PRECAUTION
Tech Tips
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.
REMOVE BATTERY SERVICE HOLE COVER
Disengage the 2 clips and 2 guides, and remove the battery service hole cover.
Tech Tips
Because these are 2-piece clips, one side will remain in the bracket when they are being removed.
REMOVE SERVICE PLUG GRIP
CAUTION:
Remove the service plug grip to interrupt a high voltage circuit at the time of the check.
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 orange colored.
Wear insulated gloves. Remove the service plug grip after sliding the lever of the service plug grip.
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 disconnecting the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals.
Tech Tips
Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.
REMOVE NO. 1 ENGINE UNDER COVER
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.
Remove the inverter reserve tank cap.
CAUTION:
To avoid the danger of being burned, do not remove the inverter reserve tank cap while the coolant for the inverter is still hot.
Loosen 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.
Tighten the plug.
REMOVE AIR CLEANER ASSEMBLY WITH HOSE
Tech Tips
REMOVE NO. 3 INVERTER BRACKET
Disconnect the water hose clamp from the No. 3 inverter bracket.
Remove the bolt, nut and No. 3 inverter bracket.
REMOVE INVERTER RESERVE TANK ASSEMBLY
Disconnect the hose from the inverter reserve tank.
Slide the 3 hose clamps, and disconnect the 3 water hoses from the inverter reserve tank assembly.
Remove the bolt, nut and inverter reserve tank assembly.
REMOVE NO. 1 INVERTER RESERVE TANK BRACKET
Remove the 2 bolts and No. 1 inverter reserve tank bracket.
REMOVE INVERTER TERMINAL COVER
CAUTION:
Wear insulating gloves.
Remove the 11 bolts and inverter terminal cover.
Note
Make sure to pull the inverter cover straight up, as a connector is connected to the bottom of the cover.
CHECK TERMINAL VOLTAGE
CAUTION:
Wear insulating gloves.
Note
Insulate the removed terminals with insulating tape.
Do not allow any foreign objects or water to enter the inverter with converter assembly.
Using a voltmeter, measure the voltage between the 2 terminals.
Standard voltage |
---|
0 V |
Tech Tips
Use a measuring range of DC 750 V or more on the voltmeter.
DISCONNECT NO. 4 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.
Remove the 5 bolts, and disconnect the No. 4 engine wire (high voltage cables of the air conditioning) from the inverter with converter assembly.
DISCONNECT NO. 3 WIRE FRAME (for AWD)
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.
Remove the 5 bolts, and disconnect the No. 3 wire frame (high voltage cables of the rear motor (MGR)) from the inverter with converter assembly.
Disconnect the harness clamp.
DISCONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR
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.
Remove the 5 bolts, and disconnect the high voltage cables of the generator (MG1) from the inverter with converter assembly.
Remove the 5 bolts, and disconnect the high voltage cables of the motor (MG2) from the inverter with converter assembly.
DISCONNECT NO. 3 WIRE FRAME
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.
Remove the 4 bolts, and disconnect the No. 3 wire frame (high voltage cables of the hybrid battery) from the inverter with converter assembly.
Disconnect the 3 harness clamps.
INSTALL INVERTER TERMINAL COVER
Temporarily install the inverter cover with the 11 bolts to prevent any foreign objects or water from entering the inverter with converter assembly.
REMOVE NO. 6 INVERTER BRACKET (w/ Bracket)
Remove the 2 bolts and No. 6 inverter bracket.
SEPARATE RELAY BLOCK SUB-ASSEMBLY
Disconnect the clamp, and release the relay block sub-assembly.
DISCONNECT MG ECU CONNECTOR
CAUTION:
Wear insulating gloves.
Note
Insulate the removed terminals with insulating tape.
Do not allow any foreign objects or water to enter the inverter with converter assembly.
To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.
Raise the lock lever and disconnect the inverter with converter connector.
Disconnect the connector from the inverter with converter assembly.
DISCONNECT WATER HOSE
Slide the 2 clamps, and disconnect the 2 water hoses from the inverter with converter assembly.
*1 | Retainer |
Release the retainer and disconnect the water hose from the inverter with converter assembly.
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 in order to prevent coolant from spilling around the inverter with converter assembly.
DISCONNECT NO. 2 ENGINE ROOM WIRE
Remove the relay block cover.
Remove the nut from the No. 2 engine room wire.
Release the claw, and disconnect the No. 2 engine room wire.
Disconnect the clamp.
REMOVE NO. 4 INVERTER BRACKET
Remove the bolt, nut and No. 4 inverter bracket.
SEPARATE RADIATOR RESERVE TANK ASSEMBLY
Disconnect the 2 clamps and remove the bolt and radiator reserve tank from the radiator.
SEPARATE CONDENSER
Remove the bolt, and separate the condenser.
REMOVE INVERTER WITH CONVERTER ASSEMBLY
CAUTION:
Wear insulating gloves.
Remove the 2 bolts, nut 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.
REMOVE INVERTER DRAIN HOSE
Slide the clip and remove the inverter drain hose from the inverter with converter assembly.
REMOVE INVERTER COOLING PIPE
Slide the clip and disconnect the inlet No. 2 inverter cooling hose from the inverter with converter assembly.
Remove the 2 bolts and inverter cooling pipe from the inverter with converter assembly.
REMOVE HIGH VOLTAGE FUSE
CAUTION:
Wear insulating gloves.
Tech Tips
Perform this procedure only when replacement of the high voltage fuse is necessary.
Remove the 11 bolts and inverter terminal cover.
Note
Make sure to pull the inverter cover straight up, as a connector is connected to the bottom of the cover.
Remove the 2 nuts 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.
Temporarily install the inverter cover with the 11 bolts to prevent any foreign objects or water from entering the inverter with converter assembly.
Place the high voltage fuse as shown in the illustration.
Tech Tips
Either the location shown in the illustration or other methods can be used to hold the high voltage fuse for the subsequent step.
Remove the 2 nuts and high voltage fuse from the holder.