INVERTER WITH CONVERTER INSTALLATION

INSTALL HIGH VOLTAGE FUSE
CAUTION:

Wear insulating gloves.
1. Remove the 11 bolts and inverter cover from the inverter with converter assembly.
  
  Note
  
  Make sure to pull the inverter cover straight up, as a connector is connected to the bottom of the cover.
2. Place the high voltage fuse as shown in the illustration.
  
  Tech Tips
  
  Either the location shown in the illustration or other methods can be used to hold the high voltage fuse for the subsequent step.
3. Install the high voltage fuse with 2 new nuts.
  
  Torque:
  
  4.2 N*m { 43 kgf*cm, 37 in.*lbf }
  
  Note
  
  Be sure to use a torque wrench to tighten the nuts.
4. Install the high voltage fuse with 2 new nuts.
  
  Torque:
  
  4.2 N*m { 43 kgf*cm, 37 in.*lbf }
  
  Note
  
  Be sure to use a torque wrench to tighten the nuts.
5. Temporarily install the inverter cover with the 11 bolts to prevent any foreign objects or water from entering the inverter with converter assembly.

INSTALL INVERTER COOLING PIPE

Text in Illustration
*a	Upper Side
*b	Front Side
*c	2 to 7 mm (0.0787 to 0.276 in.)

Install the inverter cooling pipe to the inverter with converter assembly with the 2 bolts.

Torque:: 9.0 N*m { 92 kgf*cm, 80 in.*lbf }

Connect the inlet No. 2 inverter cooling hose to the inverter with converter assembly and slide the clip to secure it.

Tech Tips

Make sure that the clip is positioned as shown in the illustration.

INSTALL INVERTER DRAIN HOSE

Text in Illustration
*a	Upper Side
*b	Front Side
*c	2 to 7 mm (0.0787 to 0.276 in.)

Install the inverter drain hose to the inverter with converter assembly and slide the clip to secure it.

Tech Tips

Make sure that the clip is positioned as shown in the illustration.

INSTALL INVERTER WITH CONVERTER ASSEMBLY
CAUTION:

Wear insulating gloves.
1. Install the inverter with converter assembly with the 2 nuts and bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  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.
INSTALL CONDENSER
1. Install the condenser with the bolt.
  
  Torque:
  
  8.4 N*m { 86 kgf*cm, 74 in.*lbf }
INSTALL RADIATOR RESERVE TANK ASSEMBLY
1. Install the radiator reserve tank with the bolt and connect the 2 clamps to the radiator.
  
  Torque:
  
  5.3 N*m { 54 kgf*cm, 47 in.*lbf }
INSTALL NO. 4 INVERTER BRACKET
1. Install the No. 4 inverter bracket with the bolt and nut.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
CONNECT NO. 2 ENGINE ROOM WIRE
1. Connect the No. 2 engine room wire with the nut.
  
  Torque:
  
  8.4 N*m { 86 kgf*cm, 74 in.*lbf }
2. Connect the clamp.
3. Install the relay block cover.
CONNECT WATER HOSE
1. Text in Illustration
  
  *1 Match Mark
  
  Connect the 2 water hoses with the hose clamp to the inverter with converter assembly.
  Note
  
  Align the match marks of the hoses and pipes.
  
  Be sure to insert the hose until it reaches the rib on the pipe.
  
  Align the hose clamps to the markings as shown in the illustration.
  Tech Tips
  
  The direction of the hose and hose clamp is indicated in the illustration.
2. Connect the water hose of 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.
CONNECT MG ECU CONNECTOR
Note
- Make sure that the connectors are fully engaged.
- Do not allow any foreign objects or water to enter the inverter with converter assembly.
1. Connect the connector to the inverter with converter assembly.
2. Connect the low voltage connector of the inverter with converter assembly and lock the connector with the lock lever.
INSTALL RELAY BLOCK SUB-ASSEMBLY
1. Install the relay block sub-assembly.
INSTALL NO. 6 INVERTER BRACKET (w/ Bracket)
1. Install the No. 6 inverter bracket with the 2 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
REMOVE INVERTER TERMINAL COVER
1. Remove the 11 bolts and inverter cover from the inverter with converter assembly.
  
  Note
  
  Make sure to pull the inverter cover straight up, as a connector is connected to the bottom of the cover.
CONNECT NO. 3 WIRE FRAME
CAUTION:

Wear insulating gloves.
Note
- Make sure that the interlock are fully engaged.
- Do not allow any foreign objects or water to enter the inverter with converter assembly.
1. Connect the No. 3 wire frame (high voltage cables of the hybrid battery) with the 4 bolts to the inverter with converter assembly.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  
  Note
  
  Be sure to use a torque wrench to tighten the bolt.
2. Connect the 3 clamps.
CONNECT NO. 1 CIRCUIT BREAKER SENSOR
1. Connect the No. 1 circuit breaker sensor connector.
CONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR
CAUTION:

Wear insulating gloves.

Note

Do not allow any foreign objects or water to enter the inverter with converter assembly.
1. Connect the high voltage cable of the generator (MG1) with the 5 bolts to the inverter with converter assembly.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
2. Connect the high voltage cable of the motor (MG2) with 5 bolts to the inverter with converter assembly.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
CONNECT NO. 3 WIRE FRAME
CAUTION:

Wear insulating gloves.

Note

Do not allow any foreign objects or water to enter the inverter with converter assembly.
1. Connect the No. 3 wire frame (high voltage cable of the rear motor (MGR)) with 5 bolts to the inverter with converter assembly
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
2. Connect the clamp.
CONNECT NO. 4 ENGINE WIRE
CAUTION:

Wear insulating gloves.

Note

Do not allow any foreign objects or water to enter the inverter with converter assembly.
1. Connect the No. 4 engine wire (high voltage cables of the air conditioning) with the 5 bolts to the inverter with converter assembly
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
CHECK HIGH VOLTAGE CABLE CONNECTION
CAUTION:

Wear insulating gloves.

Note

Do not allow any foreign objects or water to enter the inverter with converter assembly.
1. Check that each connector and terminal is firmly installed.
  
  Note
  
  Make sure that the bolts are fully tightened.
INSTALL INVERTER TERMINAL COVER
CAUTION:

Wear insulating gloves.
Note
- Make sure that the interlock are fully engaged.
- Do not allow any foreign objects or water to enter the inverter with converter assembly.
1. Using several steps, install and tighten the 11 bolts uniformly in the sequence shown in the illustration.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSTALL NO. 1 INVERTER RESERVE TANK BRACKET
1. Install the No. 1 inverter reserve tank bracket with the 2 bolts to the inverter with converter assembly.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL INVERTER RESERVE TANK ASSEMBLY
1. Install the inverter reserve tank with the bolt and nut to the No. 1 inverter reserve tank bracket.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Connect the 3 water hoses to the inverter reserve tank sub-assembly with the 3 hose clamps.
3. Connect the hose to the clamp.
INSTALL NO. 3 INVERTER BRACKET
1. Install the No. 6 inverter bracket with the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Install the hose and hose clamp to the No. 3 inverter bracket.
INSTALL AIR CLEANER ASSEMBLY WITH HOSE

Tech Tips

Click here.
INSTALL SERVICE PLUG GRIP
CAUTION:

Wear insulated gloves.

Note

Before connecting the service plug, check that no parts and tools remain and that the high voltage terminals and connectors are connected securely.
1. Wear insulated gloves and insert the service plug grip in the order shown in the illustration.
2. Tilt the service plug grip 90° and slide it down until a click sound is heard.
INSTALL BATTERY SERVICE HOLE COVER
1. Engage the 2 clips, 2 guides and install the battery service hole cover.
  
  Note
  
  Make sure that the battery service hole cover is installed securely.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Text in Illustration
*1	Match Mark

ADD COOLANT (for Inverter)

Note

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

If the vehicle is driven with air in the inverter cooling system, the following DTCs may be set.

DTC Code	Detection Item
P0A01-726	Motor Electronics Coolant Temperature Sensor Circuit Range / Performance
P0A04-725	Motor Electronics Coolant Temperature Sensor Circuit Intermittent
P0A08-264	DC / DC Converter Status Circuit
P0A78-284	Drive Motor "A" Inverter Performance
P0A78-286	Drive Motor "A" Inverter Performance
P0A79-692	Drive Motor "B" Inverter Performance
P0A79-696	Drive Motor "B" Inverter Performance
P0A7A-322	Generator Inverter Performance
P0A7A-324	Generator Inverter Performance
P0A93-346	Inverter Cooling System Performance
P0A94-553	DC / DC Converter Performance
P0A94-557	DC / DC Converter Performance
P0AEE-277	Motor Inverter Temperature Sensor "A" Circuit Range / Performance
P0AF1-276	Drive Motor Inverter Temperature Sensor "A" Circuit Intermittent / Erratic
P0AF3-676	Sensor of Rear Motor Inverter Temperature
P0AF6-675	Drive Motor Inverter Temperature Sensor "B" Circuit Intermittent / Erratic
P0BCD-315	Generator Inverter Temperature Sensor Circuit Range / Performance
P0BD0-314	Generator Inverter Temperature Sensor Circuit Intermittent / Erratic
P0C39-626	DC / DC Converter Temperature Sensor "A" Range / Performance
P0C3C-625	DC / DC Converter Temperature Sensor "A" Intermittent / Erratic
P0C3E-628	DC / DC Converter Temperature Sensor "B" Range / Performance
P0C41-627	DC / DC Converter Temperature Sensor "B" Intermittent / Erratic
P0C73-776	Motor Electronics Coolant Pump "A" Control Performance

Add coolant to the reserve tank.
Slowly pour coolant into the radiator reservoir tank until it reaches the FULL line.

Coolant quantity

1.9 liter (2.0 US qts, 1.7 Imp. qts.)

Coolant quantity
1.9 liter (2.0 US qts, 1.7 Imp. qts.)

When using the intelligent tester:

Connect the intelligent tester to the DLC3.
Turn the power switch on (IG).
On the intelligent tester, enter the following menus: Powertrain / Hybrid Control / Active Test / Activate the Water Pump.

Keep the coolant at the FULL level in the reserve tank to compensate for the drop in coolant level when the air bleeds.

Standard
Air bleeding from the coolant system is completed when the noise made by the water pump becomes smaller and the circulation of coolant in the reserve tank improves.

Tech Tips

Loud noise made by the water pump and poor circulation of coolant in the reserve tank indicates that there is air in the coolant system.

When not using the intelligent tester:

Turn the power switch on (READY). [*1]
Turn the power switch off and keep the coolant at the FULL level in the reserve tank to compensate for the drop in coolant level when the air bleeds. [*2]
Note
- Be sure to turn the power switch off before adding SLLC.
- Do not work on the components in the engine compartment while the vehicle is in the READY-on state because the engine is in intermittent operation.

Repeat steps [*1] and [*2] until air bleeding from the coolant system is completed.

Standard
Air bleeding from the coolant system is completed when the noise made by the water pump becomes smaller and the circulation of coolant in the reserve tank improves.

Tech Tips

Loud noise made by the water pump and poor circulation of coolant in the reserve tank indicates that there is air in the coolant system.

Add coolant to the FULL mark of the reserve tank.

INSPECT FOR COOLANT LEAK (for Inverter)
1. Remove the reserve tank cap.
  
  CAUTION:
  
  To avoid the danger of being burned, do not remove the reserve tank cap while the coolant for the inverter is still hot.
2. Install the radiator cap tester.
3. Pump the radiator cap tester to 118 kPa (1.2 kgf/ cm², 17 psi), and then check that the pressure does not drop.
  
  Tech Tips
  
  If the pressure drops, check the hoses, radiator, water pump, inverter with converter, and hybrid vehicle transaxle assembly for leaks.
4. Reinstall the reserve tank cap.
INSTALL NO. 1 ENGINE UNDER COVER
PERFORM INITIALIZATION

Some systems need initialization after reconnecting the cable to the negative battery terminal Click here.