Voltage Converter: Service and Repair

Inverter With Converter:

REMOVAL

CAUTION:
- When working on high voltage systems, always wear insulating gloves.
- Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle.
- After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes.

NOTE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU.

1. PRECAUTION

CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/removal, inspection and replacement of parts), be sure to follow the procedures.

2. REMOVE ENGINE UNDER COVER LH
3. REMOVE ENGINE UNDER COVER RH
4. DRAIN HV COOLANT
5. REMOVE REAR NO. 2 FLOOR BOARD
6. REMOVE REAR DECK FLOOR BOX
7. REMOVE REAR NO. 3 FLOOR BOARD
8. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

9. REMOVE SERVICE PLUG GRIP
10. REMOVE FRONT WIPER ARM COVER
11. REMOVE FRONT WIPER ARM RH
12. REMOVE FRONT WIPER ARM LH
13. REMOVE HOOD TO COWL TOP SEAL
14. REMOVE COWL TOP VENTILATOR LOUVER LH
15. REMOVE COWL TOP VENTILATOR LOUVER RH
16. REMOVE FRONT WIPER LINK AND WIPER MOTOR ASSEMBLY
17. REMOVE FRONT COWL TOP PANEL OUTER
18. REMOVE RADIATOR SUPPORT OPENING COVER
19. REMOVE INVERTER COVER

a. Using a T30 "torx" socket, remove the screw.
b. Remove the 12 bolts and inverter cover.

20. VERIFY THAT VOLTAGE OF INVERTER WITH CONVERTER IS 0 V

CAUTION: Wear insulating gloves.

a. Using a voltmeter, measure the voltage of the high voltage DC line.

Standard voltage: 0 V

HINT: Use a measuring range of DC 400 V or more on the voltmeter.

b. Using the voltmeter, measure the voltage between the terminals of the three phase connector (U - V, V - W, U - W).

Standard voltage: 0 V

HINT: Use a measuring range of DC 400 V or more on the voltmeter.

21. DISCONNECT NO. 2 INVERTER COOLING HOSE

22. DISCONNECT NO. 1 INVERTER COOLING HOSE

23. DISCONNECT NO. 6 INVERTER COOLING HOSE
24. DISCONNECT NO. 1 CIRCUIT BREAKER SENSOR

a. Move the outer section to the wire harness side as illustrated, and then disconnect the circuit breaker sensor.

25. DISCONNECT FRAME WIRE

CAUTION:
- Wear insulating gloves.
- After removing the service plug grip, be sure to wait for at least 5 minutes before performing any work.
- Insulate the electrode and connector parts with insulating tape.

a. Remove the 2 frame wire connectors from the inverter with converter assembly.

26. REMOVE INVERTER WITH CONVERTER ASSEMBLY

a. Using a small screwdriver, lift up the lock pin (green) as illustrated to unlock it.

CAUTION: Wear insulating gloves.

b. Disconnect the connector for the air conditioning inverter.

CAUTION: Wear insulating gloves.

c. Disconnect the 3 connectors shown in the illustration.

d. Disconnect the 3 connectors shown in the illustration and the engine main wire harness.

e. Remove the 5 bolts, then disconnect the MG2 power cable.

CAUTION:
- Wear insulating gloves.
- Insulate the connector parts with insulating tape.

f. Remove the 5 bolts, then disconnect the MG1 power cable.

CAUTION:
- Wear insulating gloves.
- Insulate the connector parts with insulating tape.

g. Remove the 3 bolts and the inverter with converter assembly.

h. Disconnect the connector for the air conditioning inverter from the bracket.
i. Remove the bolt and connector bracket for the air conditioning inverter.

27. REMOVE NO. 1 INVERTER BRACKET

a. Remove the 2 bolts and inverter bracket.

28. REMOVE NO. 2 INVERTER BRACKET

a. Remove the 2 bolts and inverter bracket.

29. REMOVE NO. 1 CIRCUIT BREAKER SENSOR

a. Remove the 2 bolts and circuit breaker sensor.

INSTALLATION

1. INSTALL NO. 1 CIRCUIT BREAKER SENSOR

a. Install the circuit breaker sensor with the 2 bolts.

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

2. INSTALL NO. 2 INVERTER BRACKET

a. Install the inverter bracket with the 2 bolts.

Torque: 25 N.m (255 kgf.cm, 18 in.lbf)

3. INSTALL NO. 1 INVERTER BRACKET

a. Install the inverter bracket with the 2 bolts.

Torque: 25 N.m (255 kgf.cm, 18 in.lbf)

4. INSTALL INVERTER WITH CONVERTER ASSEMBLY

a. Install the connector bracket for the air conditioning inverter with the bolt.

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

b. Install the connector for the air conditioning inverter on the bracket.

c. Install the inverter with converter assembly with the 3 bolts.

Torque: 21 N.m (214 kgf.cm, 16 in.lbf)

CAUTION: Wear insulating gloves.

d. Install the MG1 power cable to the MG1 power cable terminal with the 5 bolts.

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

CAUTION: Wear insulating gloves.

e. Install the MG2 power cable to the MG2 power cable terminal with the 3 bolts.

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

CAUTION: Wear insulating gloves.

f. Connect the 3 connectors shown in the illustration.

CAUTION: Wear insulating gloves.

g. Insert the grommet of the engine main wire harness into the U-shaped groove of the inverter case.

CAUTION: Wear insulating gloves.

h. Connect the 3 connectors shown in the illustration.

CAUTION: Wear insulating gloves.

i. Connect the connector for the air conditioning inverter, then lock the connector with the lock pin.

CAUTION: Wear insulating gloves.

5. CONNECT FRAME WIRE

a. Connect the 2 frame wire connectors to the inverter with converter assembly.

CAUTION: Wear insulating gloves.

6. CONNECT NO. 1 CIRCUIT BREAKER SENSOR

CAUTION: Wear insulating gloves.

7. CONNECT NO. 6 INVERTER COOLING HOSE
8. CONNECT NO. 1 INVERTER COOLING HOSE
9. CONNECT NO. 2 INVERTER COOLING HOSE
10. INSTALL INVERTER COVER

a. Temporarily fasten the inverter cover with the 12 bolts and "torx" screw.
b. Tighten the 12 bolts.

Torque: 11 N.m (112 kgf.cm, 8.1 in.lbf)

c. Using a T30 "torx" socket, tighten the "torx" screw.

Torque: 11 N.m (112 kgf.cm, 8.1 in.lbf)

11. INSTALL RADIATOR SUPPORT OPENING COVER
12. INSTALL FRONT COWL TOP PANEL OUTER
13. INSTALL WINDSHIELD WIPER LINK AND WIPER MOTOR ASSEMBLY
14. INSTALL COWL TOP VENTILATOR LOUVER RH
15. INSTALL COWL TOP VENTILATOR LOUVER LH
16. INSTALL HOOD TO COWL TOP SEAL
17. INSTALL FRONT WIPER ARM LH
18. INSTALL FRONT WIPER ARM RH
19. INSTALL WINDSHIELD WIPER ARM COVER
20. INSTALL SERVICE PLUG GRIP
21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
22. INSTALL REAR NO. 3 FLOOR BOARD
23. INSTALL REAR DECK FLOOR BOX
24. INSTALL REAR NO. 2 FLOOR BOARD
25. ADD HV COOLANT
26. CHECK FOR ENGINE COOLANT LEAKAGE
27. INSTALL ENGINE UNDER COVER RH
28. INSTALL ENGINE UNDER COVER LH
29. PERFORM INITIALIZATION
a. Perform initialization.

NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.