INVERTER WITH CONVERTER REMOVAL


  1. PRECAUTION

    Click here

  2. REMOVE REAR FLOOR MAT


    1. A003TLX

      Remove the rear floor mat.

  3. REMOVE REAR DECK FLOOR BOX


    1. A003TAA

      Remove the rear deck floor box.

  4. REMOVE BATTERY BOX COVER


    1. A003UZD

      Disengage the 3 guides and remove the battery box cover.

  5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  6. REMOVE SERVICE PLUG GRIP

    CAUTION:


    • Wear insulating gloves.

    • Remove the service plug grip to interrupt the high voltage circuit at the time of inspection or repair.

    • Keep the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.

    • All the high voltage wiring connectors are colored in orange.


    1. Wear insulating gloves and remove the service plug grip after sliding up the lever of the service plug grip as shown in the illustration.

      A003U1R

      CAUTION:


      • Keep the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.

      • After removing the service plug grip, do not touch the high voltage connectors or terminals for 10 minutes.

      Tech Tips

      Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

  7. REMOVE ENGINE UNDER COVER

  8. REMOVE NO. 1 ENGINE UNDER COVER

  9. DRAIN COOLANT (for Inverter)

    Note


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

    • 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. A003RRD

      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 }

  10. REMOVE NO. 1 INVERTER BRACKET


    1. A003USV

      Remove the 3 bolts and No. 1 inverter bracket.

  11. DISCONNECT ENGINE ROOM MAIN WIRE


    1. A003TTL

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

    2. A003SVE

      Disconnect the engine wire from the engine room main wire.

    3. A003U3X

      Remove the bolt.

    4. A003SLB

      Remove the bolt, clamp and clip, and disconnect the engine room main wire.

  12. REMOVE INVERTER TERMINAL COVER

    CAUTION:

    Wear insulating gloves.


    1. A003UIY

      Remove the 9 bolts and inverter terminal cover.

      Note

      Make sure to pull the inverter terminal cover straight up, as a connector is connected to the bottom of the cover.

  13. CHECK TERMINAL VOLTAGE

    CAUTION:

    Wear insulating gloves.

    Note

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


    1. A003TFR

      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 FRAME WIRE

    CAUTION:

    Wear insulating gloves.

    Note


    • Insulate the removed 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. A003UF4

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

    2. A003S3B

      Disconnect the harness clamp.

  15. DISCONNECT HIGH VOLTAGE CABLE OF FRONT TRANSAXLE

    CAUTION:

    Wear insulating gloves.

    Note


    • Insulate the removed 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. A003S2I

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

    2. A003UG1

      Turn back the wire harness cover and release the cable.

    3. A003T9Z

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

    4. A003T2M

      Disconnect the harness clamp.

  16. DISCONNECT NO. 2 ENGINE WIRE

    CAUTION:

    Wear insulating gloves.

    Note


    • Insulate the removed 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. A003V0O

      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. A003SJE

      Disconnect the harness clamp.

  17. INSTALL INVERTER TERMINAL COVER


    1. A003UIY

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

  18. DISCONNECT NO. 2 ENGINE ROOM WIRE


    1. Remove the relay block cover.

    2. A003SOM

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

    3. A003UOY

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

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

    5. A003TC1

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

  19. DISCONNECT WATER HOSE


    1. A003TXOE01
      Text in Illustration
      *1 Retainer

      Release the retainer and disconnect the water hose from the inverter with converter assembly.

    2. A003UE2E01
      Text in Illustration
      *1 Retainer

      Release the retainer and disconnect the water hose from the inverter with converter assembly.

    3. A003TPR

      Disconnect the coolant hose from the inverter with converter assembly. Put a piece of cloth in the pipe and in the disconnected hose or cover the pipe and hose with plastic bags as shown in the illustration, so that foreign matter doesn't stick to the union or the inside of the connector and to prevent coolant from spilling near the inverter with converter assembly.

  20. REMOVE INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Wear insulating gloves.


    1. A003T4S

      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. A003T3K

      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. A003RGB

      Remove the 2 bolts and motor cable bracket.

  22. REMOVE HIGH VOLTAGE FUSE

    CAUTION:

    Wear insulating gloves.

    Tech Tips

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


    1. A003UIY

      Remove the 9 bolts and inverter terminal cover.

      Note

      Make sure to pull the inverter terminal cover straight up, as a connector is connected to the bottom of the cover.

    2. A003TY5

      Remove the 2 bolts and high voltage fuse from the inverter with converter assembly.

      Note

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

    3. A003UIY

      Temporarily install the inverter terminal cover with the 9 bolts to prevent any foreign objects or water from entering 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. A003RLP

      Disengage the 2 claws and open the terminal cover.

    2. A003UM7

      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.