Voltage Inverter: Service and Repair
REMOVAL1. OBSERVE PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE
2. REMOVE LUGGAGE COMPARTMENT FLOOR MAT
3. REMOVE BATTERY SERVICE HOLE COVER LH
4. 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.
5. REMOVE SERVICE PLUG GRIP
6. REMOVE COOL AIR INTAKE DUCT SEAL
7. REMOVE ENGINE ROOM SIDE COVER LH
8. REMOVE ENGINE ROOM SIDE COVER RH
9. REMOVE NO. 2 ENGINE ROOM SIDE RH COVER
a. Pull the A part upward to disengage the clip.
b. Pull the B parts upward by hand to disengage the 2 clips, and remove the No. 2 engine room side cover RH.
10. REMOVE FRONT UPPER FENDER PROTECTOR LH
11. REMOVE FRONT UPPER FENDER PROTECTOR RH
12. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH
13. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH
14. REMOVE FRONT FENDER TO COWL SIDE SEAL LH
15. REMOVE FRONT FENDER TO COWL SIDE SEAL RH
16. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY
17. REMOVE ENGINE UNDER COVER
18. REMOVE NO. 2 ENGINE UNDER COVER
19. DRAIN COOLANT (for Inverter)
20. REMOVE CONNECTOR COVER ASSEMBLY
a. Remove the 2 bolts and connector cover assembly.
CAUTION: Wear insulating gloves.
21. CHECK TERMINAL VOLTAGE
a. Using the voltmeter, measure the voltage between the terminals of the 2 phase connectors (N-P).
Standard voltage: 0 V
CAUTION: Wear insulating gloves.
HINT: Use measuring range of DC 750 V or more on the voltmeter.
22. SEPARATE GENERATOR CABLE
a. Remove the 2 bolts (A).
CAUTION: Wear insulating gloves.
NOTE: Removing bolts A and B in a wrong order may cause the cable and the inverter with converter to break.
b. While loosening bolt B, disconnect the generator cable.
CAUTION: Wear insulating gloves.
NOTE:
- Removing bolts A and B in a wrong order may cause the cable and the inverter with converter to break.
- Insulate the removed terminals with insulating tape.
- Cover the hole where the cable was connected with tape or equivalent (nonresidue type) to prevent entry of foreign matter.
23. SEPARATE MOTOR CABLE
a. Remove the 2 bolts (A).
CAUTION: Wear insulating gloves.
NOTE: Removing bolts A and B in a wrong order may cause the cable and the inverter with converter to break.
b. While loosening bolt B, disconnect the motor cable.
CAUTION: Wear insulating gloves.
NOTE:
- Removing bolts A and B may cause the cable and the inverter with converter to break.
- Insulate the removed terminals with insulating tape.
- Cover the hole where the cable was connected with tape or equivalent (nonresidue type) to prevent entry of foreign matter.
c. Remove the 2 nuts and disconnect the inverter motor cable bracket.
24. SEPARATE AIR CONDITIONING HARNESS ASSEMBLY
a. Disconnect the air conditioning harness assembly.
CAUTION: Wear insulating gloves.
NOTE: Insulate the removed terminals with insulating tape.
25. SEPARATE FRAME WIRE
a. Remove the bolt and disconnect the frame wire.
CAUTION: Wear insulating gloves.
NOTE: Insulate the removed terminals with insulating tape.
26. REMOVE NO. 6 INVERTER BRACKET
a. Remove the 2 bolts and No. 6 inverter bracket.
27. REMOVE INVERTER WITH CONVERTER ASSEMBLY
a. Raise the lock lever and disconnect the inverter with converter connector.
NOTE: Cover the hole where the connector was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter.
b. Disconnect the wire harness clamp.
c. Remove the 2 clips, and disconnect the No. 8 inverter cooling hose and No. 13 inverter cooling hose.
NOTE: Cover the disconnected water hose and pipe with a plastic bag and tape to prevent coolant from spilling.
d. Remove the 4 bolts and inverter with converter assembly.
CAUTION: Wear insulating gloves.
NOTE: 2 people are needed to remove the inverter with converter assembly.
28. REMOVE HIGH VOLTAGE FUSE
a. Remove the 2 nuts and high voltage fuse.
CAUTION: Wear insulating gloves.
INSTALLATION
1. INSTALL HIGH VOLTAGE FUSE
a. Install the high voltage fuse with 2 new nuts.
Torque: 4.0 N.m (41 kgf.cm, 35 in.lbf)
CAUTION: Wear insulating gloves.
NOTE: Be sure to use a torque wrench to tighten the nuts.
2. INSTALL INVERTER WITH CONVERTER ASSEMBLY
a. Install the inverter with converter assembly with 4 new bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
CAUTION: Wear insulating gloves.
NOTE: 2 people are needed to remove the inverter with converter assembly.
b. Connect the No. 8 inverter cooling hose and No. 13 inverter cooling hose with the 2 clips.
c. Connect the inverter with converter connector and lock the connector with the lock lever.
d. Connect the wire harness clamp.
3. INSTALL NO. 6 INVERTER BRACKET
a. Install the No. 6 inverter bracket with 2 new bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
4. CONNECT FRAME WIRE
a. Connect the frame wire to the inverter with converter assembly.
b. Fix the frame wire to the inverter with converter assembly with the bolt.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
CAUTION: Wear insulating gloves.
5. REMOVE AIR CONDITIONING HARNESS ASSEMBLY
a. Connect the air conditioning harness assembly to the inverter with converter assembly.
CAUTION: Wear insulating gloves.
6. CONNECT MOTOR CABLE
a. Connect the motor cable. Tighten bolt B and insert the motor cable into the inverter with converter assembly.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
CAUTION: Wear insulating gloves.
NOTE:
- Tightening bolts A and B in a wrong order may cause the cable and the inverter with converter to break.
- Make sure that the tightening torque is between 6.4 and 9.6 N.m (65 and 98 kgf.cm, 57 and 85 in.lbf).
b. Fix the motor cable to the inverter with converter assembly with the 2 bolts (A).
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
CAUTION: Wear insulating gloves.
NOTE:
- Tightening bolts A and B in a wrong order may cause the cable and the inverter with converter to break.
- Make sure that the tightening torque is between 6.4 and 9.6 N.m (65 and 98 kgf.cm, 57 and 85 in.lbf).
c. Install the inverter motor cable bracket with the 2 nuts (C).
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
NOTE: Make sure that the tightening torque is between 6.4 and 9.6 N.m (65 and 98 kgf.cm, 57 and 85 in.lbf).
7. CONNECT GENERATOR CABLE
a. Connect the generator cable. Tighten bolt B and insert the generator cable into the inverter with converter.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
CAUTION: Wear insulating gloves.
NOTE:
- Tightening bolts A and B in a wrong order may cause the cable and the inverter with converter to break.
- Make sure that the tightening torque is between 6.4 and 9.6 N.m (65 and 98 kgf.cm, 57 and 85 in.lbf).
b. Fix the generator cable to the inverter with converter assembly with the 2 bolts (A).
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
CAUTION: Wear insulating gloves.
NOTE:
- Tightening bolts A and B in a wrong order may cause the cable and the inverter with converter to break.
- Make sure that the tightening torque is between 6.4 and 9.6 N.m (65 and 98 kgf.cm, 57 and 85 in.lbf).
8. INSTALL CONNECTOR COVER ASSEMBLY
a. Install the connector cover assembly with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
CAUTION: Wear insulating gloves.
9. INSTALL SERVICE PLUG GRIP
10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
11. INSTALL BATTERY SERVICE HOLE COVER LH
12. INSTALL LUGGAGE COMPARTMENT FLOOR MAT
13. ADD COOLANT (for Inverter)
14. CHECK FOR COOLANT LEAKS (for Inverter)
15. INSTALL NO. 2 ENGINE UNDER COVER
16. INSTALL ENGINE UNDER COVER
17. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY
18. INSTALL FRONT FENDER TO COWL SIDE SEAL LH
19. INSTALL FRONT FENDER TO COWL SIDE SEAL RH
20. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH
21. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH
22. INSTALL FRONT UPPER FENDER PROTECTOR LH
23. INSTALL FRONT UPPER FENDER PROTECTOR RH
24. INSTALL NO. 2 ENGINE ROOM SIDE RH COVER
a. Engage the 3 clips and install the No. 2 engine room side RH cover.
25. INSTALL ENGINE ROOM SIDE COVER LH
26. INSTALL ENGINE ROOM SIDE COVER RH
27. INSTALL COOL AIR INTAKE DUCT SEAL
28. PERFORM INITIALIZATION
a. Perform initialization procedure.
NOTE: Some vehicle systems require initialization after reconnecting the cable to the negative battery terminal.