INVERTER WITH CONVERTER INSTALLATION


  1. INSTALL HIGH VOLTAGE FUSE

    CAUTION:

    Wear insulating gloves.

    Tech Tips

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


    1. A01NEKJ

      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. A01NGB4

      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. A01NFNI

      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. A01ND3A

      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. A01NEKJ

      Temporarily install the inverter cover with the 11 bolts to prevent any foreign objects or water from entering the inverter with converter assembly.

  2. INSTALL INVERTER COOLING PIPE


    1. A01NFCYE01
      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 }

    2. 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.

  3. INSTALL INVERTER DRAIN HOSE


    1. A01NHXGE01
      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.

  4. INSTALL INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Wear insulating gloves.


    1. A01NES7

      Install the inverter with converter assembly with the 2 bolts and nut.

      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.

  5. INSTALL CONDENSER


    1. A01NEQT

      Install the condenser with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

  6. INSTALL RADIATOR RESERVE TANK ASSEMBLY


    1. A01NH90

      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 }

  7. INSTALL NO. 4 INVERTER BRACKET


    1. A01NE29

      Install the No. 4 inverter bracket with the bolt and nut.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  8. CONNECT NO. 2 ENGINE ROOM WIRE


    1. A01NEVQ

      Engage the claw and 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.

  9. CONNECT WATER HOSE


    1. A01NF1KE01
      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

      Each direction of the hose and hose clamp is indicated in the illustration.

    2. A01NFCME01
      Text in Illustration
      *1 Retainer

      Connect the water 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.

  10. 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. A01NENO

      Connect the connector to the inverter with converter assembly.

    2. A01NCTN

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

  11. INSTALL RELAY BLOCK SUB-ASSEMBLY


    1. A01NEEI

      Install the relay block sub-assembly with the clamp.

  12. INSTALL NO. 6 INVERTER BRACKET (w/ Bracket)


    1. A01NDEI

      Install the No. 6 inverter bracket with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  13. REMOVE INVERTER TERMINAL COVER


    1. A01NEKJ

      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.

  14. 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. A01NDBM

      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. A01NFSF

      Connect the 3 clamps.

  15. 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. A01NHAM

      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. A01NCUY

      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 }

  16. CONNECT NO. 3 WIRE FRAME (for AWD)

    CAUTION:

    Wear insulating gloves.

    Note

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


    1. A01NGTS

      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. A01NGHV

      Connect the clamp.

  17. 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. A01NDCQ

      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 }

  18. 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. A01NDY8E01

      Check that each connector and terminal is firmly installed.

      Torque:
      for Bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      for Nut
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

      Note

      Make sure that the bolts are fully tightened.

  19. 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. A01NEKJE01

      Using several steps, install the inverter terminal cover with the 11 bolts uniformly in the sequence shown in the illustration.

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

  20. INSTALL NO. 1 INVERTER RESERVE TANK BRACKET


    1. A01NE40

      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 }

  21. INSTALL INVERTER RESERVE TANK ASSEMBLY


    1. A01NFI7

      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. A01NDBK

      Connect the 3 water hoses to the inverter reserve tank sub-assembly with the 3 hose clamps.

    3. Connect the hose to the clamp.

  22. INSTALL NO. 3 INVERTER BRACKET


    1. A01NCVA

      Install the No. 3 inverter bracket with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Install the hose clamp to the No. 3 inverter bracket.

  23. INSTALL AIR CLEANER ASSEMBLY WITH HOSE

    Tech Tips

    Click here.

  24. 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. A01NHEW

      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.

  25. INSTALL BATTERY SERVICE HOLE COVER


    1. A01NG1N

      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.

  26. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  27. 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

    1. Add coolant to the reserve tank.

    2. A01NFAW

      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.)

    3. When using the intelligent tester:


      1. Connect the intelligent tester to the DLC3.

      2. Turn the power switch on (IG).

      3. On the intelligent tester, enter the following menus: Powertrain / Hybrid Control / Active Test / Activate the Water Pump.

      4. 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.

    4. When not using the intelligent tester:


      1. Turn the power switch on (READY). [*1]

      2. 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.

      3. 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.

    5. A01NFAW

      Add coolant to the FULL mark of the reserve tank.

  28. 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. A01NFFO

      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.

  29. INSTALL NO. 1 ENGINE UNDER COVER

  30. PERFORM INITIALIZATION

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