MOTOR CABLE INSTALLATION


  1. INSTALL MOTOR CABLE

    Note

    Wear insulated gloves.


    1. Install the motor cable to the hybrid transaxle assembly with the 3 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note

      Keep the sealing surface of the motor cable and the connector terminal joint free of foreign matter.

    2. Engage the 2 claws to install a new terminal cap.

      Note

      When installing the terminal cap to the motor cable terminal block, keep the sealing surface free of foreign matter.

    3. A003XLL

      Place the motor cable connector shell in position and install it with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    4. Connect the 3 clamps.

  2. INSTALL INVERTER TRAY BRACKET (for 2ZR-FXE)


    1. A003XZQE01

      Position the inverter tray bracket as shown in the illustration.

    2. Temporarily install bolt B to the inverter tray bracket.

    3. Tighten the 5 bolts to the inverter tray bracket in the order bolt A, bolt C, bolt D, bolt E and bolt B.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    4. Connect the 2 clamps to the inverter tray bracket.

  3. INSTALL INVERTER TRAY BRACKET (for 5ZR-FXE)


    1. A003XZQE01

      Position the inverter tray bracket as shown in the illustration.

    2. Temporarily install bolt B to the inverter tray bracket.

    3. Tighten the 5 bolts to the inverter tray bracket in the order bolt A, bolt C, bolt D, bolt E and bolt B.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    4. Connect the 2 clamps to the inverter tray bracket.

  4. INSTALL INVERTER RESERVE TANK ASSEMBLY (for 2ZR-FXE)


    1. A003V8FE01

      Temporarily install bolt A to the inverter reserve tank assembly.

    2. Tighten the 2 bolts to the inverter reserve tank assembly in the order bolt B and bolt A.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  5. INSTALL INVERTER RESERVE TANK ASSEMBLY (for 5ZR-FXE)


    1. A003V8FE01

      Temporarily install bolt A to the inverter reserve tank assembly.

    2. Tighten the 2 bolts to the inverter reserve tank assembly in the order bolt B and bolt A.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  6. INSTALL INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Wear insulating gloves.


    1. A003WZ0E02

      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 }

  7. CONNECT WATER HOSE


    1. A003Z9JE01

      Connect the water 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.

    2. A003V7TE01

      Connect the water 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.

  8. 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.

  9. REMOVE INVERTER COVER

    CAUTION:

    Wear insulating 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.

  10. CONNECT NO. 2 ENGINE WIRE

    CAUTION:

    Wear insulating gloves.

    Note

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


    1. A003ZM2E01

      Temporarily install the No. 2 engine wire (high voltage cables of the air conditioning) and 4 bolts to the inverter assembly by hand.

    2. 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.

  11. CONNECT MOTOR CABLE

    CAUTION:

    Wear insulating gloves.

    Note

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


    1. A003VLRE01

      Temporarily install the high voltage cable of the motor (MG2) and 5 bolts to the inverter assembly by hand.

    2. 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.

  12. CONNECT GENERATOR CABLE

    CAUTION:

    Wear insulating gloves.

    Note

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


    1. A003ZEQE01

      Temporarily install the high voltage cable of the generator cable (MG1) and 5 bolts to the inverter assembly by hand.

    2. 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. A003V6NE02
      Text in Illustration
      *a Align Mark

      Install the generator cable and cover.

      Note

      Close the cover so that the matchmarks are not visible.

  13. CONNECT FRAME WIRE

    CAUTION:

    Wear insulating gloves.

    Note


    • Make sure that the interlock is fully engaged.

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


    1. A003WPGE01
      Text in Illustration
      *1 Interlock
      *2 High voltage cables of the 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.

    2. 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.

    3. Connect the 2 harness clamps.

  14. CHECK HIGH VOLTAGE CABLE CONNECTION

    CAUTION:

    Wear insulating gloves.

    Note

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


    1. A003W5Y

      Check that each connector and terminal is firmly installed.

      Note

      Make sure that the bolts are fully tightened.

  15. INSTALL INVERTER COVER

    CAUTION:

    Wear insulating gloves.

    Note


    • Make sure that the interlock is fully engaged.

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


    1. A003XT9E01
      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 }

  16. INSTALL ENGINE ROOM MAIN WIRE

    Note


    • Make sure that the connectors are fully engaged.

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


    1. Install the bolt, clamp and clip, and connect the engine room main wire.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    2. Install the bolt.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    3. A003XTD

      Connect the engine wire to the engine room main wire.

    4. A003XSM

      Connect the connector to the inverter with converter assembly and lock the connector with the lock lever.

  17. INSTALL NO. 1 INVERTER BRACKET


    1. A003YRXE01

      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 }

  18. INSTALL SERVICE PLUG GRIP

    CAUTION:

    Wear insulating gloves.

    Note

    Before connecting the service plug, check that no parts and tools remain and that the high voltage terminals and connectors are connected securely.


    1. Wear insulated gloves and install the service plug grip in the order shown in the illustration.

      A003X0M

    2. Rotate the handle of the service plug grip 90° toward the battery and slide it in the direction shown by the arrow until a click sound is heard.

  19. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

  20. INSTALL REAR FLOOR BOARD UPPER NO. 3 PLATE


    1. Engage the 4 claws and 2 guides to install the rear floor board upper No. 3 plate.

  21. INSTALL DECK FLOOR BOX RH


    1. Engage the 6 guides.

    2. Install the deck floor box RH with the clip.

  22. INSTALL REAR NO. 3 FLOOR BOARD


    1. Install the rear No. 3 floor board.

  23. INSTALL REAR DECK FLOOR BOX


    1. Install the rear deck floor box.

  24. INSTALL REAR NO. 2 FLOOR BOARD


    1. Install the rear No. 2 floor board.

  25. ADD COOLANT (for Inverter)

    Note


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

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

      DTC No. 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
      P0C73-776 Motor Electronics Coolant Pump "A" Control Performance

    1. A003W8W

      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.)

    2. When using the intelligent tester:


      1. Connect the intelligent tester to the DLC3.

      2. Turn the power switch on (IG).

      3. Enter the following menus: Powertrain / Hybrid Control / Active Test / Activate the Water Pump.

      4. 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

        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.

    3. When not using the intelligent tester:


      1. Turn the power switch on (READY). [*1]

      2. 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.

      3. 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.

    4. After the air is completely bled from the cooling system, tighten the reserve tank cap.

    5. A003W8W

      Add coolant to the full line of the reserve tank.

  26. 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. A003V28

      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.

  27. INSTALL RADIATOR SUPPORT OPENING COVER


    1. Install the radiator support opening cover with the 9 clips (for 9 Clip Type).

    2. Install the radiator support opening cover with the 7 clips (for 7 Clip Type).

  28. INSTALL INVERTER COVER ASSEMBLY LH (w/ Cover)


    1. Engage the claw and install the inverter cover assembly LH.

    2. Install the 2 clips.

  29. INSTALL NO. 1 ENGINE UNDER COVER

  30. INSTALL FRONT LOWER BUMPER ABSORBER