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MOTOR CABLE REMOVAL

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  1. Click here

    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 notices before proceeding with work (Click here).

  2. Click here

    REMOVE REAR NO. 2 FLOOR BOARD


    1. Remove the rear No. 2 floor board.

  3. Click here

    REMOVE REAR DECK FLOOR BOX


    1. Remove the rear deck floor box.

  4. Click here

    REMOVE REAR NO. 3 FLOOR BOARD


    1. Remove the rear No. 3 floor board.

  5. Click here

    REMOVE DECK FLOOR BOX RH


    1. A003Z5J

      Remove the clip.

    2. Disengage the 6 guides and remove the deck floor box RH.

  6. Click here

    REMOVE REAR FLOOR BOARD UPPER NO. 3 PLATE


    1. A003VKN

      Disengage the 4 claws and 2 guides, and remove the rear floor board upper No. 3 plate.

  7. Click here

    DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

    Note:

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

  8. Click here

    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.

    • High voltage wiring connectors are orange.


    1. A003XIK

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

      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.

      Tip:

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

  9. Click here

    REMOVE FRONT LOWER BUMPER ABSORBER

  10. Click here

    REMOVE NO. 1 ENGINE UNDER COVER

  11. Click here

    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.

      39 N*m 397 kgf*cm 29 ft.*lbf
  12. Click here

    REMOVE INVERTER COVER ASSEMBLY LH (w/ Cover)


    1. A003WP0

      Remove the 2 clips

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

  13. Click here

    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).

  14. Click here

    REMOVE NO. 1 INVERTER BRACKET


    1. A003YRX

      Remove the 3 bolts and No. 1 inverter bracket.

  15. Click here

    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.

  16. Click here

    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.

  17. Click here

    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
      Tip:

      Use measuring range of DC 750 V or more on the voltmeter.

  18. Click here

    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.

  19. Click here

    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.

  20. Click here

    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.

  21. Click here

    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.

  22. Click here

    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.

  23. Click here

    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.

  24. Click here

    DISCONNECT WATER HOSE


    1. A003YYGE01

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

      Table 1. Text in Illustration
      *1 Retainer
    2. A003ZGQE01

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

      Table 2. Text in Illustration
      *1 Retainer
    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.

  25. Click here

    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.

  26. Click here

    REMOVE INVERTER RESERVE TANK ASSEMBLY


    1. A003V8F

      Remove the 2 bolts and separate the inverter reserve tank assembly.

  27. Click here

    REMOVE INVERTER TRAY BRACKET


    1. A003XZQ

      Separate the 2 clamps.

    2. Remove the 5 bolts and inverter tray bracket.

  28. Click here

    REMOVE MOTOR CABLE

    Note:

    Wear insulated gloves.


    1. A003X6A

      Disconnect the 3 clamps.

    2. A003ZKB

      Remove the 2 bolts and slide the motor cable connector shell back.

    3. A003X6V

      Disengage the 2 claws to remove the terminal cap.

    4. A003ZB5

      Remove the 3 bolts and motor cable from the hybrid transaxle assembly.