INVERTER WITH CONVERTER REMOVAL


  1. PRECAUTION

    Note

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notice before proceeding with work Click here.

  2. REMOVE SERVICE PLUG GRIP

    Click here

  3. REMOVE NO. 1 ENGINE UNDER COVER

  4. 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. A003Z26

      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 }

  5. REMOVE INVERTER COVER ASSEMBLY LH (w/ Cover)


    1. A003WP0

      Remove the 2 clips

    2. Disengage the claw and remove the inverter cover assembly LH.

  6. REMOVE RADIATOR SUPPORT OPENING COVER


    1. A003ZJQ

      Remove the 9 clips and radiator support opening cover (for 9 Clip Type).

    2. A003XV0

      Remove the 7 clips and radiator support opening cover (for 7 Clip Type).

  7. REMOVE NO. 1 INVERTER BRACKET


    1. A003YRX

      Remove the 3 bolts and No. 1 inverter bracket.

  8. DISCONNECT ENGINE ROOM MAIN WIRE


    1. A003YY7

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

    2. A003WA0

      Disconnect the engine wire from the engine room main wire.

    3. A003VAV

      Remove the bolt.

    4. A003ZRT

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

  9. REMOVE INVERTER COVER

    CAUTION:

    Wear insulating gloves.


    1. A003WQ2

      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 insulating gloves.

    Note

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


    1. A003W23

      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 FRAME WIRE

    CAUTION:

    Wear insulating 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. A003V7O

      Disconnect the 2 harness clamps.

    2. A003WVC

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

  12. DISCONNECT GENERATOR CABLE

    CAUTION:

    Wear insulating 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. A003Y4Z

      Turn back the wire harness cover and release the cable.

    2. A003ZEQ

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

  13. DISCONNECT MOTOR CABLE

    CAUTION:

    Wear insulating 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. A003YEB

      Disconnect the harness clamp.

    2. A003VLR

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

  14. DISCONNECT NO. 2 ENGINE WIRE

    CAUTION:

    Wear insulating 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. A003ZM2

      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. A003WOR

      Disconnect the harness clamp.

  15. INSTALL INVERTER COVER


    1. A003WQ2

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

  16. DISCONNECT NO. 2 ENGINE ROOM WIRE


    1. Remove the relay block cover.

    2. A003Y00

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

    3. A003Z58

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

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

    5. A003Z1U

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

  17. DISCONNECT WATER HOSE


    1. A003YYGE01
      Text in Illustration
      *1 Retainer

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

    2. A003ZGQE01
      Text in Illustration
      *1 Retainer

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

    3. A003V32

      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.

  18. REMOVE INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Wear insulating gloves.


    1. A003WZ0

      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. A003XYA

      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.

  19. REMOVE MOTOR CABLE BRACKET


    1. A003WSU

      Remove the 2 bolts and motor cable bracket.

  20. REMOVE HIGH VOLTAGE FUSE

    CAUTION:

    Wear insulating gloves.

    Tech Tips

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


    1. A003WQ2

      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. A003Y9L

      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. A003WQ2

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

  21. REMOVE NO. 2 ENGINE ROOM WIRE

    Tech Tips

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


    1. A003VFS

      Disengage the 2 claws and open the terminal cover.

    2. A003VE3

      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.