RM38T0EC _51 Engine / Hybrid System _144957 HYBRID / BATTERY CONTROL _0604245 INVERTER WITH CONVERTER A

HYBRID / BATTERY CONTROL  INVERTER WITH CONVERTER  INSTALLATION  


CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)
A521675N03
5.479,3.156 6.479,3.323 1,0.167 4.729,1.344 5.813,1.594 1.083,0.25 4.771,1.385 5.771,1.552 1,0.167 3.938,0.458 4.688,0.625 0.75,0.167 0.906,0.656 1.656,0.823 0.75,0.167 4.979,1.896 5.979,2.063 1,0.167 3.031,0.604 2.948,0.333 2.948,0.333 2.781,0.333 false 3.625,2.698 3.583,2.865 3.583,2.865 3.49,2.865 false 5.021,2.542 5.354,2.542 false 4.76,1.469 4.635,1.469 4.635,1.469 4.396,2.385 false 4.969,1.979 4.844,1.979 4.844,1.979 4.771,2.271 false 5.469,3.24 5.344,3.24 5.344,3.24 5.229,3.406 false 1.667,0.75 1.885,0.75 false 3.677,0.542 3.938,0.542 false 2.25,0.208 3.052,0.563 0.802,0.354 18 false 1, 4 3.75,0.573 4.042,0.74 0.292,0.167 10 false x4 2.75,0.635 3.042,0.802 0.292,0.167 10 false x 2 5.667,2.448 6.219,2.802 0.552,0.354 18 false 3 3.229,2.729 3.781,3.083 0.552,0.354 18 false 2 5.313,3.375 5.604,3.542 0.292,0.167 10 false x3 2.042,0.688 2.333,0.854 0.292,0.167 10 false x2 4.854,2.198 5.146,2.365 0.292,0.167 10 false x4 4.521,2.458 4.813,2.625 0.292,0.167 10 false x6 4.844,1.385 5.979,1.667 1.135,0.281 8 false 8.0 (82, 71 in.*lbf) 5.042,1.896 6.177,2.177 1.135,0.281 8 false 8.0 (82, 71 in.*lbf) 5.542,3.156 6.677,3.438 1.135,0.281 8 false 8.0 (82, 71 in.*lbf) 4.01,0.458 5.146,0.74 1.135,0.281 8 false 55 (561, 41) 0.99,0.656 2.125,0.938 1.135,0.281 8 false 55 (561, 41)

Procedure Part Name Code
Z101186

Z101188

Z101187

1 SET INVERTER WITH CONVERTER ASSEMBLY G9200 (Click here) - -
2 MOTOR CABLE G1148 (Click here) - -
3 UPPER INVERTER COVER G9221 (Click here) - -
4 INSTALL INVERTER WITH CONVERTER ASSEMBLY G9200 (Click here) - -

V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)
V100146

N*m (kgf*cm, ft.*lbf): Specified torque

A521674N02
2.208,2.219 2.875,2.385 0.667,0.167 4.323,0.406 4.99,0.573 0.667,0.167 2.167,2.177 2.917,2.427 0.75,0.25 1.156,2.323 1.281,1.771 1.281,1.771 1.417,1.771 false 2.604,1.458 2.729,1.458 2.729,1.458 2.948,1.688 false 2.781,0.802 3.031,0.271 3.031,0.271 3.167,0.271 false 4.76,1.042 5.104,1.042 false 6.094,1.344 6.198,1.031 6.198,1.031 6.333,1.031 false 2.552,2.208 2.552,2.01 false 4.063,0.667 4.177,0.49 4.177,0.49 4.313,0.49 false 4.177,0.667 4.49,0.865 0.313,0.198 10 false x3 1.719,1.646 2.125,1.979 0.406,0.333 18 false 6 2.385,1.333 2.792,1.667 0.406,0.333 18 false 5 5.396,0.885 5.802,1.219 0.406,0.333 18 false 8 6.667,0.906 7.073,1.24 0.406,0.333 18 false 9 3.458,0.177 3.865,0.51 0.406,0.333 18 false 7 2.625,1.969 2.938,2.167 0.313,0.198 10 false x2 2.271,2.219 3,2.448 0.729,0.229 8 false 10 (102, 7) 4.385,0.406 5.115,0.635 0.729,0.229 8 false 10 (102, 7)

Procedure Part Name Code
Z101186

Z101188

Z101187

5 NO. 7 ENGINE, WIRE 82127D - - -
6 INLET NO. 1 INVERTER COOLING HOSE G922AA (Click here) - -
7 OUTLET NO. 1 INVERTER COOLING HOSE G922C (Click here) - -
8 ENGINE WIRE 82121 (Click here) - -
9 ENGINE ROOM MAIN WIRE 82111 (Click here) - -

V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)
V100146

N*m (kgf*cm, ft.*lbf): Specified torque

A521673N02
0.604,2.458 1.688,2.625 1.083,0.167 4.75,0.719 5.417,0.885 0.667,0.167 5.5,1.813 6.167,1.979 0.667,0.167 4.719,3.677 5.802,3.844 1.083,0.167 4.635,1.573 5.719,1.74 1.083,0.167 0.875,0.094 1.958,0.26 1.083,0.167 4.677,3.635 5.844,3.885 1.167,0.25 4.563,1.333 5.01,1.333 false 1.958,1.25 2.323,1.25 false 1.448,4.365 1.563,4.604 1.563,4.604 1.698,4.604 false 6.188,2.406 6.271,2.281 6.271,2.281 6.417,2.281 false 6.24,3.146 6.604,3.146 false 0.781,0.917 1,0.75 1,0.75 1.167,0.75 false 2.177,2.052 2.542,2.052 false 2.51,2.865 2.875,2.865 false 6.042,4.094 6.406,4.094 false 4.083,2.802 4.531,2.802 false 4.063,2.167 4.469,1.656 4.469,1.656 4.635,1.656 false 5.177,1.979 5.333,1.885 5.333,1.885 5.5,1.885 false 1.688,2.542 1.854,2.542 1.854,2.542 2.115,2.365 false 5.813,3.771 5.979,3.771 5.979,3.771 6.479,3.552 false 4.344,1.115 4.573,0.802 4.573,0.802 4.74,0.802 false 0.583,0.708 0.708,0.177 0.708,0.177 0.875,0.177 false 5.083,1.156 5.635,1.51 0.552,0.354 18 false 11 6.469,2.146 7.021,2.5 0.552,0.354 18 false 13 6.646,3.01 7.063,3.417 0.417,0.406 18 false 15 1.229,0.604 1.781,0.958 0.552,0.354 18 false 16 2.927,2.74 3.479,3.094 0.552,0.354 18 false 17 2.563,1.885 3.115,2.24 0.552,0.354 18 false 18 2.198,2.354 2.75,2.708 0.552,0.354 10 false x3 2.427,1.125 2.813,1.479 0.385,0.354 18 false 19 1.948,4.531 2.333,4.885 0.385,0.354 18 false 14 5.688,3.938 6.24,4.292 0.552,0.354 18 false 12 4.552,2.656 5.104,3.01 0.552,0.354 18 false 10 0.708,2.458 1.896,2.854 1.188,0.396 8 false 4.0 (41, 35 in.*lbf) 5.563,1.813 6.75,2.208 1.188,0.396 8 false 12 (122, 9) 4.792,3.677 6.073,4.073 1.281,0.396 8 false 8.35 (85, 74 in.*lbf) 4.802,0.719 6.083,1.115 1.281,0.396 8 false 10 (102, 7) 4.75,1.583 5.938,1.979 1.188,0.396 8 false 6.0 (61, 53 in.*lbf) 0.958,0.104 2.146,0.5 1.188,0.396 8 false 2.0 (20, 18 in.*lbf)

Procedure Part Name Code
Z101186

Z101188

Z101187

10 TRANSMISSION CONTROL CABLE ASSEMBLY 33820B - - -
11 VACUUM SWITCHING VALVE ASSEMBLY 17650 - - -
12 NO.3 ENGINE WIRE 82123 - - -
13 NO.2 RELAY BLOCK COVER 82662B - - -
14 HIGH VOLTAGE AIR CONDITIONING WIRE 821H2A (Click here) - -
15 ECM 89661 - - -
16 NO. 1 AIR CLEANER HOSE 17881 - - -
17 AIR CLEANER CASE SUB-ASSEMBLY 17701 - - -
18 AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 17801 - - -
19 AIR CLEANER CAP SUB-ASSEMBLY 17705 - - -

V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)
V100146

N*m (kgf*cm, ft.*lbf): Specified torque

A548692N01
4.167,1.229 5.167,1.396 1,0.167 3.229,0.792 4.313,1.042 1.083,0.25 3.271,0.833 4.271,1 1,0.167 2.948,1.375 3.104,0.917 3.104,0.917 3.271,0.917 false 3.99,2.083 4.25,2.083 false 3.875,1.313 4.156,1.313 false 3.896,1.313 4.208,1.469 0.313,0.156 10 false x2 4.646,1.896 5.073,2.219 0.427,0.323 18 false 20 4.208,1.229 5.24,1.521 1.031,0.292 8 false 8.0 (82, 71 in.*lbf) 3.01,1.396 3.323,1.552 0.313,0.156 10 false x4 3.323,0.833 4.354,1.125 1.031,0.292 8 false 8.0 (82, 71 in.*lbf)

Procedure Part Name Code
Z101186

Z101188

Z101187

20 FLOOR UNDER WIRE 821H1 (Click here) - -

V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)
V100146

N*m (kgf*cm, ft.*lbf): Specified torque

A523064N02
6.385,0.208 6.76,0.208 false 6.448,0.688 6.823,0.688 false 1.99,1.229 2.365,1.229 false 6.427,1.083 6.802,1.083 false 5.719,0.948 6.667,1.438 0.948,0.49 18 false 24, 25 1.656,1.104 2.604,1.594 0.948,0.49 18 false 21 6.135,0.552 6.646,0.948 0.51,0.396 18 false 22 6.094,0.083 7.042,0.573 0.948,0.49 18 false 23

Procedure Part Name Code
Z101186

Z101188

Z101187

21 SERVICE PLUG GRIP G3834 - - -
22 COOLANT (for Inverter) - - (Click here) -
23 FOR COOLANT LEAK - (Click here) - -
24 ECU CONFIGURATION - - - (Click here)
25 RESOLVER LEARNING - - - (Click here)

PROCEDURE

Hide G9200 1.SET INVERTER WITH CONVERTER ASSEMBLY

Z101186

CAUTION:

Be sure to wear insulated gloves.


NOTICE:
·

When installing the inverter with converter assembly, be careful not to damage the parts around it.

·

To prevent damage, do not hold the inverter with converter assembly by the connectors, brackets or cooling pipes.

·

To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.

·
A521708N01
0.729,2.323 1.042,2.521 0.313,0.198 10 false OK 0.75,3.385 1.063,3.583 0.313,0.198 10 false NG

Make sure that the inverter with converter assembly is positioned so that the stud bolts are in contact with the base of the U-shaped portions of the No. 1 inverter bracket.




a.
A521698


Hide G1148 2.CONNECT MOTOR CABLE

Z101186

CAUTION:

Wear insulated gloves.


NOTICE:

Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.



a.
A523036C02
1.448,1.792 1.24,1.646 true 1.021,1.531 1.333,1.729 0.313,0.198 10 false *a 3.167,0.302 3.323,0.5 0.156,0.198 10 true 1 2.865,1.271 3.021,1.469 0.156,0.198 10 true A 0.729,1.271 0.885,1.469 0.156,0.198 10 true 2 0.615,0.177 0.802,0.344 0.188,0.167 10 true 3 0.406,0.052 0.688,0.406 0.281,0.354 18 false i 4.063,0.042 4.26,0.333 0.198,0.292 18 true ii
*a Waterproof Seal - -


i.

Temporarily install the motor cable to the inverter with converter assembly with the 4 bolts,

NOTICE:
·

Do not touch the waterproof seal or terminals of the motor cable.

·

Do not damage the terminals, connector housing or inverter with converter assembly during connection.

·

Be careful to avoid cutting or pinching the waterproof seal during installation.




ii.

Fully tighten the 3 bolts in the order shown in the illustration.

Torque:
8.0 N・m (82 kgf・cm, )


iii.

Using a 10 mm union nut wrench, fully tighten the bolt(A).

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

HINT:
·

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION

·

When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 7.0 N*m (71 kgf*cm, 62 in.*lbf)




iv.

Temporarily install the terminals of the motor cable with the bolts, and using an insulated tool, fully tighten the bolts.

Torque:
8.0 N・m (82 kgf・cm, )

NOTICE:
·

To prevent the threads from being damaged, temporarily tighten the 6 bolts by hand.

·

Be sure to use a torque wrench to tighten the bolts.





Hide G9221 3.INSTALL UPPER INVERTER COVER

Z101186

CAUTION:

Wear insulated gloves.



a.
A523037C01
5.698,3.76 5.573,3.656 true 4.177,3.865 4.104,3.74 true 4.583,3.5 4.271,3.323 4.271,3.323 4.521,3.75 true 4.854,4.156 4.615,3.854 true 3.24,4.208 2.833,4.063 true 3.99,3.573 4.146,3.771 0.156,0.198 10 false A 5.75,3.76 5.906,3.958 0.156,0.198 10 false A 4.104,3.177 4.354,3.344 0.25,0.167 10 false *b 4.854,4.156 5.104,4.323 0.25,0.167 10 true *a 0.385,0.083 0.542,0.375 0.156,0.292 18 true i 4.146,0.063 4.344,0.365 0.198,0.302 18 true ii 1.26,3 1.521,3.313 0.26,0.313 18 true iii 3.323,4.135 3.479,4.333 0.156,0.198 10 true B
*a Interlock *b Waterproof Seal


i.

To prevent the inverter with converter assembly from falling, temporarily install the bolt in the location shown in the illustration.


ii.

Shift the position of the inverter with converter assembly and temporarily set it on top of the stud bolts as shown in the illustration.

NOTICE:

When lifting, make sure not to apply force to the motor cable.



iii.

Install the inverter cover to the inverter with converter assembly with the bolts.

Torque:
8.0 N・m (82 kgf・cm, )

NOTICE:
·

To avoid deforming portion (A) of the inverter cover, do not hold portion (A) when installing.

·

Be careful not to scratch or damage portion (B) of the inverter cover.

·

Visually confirm that the inverter cover waterproof seal is securely installed before installing the upper inverter cover.

·

Do not touch the waterproof seal of the upper inverter cover.

·

Make sure that the interlock is fully engaged.

·

Do not damage the terminals, interlock connector or hybrid motor control inverter assembly during installation.

·

Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.

·
A521692C02
1.958,1.917 2.573,1.479 2.573,1.479 1.917,1.302 true 1.125,0.271 1.344,0.271 1.344,0.271 1.698,0.677 true 0.917,0.177 1.229,0.375 0.313,0.198 10 false *a 2.656,1.385 2.969,1.583 0.313,0.198 10 false *1
*1 Inverter Cover
*a Screw


Do not remove or excessively tighten the screw of the upper inverter cover.

·

Although the upper inverter cover may feel loose, this is not due to a malfunction.

·
A521709C01
1.813,1.833 2.031,2.01 0.219,0.177 10 true *a
*a No Gap


Push in the upper inverter cover until it contacts the hybrid motor control inverter assembly.





b.
A523038C01
0.417,0.052 0.594,0.354 0.177,0.302 18 true i 3.875,0.135 4.052,0.438 0.177,0.302 18 false ii

i.

Shift the position of the inverter with converter assembly and temporarily set it on the hybrid vehicle transaxle assembly as shown in the illustration.

NOTICE:

When lifting, make sure not to apply force to the motor cable.



ii.

Connect the inverter cover to the hybrid vehicle transaxle assembly with the bolt.

Torque:
8.0 N・m (82 kgf・cm, )



Hide G9200 4.INSTALL INVERTER WITH CONVERTER ASSEMBLY

Z101186

CAUTION:

Wear insulated gloves.



a.
A524806N01
4.083,0.063 4.24,0.26 0.156,0.198 10 true 1 3.51,0.344 3.667,0.542 0.156,0.198 10 true 2 2.938,0.115 3.073,0.281 0.135,0.167 10 true 3 4.177,1.427 4.333,1.625 0.156,0.198 10 true 4 3.542,1.344 3.688,1.531 0.146,0.188 10 true 5 2.948,1.563 3.083,1.719 0.135,0.156 10 true 6 2.01,0.094 2.292,0.448 0.281,0.354 18 false i

i.

Temporarily install the inverter with converter assembly with the bolts and the nuts, and then fully tighten the bolts and nuts in the order shown in the illustration.

Torque:
55 N・m (561 kgf・cm, )

NOTICE:
·

When installing the inverter with converter assembly, be careful not to damage the parts around it.

·

To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.

·
A521708C01
0.771,2.323 0.979,2.51 0.208,0.188 10 true *a 0.76,3.385 0.979,3.563 0.219,0.177 10 true *b
*a Correct
*b Incorrect


Make sure that the inverter with converter assembly is positioned so that the stud bolts are in contact with the base of the U-shaped portions of the No. 1 inverter bracket.



HINT:

If the bolts and nuts are not tightened appropriately, the inverter with converter assembly may make an abnormal noise.




Hide 82127D 5.INSTALL NO. 7 ENGINE WIRE

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

Hide G922AA 6.CONNECT INLET NO. 1 INVERTER COOLING HOSE

a.
A548699C01
5.031,0.802 4.906,0.479 true 4.677,0.802 4.531,0.51 true 4.417,0.323 4.729,0.479 0.313,0.156 10 false *a 4.792,0.323 5.104,0.479 0.313,0.156 10 false *b 4.885,1.198 5.198,1.354 0.313,0.156 10 false *c 5.823,0.188 6.135,0.344 0.313,0.156 10 false *d 6.375,0.76 6.688,0.917 0.313,0.156 10 false *e 5.344,0.469 5.958,0.667 0.615,0.198 10 false 305° 4.01,0.115 4.292,0.469 0.281,0.354 18 false i 1.802,0.104 2.083,0.458 0.281,0.354 18 true i
*a Alignment Mark *b Rib
*c 2 to 11 mm (0.079 to 0.433 in.) *d Up
*e LH Side - -


i.

Connect the inlet No. 1 inverter cooling hose to the hybrid motor control inverter assembly and slide the clip to secure it.

NOTICE:

To prevent foreign matter from entering the hybrid motor control inverter assembly and inverter cooling system, do not remove the pieces of cloth from the pipe and disconnected hose until installation.




Hide G922C 7.CONNECT OUTLET NO. 1 INVERTER COOLING HOSE

a.
A548700C01
5.021,0.802 4.896,0.479 true 4.688,0.792 4.542,0.5 true 4.438,0.354 4.75,0.51 0.313,0.156 10 false *a 4.833,0.344 5.146,0.5 0.313,0.156 10 false *b 4.875,1.208 5.188,1.365 0.313,0.156 10 false *c 5.802,0.198 6.115,0.354 0.313,0.156 10 false *d 6.406,0.729 6.719,0.885 0.313,0.156 10 false *e 6.135,0.396 6.75,0.594 0.615,0.198 10 false 360° 4.01,0.115 4.292,0.469 0.281,0.354 18 false i 1.792,0.125 2.073,0.479 0.281,0.354 18 true i
*a Alignment Mark *b Rib
*c 2 to 11 mm (0.079 to 0.433 in.) *d Up
*e LH Side - -


i.

Connect the outlet No. 1 inverter cooling hose to the hybrid motor control inverter assembly and slide the clip to secure it.

NOTICE:

To prevent foreign matter from entering the hybrid motor control inverter assembly and inverter cooling system, do not remove the pieces of cloth from the pipe and disconnected hose until installation.




Hide 82121 8.INSTALL ENGINE WIRE

Z101186

CAUTION:

Wear insulated gloves.


NOTICE:
·

To prevent the threads from being damaged, temporarily tighten the nut by hand.

·

Do not touch the waterproof seal or terminals of the connectors.

·

To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.

·

Do not damage the terminals, connector housing or hybrid motor control inverter assembly when connecting the connectors.




Torque:
10 N*m (102 kgf*cm, 89 in.*lbf)

Hide 82111 9.INSTALL ENGINE ROOM MAIN WIRE

Hide 33820B 10.INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY

Torque:
Nut : 6.0 N*m (61 kgf*cm, 53 in.*lbf)
Bolt : 12 N*m (122 kgf*cm, 9 ft.*lbf)

Hide 25860 11.INSTALL PURGE VALVE (PURGE VSV)

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

Hide 82123 12.INSTALL NO. 3 ENGINE WIRE

Torque:
8.35 N*m (85 kgf*cm, 74 in.*lbf)

Hide 82661A 13.INSTALL NO. 2 RELAY BLOCK COVER

Hide 821H2A 14.CONNECT HIGH VOLTAGE AIR CONDITIONING WIRE

Z101186

CAUTION:

Wear insulated gloves.


NOTICE:
·

Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.

·

Do not touch the waterproof seal or terminals of the connector.

·

Do not damage the terminals, connector housing or hybrid motor control inverter assembly when connecting the connector.




a.
A521678C01
0.563,0.125 0.76,0.438 0.198,0.313 1.51,1.26 1.24,1.073 true 1.552,1.271 1.865,1.469 0.313,0.198 10 false *a 0.635,0.156 0.917,0.51 0.281,0.354 14 false ! 0.823,0.135 1.24,0.49 0.417,0.354 18 false i 5.594,0.323 5.792,0.667 0.198,0.344 18 true ii
*a Green-colored Lock - -
V100137

Slide - -


i.

Connect the connector and slide the green-colored lock as shown in the illustration to securely lock it.


ii.

Engage the 2 clamps.



Hide 17881 16.INSTALL NO. 1 AIR CLEANER HOSE

Torque:
2.0 N*m (20 kgf*cm, 18 in.*lbf)

Hide 17701 17.INSTALL AIR CLEANER CASE SUB-ASSEMBLY

Torque:
4.0 N*m (41 kgf*cm, 35 in.*lbf)

Hide 17801 18.INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

Hide 17705 19.INSTALL AIR CLEANER CAP SUB-ASSEMBLY

Hide 821H1 20.CONNECT FLOOR UNDER WIRE

Z101186

CAUTION:

Wear insulated gloves.


NOTICE:
·

Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.

·

Do not touch the waterproof seal or terminals of the connector.

·

Do not damage the terminals, connector housing or hybrid motor control inverter assembly when connecting the connector.




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