INVERTER WITH CONVERTER INSTALLATION

INSTALL NO. 2 ENGINE ROOM WIRE
Tech Tips

Perform this procedure only when replacement of the No. 2 engine room wire is necessary.
1. 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. Engage the 2 claws and close the terminal cover.
INSTALL HIGH VOLTAGE FUSE

CAUTION:

Wear insulated gloves.

Tech Tips

Perform this procedure only when replacement of the high voltage fuse is necessary.
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 cover.
2. Text in Illustration
  
  *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.
  - The 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.
INSTALL MOTOR CABLE BRACKET
1. Temporarily install the motor cable bracket with the 2 bolts.
2. Tighten the 2 bolts in the order shown in the illustration.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSTALL INVERTER WITH CONVERTER ASSEMBLY
CAUTION:

Wear insulated gloves.
1. 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, 8 ft.*lbf }
3. Tighten the 2 bolts.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 8 ft.*lbf }
CONNECT NO. 6 INVERTER COOLING HOSE
1. 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 pipes and disconnected hoses until installation.
CONNECT NO. 1 INVERTER COOLING HOSE
1. 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 pipes and disconnected hoses until installation.
CONNECT NO. 2 ENGINE ROOM WIRE
1. Disconnect the No. 2 engine room wire from the protector.
2. Connect the No. 2 engine room wire with the bolt and 2 claws.
  
  Torque:
  
  8.3 N*m { 85 kgf*cm, 73 in.*lbf }
  
  Note
  
  Pass the No. 2 engine room wire under the two cooling hoses that pass beside the inverter.
3. Install the No. 1 relay block cover and 2 clamps.
4. Install the relay block cover.
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 cover.
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 assembly by hand.
2. Using an insulated tool, fully tighten the 4 bolts.
  
  Torque:
  
  Bolt A
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  
  Bolt B
  
  9.2 N*m { 94 kgf*cm, 81 in.*lbf }
  
  Note
  
  Be sure to use a torque wrench to tighten the bolts.
3. Connect the harness clamp.
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 assembly by hand.
2. Using an insulated tool, fully tighten the 5 bolts.
  
  Torque:
  
  Bolt A
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  
  Bolt B
  
  9.2 N*m { 94 kgf*cm, 81 in.*lbf }
  
  Note
  
  Be sure to use a torque wrench to tighten the bolts.
3. Connect the harness clamp.
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 assembly by hand.
2. Using an insulated tool, fully tighten the 5 bolts.
  
  Torque:
  
  Bolt A
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  
  Bolt B
  
  9.2 N*m { 94 kgf*cm, 81 in.*lbf }
  
  Note
  
  Be sure to use a torque wrench to tighten the bolts.
3. Text in Illustration
  
  *a Alignment Mark
  
  Install the generator cable and cover.
  
  Note
  
  Close the cover so that the alignment marks are not visible.

Text in Illustration
*a	CORRECT
*b	INCORRECT

Text in Illustration
*a	Alignment Mark

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.

Text in Illustration
*1	Interlock
*2	High voltage cables of hybrid battery
*a	Front view of frame wire connector

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

Using an insulated tool, fully tighten the 4 bolts.

Torque:

Bolt A

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

Bolt B

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 are fully engaged.
Connect the harness clamp.

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. Check that each connector and terminal is firmly installed.
  
  Note
  
  Make sure that the bolts are fully tightened.
INSTALL INVERTER COVER

CAUTION:

Wear insulated gloves.
1. Text in Illustration
  
  *1 Interlock
  
  Install the inverter cover with the 9 bolts to the inverter with converter assembly.
  
  Torque:
  
  11 N*m { 112 kgf*cm, 8 ft.*lbf }
  Note
  - Make sure that the interlock is fully engaged.
  - Do not allow any foreign matter or water to enter the inverter with converter assembly.
INSTALL ENGINE ROOM MAIN WIRE
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. Connect the engine wire to the engine room main wire.
2. Connect the connector to the inverter with converter assembly and lock the connector with the lock lever.
3. Install the bolt, clamp and clip, and connect the engine room main wire.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
4. Text in Illustration
  
  *A w/ Ground Wire
  
  Install the 2 bolts (w/ Ground Wire).
  
  Torque:
  
  Bolt A
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
  
  Bolt B
  
  8.4 N*m { 86 kgf*cm, 74 in.*lbf }
5. Install the bolt (w/o Ground Wire).
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL NO. 1 INVERTER BRACKET
1. Temporarily install the No. 1 inverter bracket with the 3 bolts.
2. Tighten the 3 bolts in the order shown in the illustration.
  
  Torque:
  
  14 N*m { 138 kgf*cm, 10 ft.*lbf }
INSTALL SERVICE PLUG GRIP

Click here.

Text in Illustration
*A	w/ Ground Wire

ADD COOLANT (for Inverter)

Note

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

If the vehicle is driven with air in the inverter cooling system, damage may occur and the following DTCs may be stored.

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
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
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
P1557-887	DC / DC Converter Temperature Sensor Circuit

Slowly pour coolant into the reserve tank until it reaches the full line.

Coolant quantity

2.1 liters (2.2 US qts, 1.8 Imp. qts.)

Note

To prevent foreign matter such as dust or dirt from entering the cooling system, make sure to confirm that the container used to add coolant is clean and free of foreign matter such as dust or dirt.

Coolant quantity
2.1 liters (2.2 US qts, 1.8 Imp. qts.)

When using the GTS:

Connect the GTS to the DLC3.
Turn the power switch on (IG).
Enter the following menus: Powertrain / Hybrid Control / Active Test / Activate the Water Pump.

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

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

Tech Tips

If free spinning of the inverter water pump is detected for approximately 5 seconds, fail-safe control will be activated to suspend the operation of the pump for approximately 15 seconds and resume operation for approximately 4 seconds repeatedly. Operation of the inverter water pump will return to normal if coolant is added.
Loud noise made by the inverter water pump assembly and poor circulation of coolant in the reserve tank indicates that there is air in the cooling system.

When not using the GTS:

Turn the power switch on (READY). [*1]
Turn the power switch off and add coolant to the full line because the coolant level drops as 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 cooling system is completed.

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

Tech Tips

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

After the air is completely bled from the cooling system, tighten the reserve tank cap.
Add coolant to the full line 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 a radiator cap tester.
3. Pump the radiator cap tester to 122 kPa (1.2 kgf/ cm², 18 psi), and then check that the pressure does not drop.
  
  Tech Tips
  
  If the pressure drops, check the hoses, radiator, inverter water pump assembly, inverter with converter, and hybrid vehicle transaxle assembly for leaks.
4. Reinstall the reserve tank cap.
INSTALL NO. 1 ENGINE UNDER COVER
INSTALL FRONT SPOILER COVER (w/ Front Spoiler)
INSTALL FRONT LOWER BUMPER ABSORBER (w/ Cover)
INSTALL RADIATOR SUPPORT OPENING COVER
1. Engage the 2 claws to install the radiator support opening cover.
2. Install the 3 clips.