INVERTER WITH CONVERTER REMOVAL

PROCEDURE


  1. PRECAUTION

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  2. REMOVE FRONT FLOOR COVER RH (for Front Floor Cover Type A)

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  3. REMOVE FRONT FLOOR COVER LH (for Front Floor Cover Type A)

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  4. REMOVE CENTER FRONT FLOOR COVER (for Front Floor Cover Type A)

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  5. REMOVE CENTER FRONT FLOOR COVER (for Front Floor Cover Type B)

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  6. REMOVE FRONT FLOOR COVER RH (for Front Floor Cover Type B)

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  7. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

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  8. REMOVE SERVICE PLUG GRIP

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  9. DRAIN COOLANT (for Inverter)

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  10. REMOVE HOOD STAY HOLDER


    1. A01V157

      Disengage the claw and remove the hood stay holder.

  11. REMOVE INVERTER TERMINAL COVER

    CAUTION:

    Wear insulated gloves.


    1. A01V0NFE07
      Text in Illustration
      *1 Interlock Connector

      Remove the 2 bolts and inverter terminal cover.

      CAUTION:

      An interlock connector is installed to the inverter terminal cover. Make sure to remove the inverter terminal cover before removing the inverter cover.

      Note

      Make sure to pull the inverter terminal cover straight up to remove it, because an interlock connector is connected to the bottom of the inverter terminal cover.

  12. REMOVE INVERTER COVER

    CAUTION:

    Wear insulated gloves.


    1. A01UZD1

      Remove the 7 bolts and inverter cover.

      CAUTION:

      An interlock connector is installed to the inverter terminal cover. Make sure to remove the inverter terminal cover before removing the inverter cover.

  13. CHECK TERMINAL VOLTAGE

    CAUTION:

    Wear insulated gloves.

    Note

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


    1. A01UZPE

      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.

  14. DISCONNECT ENGINE ROOM MAIN WIRE

    CAUTION:

    Wear insulated gloves.

    Note


    • Insulate the disconnected 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.

    • To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.


    1. A01V1G2

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

    2. A01V0LB

      Disconnect the engine wire from the engine room main wire.

    3. A01UYX2E01
      Text in Illustration
      *1 Hybrid Water Pump Inlet Hose

      Disengage the clamp and disconnect the hybrid water pump inlet hose from the engine room main wire.

      Note

      Do not remove the hose clamp from the hybrid water pump inlet hose.

    4. Remove the 2 bolts.

    5. Disengage the clamp and disconnect the engine room main wire.

  15. DISCONNECT FRAME WIRE

    CAUTION:

    Wear insulated gloves.

    Note


    • Insulate the disconnected 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. A01UYJ1

      Disconnect the harness clamp.

    2. A01V01Y

      Remove the 4 bolts, and disconnect the frame wire (high voltage cables of the hybrid battery) from the inverter with converter assembly.

  16. DISCONNECT MOTOR CABLE

    CAUTION:

    Wear insulated gloves.

    Note


    • Insulate the disconnected 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. Disconnect the motor cable (for MG 1)


      1. A01UXZW

        Remove the 5 bolts, and disconnect the high voltage cables of the motor cable for (MG1) from the inverter with converter assembly.

    2. Disconnect the motor cable (for MG 2)


      1. A01UY95

        Remove the 5 bolts, and disconnect the high voltage cables of the motor cable (for MG2) from the inverter with converter assembly.

  17. DISCONNECT NO. 2 ENGINE WIRE

    CAUTION:

    Wear insulated gloves.

    Note


    • Insulate the disconnected 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. A01V0D3E06

      Remove the bolt (A).

    2. Remove the 4 bolts (B), and disconnect the No. 2 engine wire (high voltage cables for the air conditioning compressor) from the inverter with converter assembly.

  18. INSTALL INVERTER COVER

    CAUTION:

    Wear insulated gloves.


    1. A01UZD1

      Temporarily install the inverter cover with the 7 bolts to prevent any foreign matter or water from entering the inverter with converter assembly.

      Note

      Visually confirm that the inverter cover waterproofing rubber is securely installed before installing the inverter cover.

  19. INSTALL INVERTER TERMINAL COVER

    CAUTION:

    Wear insulated gloves.


    1. A01V0NFE07
      Text in Illustration
      *1 Interlock Connector

      Temporarily install the inverter terminal cover with the 2 bolts to prevent any foreign matter or water from entering the inverter with converter assembly.

      Note


      • Visually confirm that the inverter terminal cover waterproofing rubber is securely installed before installing the inverter terminal cover.

      • Make sure that the interlock connector is fully engaged.

  20. DISCONNECT WIRE HARNESS


    1. A01UXPW

      Remove the relay block cover.

    2. A01UZE6

      Disconnect the connector.

    3. A01UY6T

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

    4. A01UYB8

      Remove the nut.

    5. Disengage the 2 claws and disconnect the wire harness.

    6. A01UYT5E02
      Text in Illustration
      *1 Wire Harness
      *2 Protector

      Temporarily secure the wire harness with the inverter with converter assembly protector as shown in the illustration.

      Tech Tips

      To prevent the wire harness from getting caught by other components, connect it to the protector before removing the inverter with converter assembly.

  21. DISCONNECT NO. 1 INVERTER COOLING HOSE ASSEMBLY


    1. A01V0E8E02
      Text in Illustration
      *1 Retainer

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

    2. A01V0HF

      Put pieces of cloth into the pipes and in the 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.

  22. DISCONNECT NO. 2 INVERTER COOLING HOSE ASSEMBLY


    1. A01UYPPE02
      Text in Illustration
      *1 Retainer

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

    2. A01V23A

      Put pieces of cloth into the pipes and in the disconnected hoses, or cover the pipes and hose 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.

  23. REMOVE INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Wear insulated gloves.


    1. A01UYQ8

      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.

    2. A01UZU2

      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.

  24. REMOVE HIGH VOLTAGE FUSE

    CAUTION:

    Wear insulated gloves.

    Tech Tips

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


    1. A01V0NFE07
      Text in Illustration
      *1 Interlock Connector

      Remove the 2 bolts and inverter terminal cover.

      Note

      Make sure to pull the inverter terminal cover straight up to remove it, because an interlock connector is connected to the bottom of the inverter terminal cover.

    2. A01UZD1

      Remove the 7 bolts and inverter cover.

    3. A01UZWR

      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.

    4. A01UZD1

      Temporarily install the inverter cover with the 7 bolts to prevent any foreign matter or water from entering the inverter with converter assembly.

      Note

      Visually confirm that the inverter cover waterproofing rubber is securely installed before installing the inverter cover.

    5. A01V0NFE07
      Text in Illustration
      *1 Interlock Connector

      Temporarily install the inverter terminal cover with the 2 bolts to prevent any foreign matter or water from entering the inverter with converter assembly.

      Note


      • Visually confirm that the inverter terminal cover waterproofing rubber is securely installed before installing the inverter terminal cover.

      • Make sure that the interlock connector is fully engaged.