INVERTER WITH CONVERTER INSTALLATION

INSTALL HIGH VOLTAGE FUSE

CAUTION:

Wear insulated gloves.

Tech Tips

Perform this procedure only when replacement of the high voltage fuse is necessary.
1. Remove the bolt and connector cover.
  Note
  - Make sure to pull the connector cover straight up, as a connector is connected to the bottom of the cover.
  - Do not allow any foreign objects or water to enter the inverter with converter.
2. Install the high voltage fuse with 2 new nuts.
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
  
  Note
  
  Be sure to use a torque wrench to tighten the nuts.
3. Temporarily install the connector cover with the bolt to prevent any foreign objects or water from entering the inverter with converter.
INSTALL INVERTER BUS-BAR PLATE SUB-ASSEMBLY
1. Temporarily install the inverter bus-bar plate with the nut by tightening the nut 3 or more revolutions.
2. Install the bolt and attach the clamp.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
3. Tighten the nut.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
4. Close the cover.
INSTALL NO. 4 INVERTER BRACKET
1. Install the No. 4 inverter bracket with the 2 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
2. for RHD:
  
  Install the wire harness bracket with the bolt.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL INVERTER WITH CONVERTER ASSEMBLY

CAUTION:

Wear insulated gloves.
1. Temporarily install the inverter with converter with the 6 bolts.
  Note
  - Since the inverter with converter is very heavy, 2 people are needed to install the inverter with converter. When installing the inverter with converter, do not damage the parts around it.
  - To prevent damage, do not hold the inverter with converter by the connectors.
  - To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.
2. Remove the bolt and connector cover.
  Note
  - Make sure to pull the connector cover assembly straight up, as a connector is connected to the bottom of the cover.
  - Do not allow any foreign objects or water to enter the inverter with converter.
3. Connect the No. 4 floor wire to the inverter with converter.
  Note
  - Do not damage the terminals, connector housings or inverter with converter when connecting them.
  - Do not touch the connector waterproofing rubber or terminals.
  - Do not allow any foreign objects or water to enter the inverter with converter.
  - Make sure that the connectors are fully engaged.
  - Make sure that the connector does not come out when its body is pulled.
4. Secure the No. 4 floor wire to the inverter with converter with the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
5. Connect the air conditioner harness to the inverter with converter.
  Note
  - Do not damage the terminals, connector housings or inverter with converter when connecting them.
  - Do not touch the connector waterproofing rubber or terminals.
  - Do not allow any foreign objects or water to enter the inverter with converter.
  - Make sure that the connectors are fully engaged.
  - Make sure that the connector does not come out when its body is pulled.
6. Tighten the 6 bolts in the order shown in the illustration.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  
  Text in Illustration
  
  *A for LHD *B for RHD
7. Text in Illustration
  
  *A for LHD
  
  *B for RHD
  
  Connect the connector and lock the connector with the lock lever.
  Note
  - Do not allow any foreign objects or water to enter the inverter with converter.
  - Make sure that the connectors are fully engaged.
INSTALL WIRE HARNESS CLAMP BRACKET A (for LHD)
1. Install the wire harness clamp bracket A with the 2 nuts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
CONNECT INVERTER BUS-BAR PLATE SUB-ASSEMBLY
1. for LHD:
  1. Install the wire harness bracket with the bolt.
    
    Torque:
    
    8.5 N*m { 87 kgf*cm, 75 in.*lbf }
  2. Temporarily install the inverter bus-bar plate with the 3 nuts.
  3. Tighten the 2 nuts labeled A in the illustration.
    
    Torque:
    
    6.9 N*m { 70 kgf*cm, 61 in.*lbf }
  4. Tighten the nut labeled B in the illustration.
    
    Torque:
    
    11 N*m { 107 kgf*cm, 8 ft.*lbf }
  5. Attach the harness cover.
2. for RHD:
  1. Attach the 2 claws and install the nut.
    
    Torque:
    
    11 N*m { 107 kgf*cm, 8 ft.*lbf }
  2. Install the relay block cover.
  3. Connect the connector and attach the clamp.

Text in Illustration
*A	for LHD	*B	for RHD

Text in Illustration
*A	for LHD
*B	for RHD

CONNECT NO. 2 INVERTER COOLING INLET HOSE (for RHD)

Text in Illustration
*a	Upper
*b	LH Side
*c	30°

Connect the No. 2 inverter cooling inlet hose to the inverter with converter.

Note

To prevent foreign matter from entering the cooling system, do not remove the pieces of cloth or plastic bags from the pipes and disconnected hoses.

Tech Tips

Make sure the direction of the hose clamp is as shown in the illustration.

CONNECT NO. 1 INVERTER COOLING INLET HOSE (for LHD)

Text in Illustration
*a	Upper
*b	RH Side
*c	30°

Connect the No. 1 inverter cooling inlet hose to the inverter with converter.

Note

To prevent foreign matter from entering the cooling system, do not remove the pieces of cloth or plastic bags from the pipes and disconnected hoses.

Tech Tips

Make sure the direction of the hose clamp is as shown in the illustration.

INSTALL INVERTER RESERVOIR TANK ASSEMBLY (for RHD)
1. Connect the No. 2 inverter cooling outlet hose to the inverter with converter 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.
  
  To prevent foreign matter from entering the cooling system, do not remove the pieces of cloth or plastic bags from the pipes and disconnected hoses.
2. Connect the inverter reservoir tank to the No. 4 inverter cooling hose and install the 2 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }

INSTALL NO. 1 INVERTER COOLING OUTLET HOSE (for LHD)

Text in Illustration
*a	Upper
*b	RH Side
*c	20°
*d	29°

Install the No. 1 inverter cooling outlet hose to the inverter with converter 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.
To prevent foreign matter from entering the cooling system, do not remove the pieces of cloth or plastic bags from the pipes and disconnected hoses.

INSTALL CONNECTOR COVER ASSEMBLY

CAUTION:

Wear insulated gloves.
Note
- Make sure that the interlock is fully engaged.
- Do not allow any foreign objects or water to enter the inverter with converter.
1. Using an insulated tool, install the connector cover with the 2 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
CONNECT MOTOR CABLE
CAUTION:

Wear insulated gloves.
Note
- Do not damage the terminals, connector housings or inverter with converter when connecting them.
- Do not touch the connector waterproofing rubber or terminals.
- Do not allow any foreign objects or water to enter the inverter with converter.
- Route the cable so that it passes inside the guide of the inverter motor cable bracket.
1. Temporarily install the motor cable with the 5 bolts.
2. Using an insulated tool, tighten the 3 bolts labeled A in the illustration.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  Note
  
  The connector should be connected securely.
  
  The bolts should be tightened securely.
  
  Tighten the bolts in the order shown in the illustration.
3. Using an insulated tool, tighten the 2 bolts labeled B in the illustration.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  Note
  - The connector should be connected securely.
  - The bolts should be tightened securely.
CONNECT GENERATOR CABLE
CAUTION:

Wear insulated gloves.
Note
- Do not damage the terminals, connector housings or inverter with converter when connecting them.
- Do not touch the connector waterproofing rubber or terminals.
- Do not allow any foreign objects or water to enter the inverter with converter.
- Route the cable so that it passes inside the guide of the inverter motor cable bracket.
1. Temporarily install the generator cable with the 5 bolts.
2. Using an insulated tool, tighten the 3 bolts labeled A in the illustration.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  Note
  
  The connector should be connected securely.
  
  The bolts should be tightened securely.
  
  Tighten the bolts in the order shown in the illustration.
3. Using an insulated tool, tighten the 2 bolts labeled B in the illustration.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  Note
  - The connector should be connected securely.
  - The bolts should be tightened securely.
INSTALL INVERTER TERMINAL COVER

CAUTION:

Wear insulated gloves.
1. for Type A:
  1. Using an insulated tool, install the inverter terminal cover with the 2 bolts.
    
    Torque:
    
    8.0 N*m { 82 kgf*cm, 71 in.*lbf }
    Note
    - Do not touch the inverter terminal cover waterproofing rubber.
    - Visually confirm that the inverter terminal cover waterproofing rubber is securely installed before installing the inverter terminal cover.
    - Press down on the inverter terminal cover with both hands to securely connect the interlock.
2. for Type B:
  1. Using an insulated tool, install the inverter terminal cover with the 3 bolts.
    
    Torque:
    
    8.0 N*m { 82 kgf*cm, 71 in.*lbf }
    Note
    - Do not touch the inverter terminal cover waterproofing rubber.
    - Visually confirm that the inverter terminal cover waterproofing rubber is securely installed before installing the inverter terminal cover.
    - Press down on the inverter terminal cover with both hands to securely connect the interlock.
INSTALL INVERTER MOTOR CABLE BRACKET ASSEMBLY
1. Install the inverter motor cable bracket with the 2 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
2. Attach the 2 clamps to the inverter motor cable bracket.
  
  Note
  
  Route the cable so that it passes inside the guide of the inverter motor cable bracket.

INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE (for LHD)

Text in Illustration
*1	Bump
*2	Cutout
*3	Protrusion

Install the air cleaner cap with air cleaner hose assembly with the 4 clamps and hose clamp.

Torque:: 4.0 N*m { 41 kgf*cm, 35 in.*lbf }

Note

Insert the protrusion on the throttle body side hose into the hole of the hose clamp.
Align the bump on the throttle body side with the cutout in the hose.

Connect the VSV hose to the air cleaner hose.
Connect the mass air flow meter connector and clamp to the air cleaner.

INSTALL SERVICE PLUG GRIP

Click here
CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL
Note

When disconnecting the cable some systems need to be initialized after the cable is reconnected Click here.
1. Connect cable to the auxiliary battery positive (+) terminal with the nut.
  
  Torque:
  
  6.8 N*m { 69 kgf*cm, 60 in.*lbf }
2. Install the terminal cover.
3. Connect cable to the auxiliary battery negative (-) terminal.
  
  Torque:
  
  5.5 N*m { 56 kgf*cm, 49 in.*lbf }

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 set.

DTC Code	Detection Item
P0A04-725	Motor Electronics Coolant Temperature Sensor Circuit Intermittent
P0A01-726	Motor Electronics Coolant Temperature Sensor Circuit Range / Performance
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
P0AF1-276	Drive Motor Inverter Temperature Sensor "A" Circuit Intermittent / Erratic
P0AEE-277	Motor Inverter Temperature Sensor "A" Circuit Range / Performance
P0BD0-314	Generator Inverter Temperature Sensor Circuit Range / Erratic
P0BCD-315	Generator Inverter Temperature Sensor Circuit Range / Performance
P0C3C-625	DC / DC Converter Temperature Sensor "A" Intermittent / Erratic
P0C39-626	DC / DC Converter Temperature Sensor "A" Range / Performance
P0C41-627	DC / DC Converter Temperature Sensor "B" Intermittent / Erratic
P0C3E-628	DC / DC Converter Temperature Sensor "B" Range / Performance
P0C73-776	Motor Electronics Coolant Pump "A" Control Performance

Slowly pour coolant into the reservoir tank until it reaches the FULL line.

Standard Capacity

Item	Specified Condition
for LHD	3.1 liters (3.3 US qts, 2.7 Imp. qts.)
for RHD	2.9 liters (3.0 US qts, 2.6 Imp. qts.)

Note

To prevent foreign matter such as dust or dirt from entering the cooling system, make sure to confirm that the container used to add coolant is clean and free of foreign matter such as dust or dirt.

When using the GTS:

Connect the GTS to the DLC3.
Turn the power switch on (IG).
Enter the following menus: Powertrain / Hybrid Control / Active Test / Activate the Water Pump.

Keep the coolant at the FULL line in the reservoir 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 reservoir tank improves.

Tech Tips

If free spinning of the inverter water pump is detected for approximately 5 seconds, failsafe control will be activated to suspend the operation of the pump for approximately 15 seconds and resume operation for approximately 4 seconds repeatedly. Operation of the inverter water pump will return to normal if coolant is added.
Loud noise made by the inverter water pump and poor circulation of coolant in the reservoir tank indicates that there is air in the cooling system.

When not using the GTS:

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

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 reservoir tank improves.

Tech Tips

Loud noise made by the inverter water pump and poor circulation of coolant in the reservoir tank indicates that there is air in the cooling system.

After the air is completely bled from the cooling system, tighten the reservoir tank cap.
Add coolant to the FULL line of the reservoir tank.

INSPECT FOR COOLANT LEAK (for Inverter)
1. Remove the reservoir tank cap (for inverter).
  
  CAUTION:
  
  To avoid the danger of being burned, do not remove the reservoir tank cap while the coolant for the inverter is still hot.
2. Install the radiator cap tester.
3. Pump the radiator cap tester to 137 kPa (1.4 kgf/ cm², 20 psi), and then check that the pressure does not drop.
  
  Tech Tips
  
  If the pressure drops, check the hoses, radiator, water pump, inverter with converter, and hybrid vehicle transaxle assembly for leaks.
4. Reinstall the reservoir tank cap (for inverter).
INSTALL V-BANK COVER SUB-ASSEMBLY
1. Text in Illustration
  
  *1 Tip (Round Portion)
  
  Attach the 3 clips in the order shown in the illustration to install the V-bank cover.
  Note
  - Securely attach the clips.
  - If the clips are forcibly attached or struck with an object, they may be damaged.
  - Do not apply any oil to the tips (round portions).
INSTALL INVERTER COVER
1. Attach the 2 inverter cover claws to the inverter with converter. Then attach the inverter cover with the clip.
INSTALL NO. 2 ENGINE UNDER COVER
1. Install the No. 2 engine under cover with the 4 screws and 2 grommets.
INSTALL FRONT SUSPENSION MEMBER BRACE
1. Install the front suspension member brace with the clip and 4 bolts.
  
  Torque:
  
  52 N*m { 530 kgf*cm, 38 ft.*lbf }
INSTALL ENGINE UNDER COVER
1. Install the engine under cover with the 13 screws and 3 clips.
INSTALL NO. 1 AIR CLEANER INLET
1. Install the No. 1 air cleaner inlet with the bolt.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL COOL AIR INTAKE DUCT SEAL
1. Install the cool air intake duct seal with the 7 clips.
INSTALL ENGINE ROOM SIDE COVER
1. Install the engine room side cover with the 4 clips.
INSTALL LUGGAGE COMPARTMENT TRIM COVER LH
1. Install the luggage compartment trim cover.
INSTALL LUGGAGE COMPARTMENT FLOOR MAT
1. Install the luggage compartment floor mat.