-ring, clean it with water and finger scouring.

      • To prevent foreign matter from entering the cooling system, do not remove the pieces of cloth or plastic bags from the pipe and disconnected hose until installation.

  6. CONNECT NO. 1 INVERTER COOLING HOSE


    1. A01KR4NC01
      *a Retainer

      Connect the No. 1 inverter cooling hose to the inverter with converter assembly and lock the hose with the retainer.

      Note


      • Insert the retainer until a click sound is heard.

      • Pull on the hose to confirm that the hose is securely connected.

      • If there is foreign matter on the union or the O-ring, clean it with water and finger scouring.

      • To prevent foreign matter from entering the cooling system, do not remove the pieces of cloth or plastic bags from the pipe and disconnected hose until installation.

  7. CONNECT NO. 2 ENGINE ROOM WIRE


    1. Disconnect the No. 2 engine room wire from the clamp.

    2. Connect the No. 2 engine room wire with the bolt and 2 claws.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    3. Engage the 2 claws to install the No. 1 relay block cover.

    4. Install the relay block cover.

  8. REMOVE INVERTER COVER

    CAUTION:

    Wear insulated gloves.


    1. 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.

  9. CONNECT NO. 2 ENGINE WIRE

    CAUTION:

    Wear insulated gloves.

    Note

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


    1. Temporarily install the No. 2 engine wire (high voltage cables of the air conditioning) and 4 bolts to the inverter with converter assembly by hand.

    2. A01KR28N01

      Using an insulated tool, fully tighten the 2 bolts (A).

      Torque:
      9.2 N*m  { 94 kgf*cm, 81 in.*lbf }

      Note

      Be sure to use a torque wrench to tighten the bolts.

    3. Using an insulated tool, fully tighten the 2 bolts (B).

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Note

      Be sure to use a torque wrench to tighten the bolts.

    4. Connect the harness clamp.

  10. CONNECT MOTOR CABLE

    CAUTION:

    Wear insulated gloves.

    Note

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


    1. Temporarily install the high voltage cable of the motor cable (MG2) and 5 bolts to the inverter with converter assembly by hand.

    2. A01KTDFN01

      Using an insulated tool, fully tighten the 2 bolts (A).

      Torque:
      9.2 N*m  { 94 kgf*cm, 81 in.*lbf }

      Note

      Be sure to use a torque wrench to tighten the bolts.

    3. Using an insulated tool, fully tighten the 3 bolts (B).

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Note

      Be sure to use a torque wrench to tighten the bolts.

    4. Connect the harness clamp.

  11. CONNECT GENERATOR CABLE

    CAUTION:

    Wear insulated gloves.

    Note

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


    1. Temporarily install the high voltage cable of the generator cable (MG1) and 5 bolts to the inverter with converter assembly by hand.

    2. A01KRIMN01

      Using an insulated tool, fully tighten the 2 bolts (A).

      Torque:
      9.2 N*m  { 94 kgf*cm, 81 in.*lbf }

      Note

      Be sure to use a torque wrench to tighten the bolts.

    3. Using an insulated tool, fully tighten the 3 bolts (B).

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Note

      Be sure to use a torque wrench to tighten the bolts.

    4. A01KSJVC03
      *a Alignment Mark

      Install the cable and close the wire harness cover.

      Note

      Close the cover so that the alignment marks are not visible.

  12. CONNECT FRAME WIRE

    CAUTION:

    Wear insulated gloves.

    Note


    • Make sure that the interlock is fully engaged.

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


    1. A01KTNEC01
      *a Interlock
      *b High voltage cables of the hybrid battery
      *c Front view of frame wire connector

      Temporarily install the frame wire (high voltage cables of the hybrid battery) and 4 bolts to the inverter with converter assembly by hand.

    2. Using an insulated tool, fully tighten the 2 bolts (A).

      Torque:
      9.2 N*m  { 94 kgf*cm, 81 in.*lbf }

      Note


      • Be sure to use a torque wrench to tighten the bolts.

      • Make sure that the interlock is fully engaged.

    3. Using an insulated tool, fully tighten the 2 bolts (B).

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Note

      Be sure to use a torque wrench to tighten the bolts.

    4. Connect the harness clamp.

  13. CHECK HIGH VOLTAGE CABLE CONNECTION

    CAUTION:

    Wear insulated gloves.

    Note

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


    1. A01KRV4

      Check that each connector and terminal is firmly installed.

      Note

      Make sure that the bolts are fully tightened.

  14. INSTALL INVERTER COVER

    CAUTION:

    Wear insulated gloves.

    Note


    • Make sure that the interlock is fully engaged.

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


    1. A01KTD1C02
      *a Interlock

      Install the inverter cover with the 9 bolts to the inverter with converter assembly.

      Torque:
      10.7 N*m  { 109 kgf*cm, 8 ft.*lbf }

  15. CONNECT ENGINE ROOM MAIN WIRE

    CAUTION:

    Wear insulated gloves.

    Note


    • Make sure that the connectors are fully engaged.

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


    1. A01KSND

      Connect the engine wire to the engine room main wire.

    2. A01KRZI

      Connect the inverter with converter assembly connector to the inverter with converter assembly and lock the connector with the lock lever.

    3. A01KSHS

      Install the bolt, clamp and clip, and connect the engine room main wire.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    4. A01KTT8

      Install the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  16. INSTALL NO. 1 INVERTER BRACKET


    1. Install the No. 1 inverter bracket with the 3 bolts.

      Torque:
      13.5 N*m  { 138 kgf*cm, 10 ft.*lbf }

  17. INSTALL SERVICE PLUG GRIP

    Click here

  18. ADD COOLANT (for Inverter)

    Click here

  19. INSPECT FOR COOLANT LEAK (for Inverter)

    Click here

  20. INSTALL NO. 1 ENGINE UNDER COVER

    Click here