Voltage Inverter: Service and Repair

Inverter With Converter:

REMOVAL

1. OBSERVE PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE
2. REMOVE ENGINE ROOM SIDE LH COVER NO.2
3. REMOVE ENGINE ROOM COVER SIDE
4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
5. REMOVE SERVICE PLUG GRIP
6. DRAIN COOLANT (for Inverter)
7. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH
8. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH
9. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY
10. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
11. REMOVE REMOVE COWL TOP PANEL SUBASSEMBLY OUTER
12. REMOVE COOL AIR INTAKE DUCT SEAL
13. REMOVE AIR CLEANER CAP W/INLET
14. REMOVE AIR CLEANER W/RESONATOR
15. REMOVE INVERTER BRACKET NO.5
16. REMOVE POWER STEERING ECU ASSEMBLY

17. DISCONNECT CIRCUIT BREAKER SENSOR NO.1

a. Move the outer section to the wire harness side as illustrated, then disconnect the circuit breaker sensor No.1.

18. DISCONNECT ENGINE ROOM WIRE NO.2

a. Remove the nut from the engine room wire No.2.
b. Release the claw, and disconnect the engine room wire No.2.

19. REMOVE INVERTER RESERVE TANK SUBASSEMBLY

a. Remove the 2 bolts and inverter reserve tank subassembly.

b. Slide the 2 clamps, and disconnect the 2 water hoses from the inverter reserve tank sub-assembly.

20. DISCONNECT WATER HOSE

a. Slide the clamp, and disconnect the water hose from the w/ converter inverter assembly.

21. DISCONNECT POWER STEERING ECU BRACKET

a. Remove the bolt, and disconnect the power steering ECU bracket.

22. REMOVE INVERTER COVER

a. Remove the bolt and interlock bracket.

b. Insulate the removed terminal with insulating tape.

NOTE: Make sure that the terminal does not stick out from the insulating tape.

c. Remove the 12 bolts and inverter cover.

23. VERIFY THAT VOLTAGE OF W/CONVERTER INVERTER ASSEMBLY IS 0 V

CAUTION: Wear insulating gloves.

NOTE:
- Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly.
- Do not allow any foreign objects or water drops to enter the w/ converter inverter assembly.

a. Using the voltmeter, measure the voltage between the terminals of the 2 phase connectors (N-P).

Standard voltage: 0 V

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

24. SEPARATE ENGINE WIRE NO.4

CAUTION: Wear insulating gloves.

NOTE:
- Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly.
- Do not allow any foreign objects or water drops to enter the w/ converter inverter assembly.

a. Remove the bolt, and disconnect the engine wire No.4 from the w/ converter inverter assembly.
b. Disconnect the connector, clamps and grommet, and separate the engine wire No.4 from the w/ converter inverter assembly.

25. DISCONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR

CAUTION: Wear insulating gloves.

NOTE:
- Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly.
- Insulate the removed terminals with insulating tape.
- Do not allow any foreign objects or water drops to enter the w/ converter inverter assembly.

a. Remove the 5 bolts, and disconnect the high voltage cables of the Motor from the w/ converter inverter assembly.

b. Remove the 5 bolts, and disconnect the high voltage cables of the Generator from the w/ converter inverter assembly.

26. DISCONNECT MG ECU CONNECTOR

CAUTION: Wear insulating gloves.

NOTE:
- Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly.
- Do not allow any foreign objects or water drops to enter the w/ converter inverter assembly.

a. Disconnect the 2 connectors and grommets from the w/ converter inverter assembly.

27. DISCONNECT NO.3 WIRE FRAME

CAUTION: Wear insulating gloves.

NOTE:
- Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly.
- Insulate the removed terminals with insulating tape.
- Do not allow any foreign objects or water drops to enter the w/ converter inverter assembly.

a. Remove the 5 bolts, and disconnect the No.3 wire frame (high voltage cables of the rear motor) from the w/ converter inverter assembly. (for 4WD)

b. Remove the bolt and lift the lever to disconnect the No.3 wire frame from the w/ converter inverter assembly.

28. INSTALL INVERTER COVER

a. Temporarily install the inverter cover with the 2 bolts to prevent any foreign objects or water drops from entering the w/ converter inverter assembly.

29. SEPARATE ENGINE ROOM RELAY BLOCK ASSEMBLY

a. Disconnect the clamp, and release the engine room relay block assembly.

30. REMOVE INVERTER BRACKET NO.4

a. Remove the 2 bolts and inverter bracket No.4.

31. REMOVE W/CONVERTER INVERTER ASSEMBLY

CAUTION: Wear insulating gloves.

a. Remove the 2 nuts, bolt and w/ converter inverter assembly.

NOTE:
- 2 people are needed to remove the w/ converter inverter assembly.
- If removing and storing the w/ converter inverter assembly, make sure to install the inverter cover to prevent any foreign objects or water drops from entering the w/ converter inverter assembly.
- Attach tape or equivalent (any adhesive should not be remained) to the holes for the connectors and grommets to prevent foreign matter or water from entering.

INSTALLATION

1. INSTALL W/CONVERTER INVERTER ASSEMBLY

CAUTION: Wear insulating gloves.

a. Install the w/ converter inverter assembly with the 2 nuts and bolt.

Torque: 21 N.m (214 kgf.cm, 15 ft.lbf)

NOTE: 2 people are needed to install the w/ converter inverter assembly.

2. INSTALL INVERTER BRACKET NO.4

a. Install the inverter bracket No.4 with the 2 bolts.

Torque: 21 N.m (214 kgf.cm, 15 ft.lbf)

3. INSTALL ENGINE ROOM RELAY BLOCK ASSEMBLY

a. Install the engine room relay block assembly.

4. REMOVE INVERTER COVER

a. Remove the 2 bolts and inverter cover to the w/ converter inverter assembly.

5. CONNECT NO.3 WIRE FRAME

CAUTION: Wear insulating gloves.

NOTE:
- Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly.
- Do not allow any foreign objects or water drops to enter the w/ converter inverter assembly.

a. After connecting the connector, press the lever down to connect the No.3 wire frame and install the bolt to the w/ converter inverter assembly.

Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)

b. Connect the No.3 wire frame (high voltage cable of the rear motor) with the 5 bolts to the w/ converter inverter assembly. (for 4WD)

Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)

6. CONNECT MG ECU CONNECTOR

CAUTION: Wear insulating gloves.

NOTE:
- Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly.
- Do not allow any foreign objects or water drops to enter the w/ converter inverter assembly.

a. Connect the 2 connectors and 2 grommets to the w/ converter inverter assembly.

7. CONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR

CAUTION: Wear insulating gloves.

NOTE:
- Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly.
- Do not allow any foreign objects or water drops to enter the w/ converter inverter assembly.

a. Connect the high voltage cable of the Generator with the 5 bolts to the w/ converter inverter assembly.

Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)

b. Connect the high voltage cable of the Motor with the 5 bolts to the w/ converter inverter assembly.

Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)

8. CONNECT ENGINE WIRE NO.4

CAUTION: Wear insulating gloves.

NOTE:
- Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly.
- Do not allow any foreign objects or water drops to enter the w/ converter inverter assembly.

a. Connect the engine wire No.4 with the connector, clamp and grommet to the w/ converter inverter assembly.
b. Connect the engine wire No.4 with the bolt to the w/ converter inverter assembly.

Torque: 5. 4 N.m (55 kgf.cm, 48 in.lbf)

9. CHECK HIGH VOLTAGE CABLE CONNECTION

CAUTION: Wear insulating gloves.

NOTE:
- Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly.
- Do not allow any foreign objects or water drops to enter the w/ converter inverter assembly.

a. Check that each connector and terminal is firmly installed.

NOTE:
- Make sure that the connectors are fully engaged.
- Make sure that the bolts are fully tightened.

10. INSTALL INVERTER COVER

a. Install the inverter cover with the 12 bolts to the w/ converter inverter assembly.

Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)

b. Install the interlock bracket with the bolt to the w/ converter inverter assembly.

Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)

11. INSTALL POWER STEERING ECU BRACKET

a. Install the power steering ECU bracket with the bolt to the w/ converter inverter assembly.

Torque: 8.0 N.m (82 kgf.cm,71 in.lbf)

12. CONNECT WATER HOSE

a. Connect the water hose with the clamp to the w/ converter inverter assembly.

13. INSTALL INVERTER RESERVE TANK SUBASSEMBLY

a. Connect the 2 water hoses with the 2 clamps to the inverter reserve tank sub-assembly.

b. Install the inverter reserve tank with the 2 bolts to the w/ converter inverter assembly.

Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)

14. CONNECT ENGINE ROOM WIRE NO.2

a. Connect the engine room wire No.2 with the nut.

Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf)

15. CONNECT CIRCUIT BREAKER SENSOR NO.1

a. Connect the circuit breaker sensor No.1 connector.

16. INSTALL POWER STEERING ECU ASSEMBLY
17. INSTALL INVERTER BRACKET NO.5
18. INSTALL AIR CLEANER W/RESONATOR
19. INSTALL AIR CLEANER CAP W/INLET
20. INSTALL COOL AIR INTAKE DUCT SEAL
21. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER
22. INSTALL WINDSHIELD WIPER LINK ASSEMBLY
23. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
24. INSTALL FR WIPER ARM LH
25. INSTALL FR WIPER ARM RH
26. INSTALL ENGINE ROOM COVER SIDE
27. INSTALL ENGINE ROOM SIDE LH COVER NO.2
28. INSTALL SERVICE PLUG GRIP
29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
30. ADD COOLANT (for Inverter)
31. INSPECT FOR COOLANT LEAK (for Inverter)

32. PERFORM INITIALIZATION
a. Some systems need initialization when disconnecting the cable from the negative battery terminal.