INVERTER WITH CONVERTER REMOVAL


  1. PRECAUTION

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  2. REMOVE SERVICE PLUG GRIP

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  3. REMOVE FRONT SPOILER COVER (w/ Front Spoiler)

  4. REMOVE FRONT LOWER BUMPER ABSORBER (w/ Cover)

  5. REMOVE NO. 1 ENGINE UNDER COVER

  6. DRAIN COOLANT (for Inverter)

    Note


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

    • Collect the drained coolant and measure its volume to establish a benchmark. When adding coolant, make sure to add more coolant than the measured amount.


    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. A00407D

      Using a hexagon wrench (10 mm), remove the drain plug indicated in the illustration and drain the coolant.

      CAUTION:

      Use caution when handling coolant immediately after driving or in summer because it may be hot.

    3. Install the plug with a new gasket.

      Torque:
      39 N*m  { 397 kgf*cm, 29 ft.*lbf }

  7. REMOVE RADIATOR SUPPORT OPENING COVER


    1. A004098

      Remove the 3 clips.

    2. Disengage the 2 claws and remove the radiator support opening cover.

  8. REMOVE NO. 1 INVERTER BRACKET


    1. A0042RY

      Remove the 3 bolts and No. 1 inverter bracket.

  9. REMOVE INVERTER COVER

    CAUTION:

    Wear insulated gloves.


    1. A00446H

      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.

  10. CHECK TERMINAL VOLTAGE

    CAUTION:

    Wear insulated gloves.

    Note

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


    1. A0041DD

      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.

  11. 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. A00405QE01
      Text in Illustration
      *A w/ Ground Wire

      Remove the 2 bolts (w/ Ground Wire).

    2. Disconnect the clamp and clip, and separate the engine room main wire (w/ Ground Wire).

    3. A0041TAE01
      Text in Illustration
      *A w/o Ground Wire

      Remove the bolt (w/o Ground wire).

    4. Disconnect the clamp and clip, and separate the engine room main wire (w/o Ground Wire).

    5. A0040L2

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

    6. A0040G0

      Disconnect the engine wire from the engine room main wire.

    7. A004378

      Remove the bolt.

  12. 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. A0041XM

      Disconnect the harness clamp.

    2. A0043BQ

      Using an insulated tool, remove the 4 bolts, and disconnect the frame wire (high voltage cables of the hybrid battery) from the inverter with converter assembly.

  13. DISCONNECT GENERATOR 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. A0040XN

      Turn back the wire harness cover and release the generator cable.

    2. A004420

      Using an insulated tool, remove the 5 bolts, and disconnect the high voltage cables of the generator cable (MG1) from the inverter with converter assembly.

  14. 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. A0043SJ

      Disconnect the harness clamp.

    2. A00445G

      Using an insulated tool, remove the 5 bolts, and disconnect the high voltage cables of the motor cable (MG2) from the inverter with converter assembly.

  15. 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. A0041SJ

      Using an insulated tool, remove the 4 bolts, and disconnect the No. 2 engine wire (high voltage cables for the air conditioning compressor) from the inverter with converter assembly.

    2. A0043NV

      Disconnect the harness clamp.

  16. INSTALL INVERTER COVER

    CAUTION:

    Wear insulated gloves.


    1. A0042LKE01
      Text in Illustration
      *1 Interlock

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

      Note


      • Make sure that the interlock is fully engaged.

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

  17. DISCONNECT NO. 2 ENGINE ROOM WIRE


    1. Remove the relay block cover.

    2. A0041LD

      Release the 2 clamps, and remove the No. 1 relay block cover.

    3. A0041AR

      Remove the bolt from the No. 2 engine room wire.

    4. Release the 2 claws, and disconnect the No. 2 engine room wire.

    5. A0040N7

      Connect the No. 2 engine room wire to the protector.

  18. DISCONNECT NO. 1 INVERTER COOLING HOSE


    1. A0042WWE01
      A0040UG

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

      Text in Illustration
      *1 Retainer

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

  19. REMOVE NO. 6 INVERTER COOLING HOSE


    1. A0040HME01
      Text in Illustration
      *1 Retainer

      Release the retainer and disconnect the No. 6 inverter cooling hose from the inverter with converter assembly.

    2. A0040UG

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

  20. REMOVE INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Wear insulated gloves.


    1. A0042MA

      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. A0040NI

      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.

  21. REMOVE MOTOR CABLE BRACKET


    1. A0040N5

      Remove the 2 bolts and motor cable bracket.

  22. REMOVE HIGH VOLTAGE FUSE

    CAUTION:

    Wear insulated gloves.

    Tech Tips

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


    1. A00446H

      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. A0042KZ

      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.

    3. A0042LKE01
      Text in Illustration
      *1 Interlock

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

      Note


      • Make sure that the interlock is fully engaged.

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

  23. REMOVE NO. 2 ENGINE ROOM WIRE

    Tech Tips

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


    1. A00402D

      Disengage the 2 claws and open the terminal cover.

    2. A0041Z1

      Remove the nut from the No. 2 engine room wire.

    3. Disengage the clamp and remove the No. 2 engine room wire from the inverter with converter assembly.