RM3660EC _51 Engine / Hybrid System _080773 HYBRID / BATTERY CONTROL _0392172 8ZR-FXE INVERTER WITH CONVERTER A

HYBRID / BATTERY CONTROL 8ZR-FXE INVERTER WITH CONVERTER REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during inverter with converter assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Replacement of inverter with converter assembly	ECU configuration	-	(202304,999999,_V1,_143216,_0598316,RM100000002B3MK,)
Replacement of inverter with converter assembly	Resolver learning	· DTCs are stored · Slight vibration at a vehicle speed of 5 km/h (3 mph) or less · Shock or vibration during acceleration	(202304,999999,_51,_080773,_0600292,RM100000002BBW3,)

CAUTION:: ·

Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION201906,999999,_V1,_080724,_0393249,RM100000001HWSK,

·

To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.

NOTICE:: After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

HINT:

When the cable is disconnected / reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

Items for which learning is completed by driving the vehicle
Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
Front Camera System	Drive the vehicle straight ahead at 15 km/h (9 mph) or more for 1 seconds or more.	(202304,999999,_95,_139716,_0584193,RM1000000029F4C,)

PROCEDURE

Hide Display 1. PRECAUTION

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION201906,999999,_V1,_080724,_0393249,RM100000001HWSK,

Hide Display 89661 2.REMOVE ECM

Click hereEngine / Hybrid System>8ZR-FXE (ENGINE CONTROL)>ECM>REMOVAL202304,999999,_51,_080778,_0392134,RM10000000295VL,

Hide Display G3834 3.REMOVE SERVICE PLUG GRIP

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>SERVICE PLUG GRIP>REMOVAL202304,202307,_51,_080773,_0392185,RM100000002B8JS,202307,999999,_51,_080773,_0392185,RM100000002CWG6,

Hide Display 4.DRAIN COOLANT (for Inverter)

Click hereGeneral>MAINTENANCE>COOLANT (for Inverter)>REPLACEMENT202304,202307,_V1,_080956,_0393120,RM100000002B8L3_01_0003,202307,999999,_V1,_080956,_0393120,RM100000002CWGB_01_0003,

Hide Display 74404A 5.REMOVE BATTERY CLAMP SUB-ASSEMBLY

Remove the 3 bolts and battery clamp sub-assembly from the vehicle.

Hide Display 6.REMOVE CONNECTOR COVER ASSEMBLY

CAUTION:: Be sure to wear insulated gloves.

1.5,1.604 1.698,1.792 0.198,0.188 10 true *a 1.74,0.656 1.906,0.833 0.167,0.177 10 true *b

*a	Bolt (A)
*b	Bolt (B)

Remove the bolt (A).

Using a T20 "TORX" socket wrench, remove the bolt (B) and connector cover assembly from the inverter with converter assembly.

NOTICE:: ·

Do not touch the connector cover assembly waterproof seal.

·

Do not allow any foreign matter or water to enter the inverter with converter assembly.

Hide Display 7.CHECK TERMINAL VOLTAGE

CAUTION:: Be sure to wear insulated gloves.

Using a voltmeter, measure the voltage between the terminals of the 2 phase connectors.

4.854,1.625 5.635,1.99 5.635,1.99 5.156,1.625 true 5.688,1.917 6,2.115 0.313,0.198 10 true *a

Terminal

Standard Voltage:: 0 V

NOTICE:: Do not allow any foreign matter or water to enter the inverter with converter assembly.

HINT:: ·

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

·

Perform the measurement while holding the tips of the tester probes against the terminals as shown in the illustration.

Hide Display 8.TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

CAUTION:: Be sure to wear insulated gloves.

Temporarily install the connector cover assembly to the inverter with converter assembly.

Using a T20 "TORX" socket wrench, install the bolt.

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

NOTICE:: ·

Do not touch the connector cover assembly waterproof seal.

·

Do not allow any foreign matter or water to enter the inverter with converter assembly.

Hide Display 33822 9.SEPARATE FLOOR SHIFT TRANSMISSION CONTROL SELECT CABLE

Remove the nut to separate the floor shift transmission control select cable.

Hide Display 17705 10.REMOVE AIR CLEANER CAP SUB-ASSEMBLY

Click hereEngine / Hybrid System>8ZR-FXE (ENGINE CONTROL)>THROTTLE BODY>REMOVAL202304,999999,_51,_080778,_0392133,RM10000000295TV_01_0004,

Hide Display 11.REMOVE AIR CLEANER HOSE ASSEMBLY

Click hereEngine / Hybrid System>8ZR-FXE (ENGINE CONTROL)>THROTTLE BODY>REMOVAL202304,999999,_51,_080778,_0392133,RM10000000295TV_01_0010,

Hide Display 53289A 12.REMOVE RADIATOR SUPPORT OPENING COVER

for TFTM Made:

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER (for TFTM Made)>REMOVAL202304,202307,_59,_080736,_0392548,RM100000002AMO3_01_0035,202307,999999,_59,_080736,_0392548,RM100000002CH8T_01_0035,

for GTMC Made:

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER (for GTMC Made)>REMOVAL202304,202307,_59,_080736,_0392547,RM100000002AXCM_01_0036,202307,999999,_59,_080736,_0392547,RM100000002CHFA_01_0036,

Hide Display 17752 13.REMOVE INLET NO. 2 AIR CLEANER

Click hereEngine / Hybrid System>8ZR-FXE (INTAKE / EXHAUST)>INTAKE MANIFOLD>REMOVAL202304,999999,_51,_080790,_0392072,RM100000002B0QN_01_0157,

Hide Display 17801 14.REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

Click hereEngine / Hybrid System>8ZR-FXE (INTAKE / EXHAUST)>INTAKE MANIFOLD>REMOVAL202304,999999,_51,_080790,_0392072,RM100000002B0QN_01_0158,

Hide Display 17701 15.REMOVE AIR CLEANER CASE SUB-ASSEMBLY

Click hereEngine / Hybrid System>8ZR-FXE (INTAKE / EXHAUST)>INTAKE MANIFOLD>REMOVAL202304,999999,_51,_080790,_0392072,RM100000002B0QN_01_0159,

Hide Display 17771A 16.REMOVE AIR CLEANER BRACKET

Click hereEngine / Hybrid System>8ZR-FXE (INTAKE / EXHAUST)>INTAKE MANIFOLD>REMOVAL202304,999999,_51,_080790,_0392072,RM100000002B0QN_01_0160,

Hide Display 17751 17.REMOVE INLET NO. 1 AIR CLEANER

Click hereEngine / Hybrid System>8ZR-FXE (INTAKE / EXHAUST)>INTAKE MANIFOLD>REMOVAL202304,999999,_51,_080790,_0392072,RM100000002B0QN_01_0145,

Hide Display 821H2 18.DISCONNECT HV AIR CONDITIONING WIRE

CAUTION:: Be sure to wear insulated gloves.

1.177,0.49 1.354,0.25 1.354,0.25 1.521,0.25 true 1.563,0.177 1.875,0.333 0.313,0.156 10 false *a

*a	Green-colored Lock
	Slide

Slide the green-colored lock of the connector as shown in the illustration to release it and disconnect the HV air conditioning wire.

NOTICE:: Insulate the disconnected terminals with insulating tape.

Hide Display 82121 19.DISCONNECT ENGINE WIRE

CAUTION:: Be sure to wear insulated gloves.

NOTICE:: Do not allow any foreign matter or water to enter the inverter with converter assembly.

Remove the No. 1 relay block cover from the No. 1 engine room relay block.

Disconnect the 2 No. 1 engine room relay block connectors.

Disengage the 2 claws to separate the engine wire from the No. 1 engine room relay block.

Move the lock lever as shown in the illustration and disconnect the inverter with converter assembly connector.

NOTICE:: ·

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

·

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

·

Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.

·

Insulate the disconnected terminals with insulating tape.

Remove the 3 nuts.

Disengage the clamp.

Disengage the 2 clamps and disconnect the engine wire from the inverter with converter assembly.

Hide Display 82111 20.DISCONNECT ENGINE ROOM MAIN WIRE

CAUTION:: Be sure to wear insulated gloves.

NOTICE:: Do not allow any foreign matter or water to enter the inverter with converter assembly.

Move the lock lever as shown in the illustration and disconnect the inverter with converter assembly connector.

NOTICE:: ·

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

·

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

·

Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.

·

Insulate the disconnected terminals with insulating tape.

Disengage the 3 clamps.

Disconnect the connector and disconnect the engine room main wire from the inverter with converter assembly.

Hide Display 821H1 21.DISCONNECT FLOOR UNDER WIRE

CAUTION:: Be sure to wear insulated gloves.

0.802,2.958 1.292,2.958 true 1.333,2.885 1.521,3.073 0.188,0.188 10 true *a

*a	Waterproof Seal

Disengage the clamp.

Remove the bolt, 2 nuts and disconnect the HV floor under wire from the inverter with converter assembly.

NOTICE:: ·

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

·

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

·

Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.

·

Do not allow any foreign matter or water to enter the inverter with converter assembly.

·

Insulate the disconnected terminals with insulating tape.

Hide Display 82123 22.DISCONNECT NO. 3 ENGINE WIRE

Remove the nut.

Disengage the 2 claws.

Disengage the clamp.

Hide Display 82127D 23.DISCONNECT NO. 7 ENGINE WIRE

CAUTION:: Be sure to wear insulated gloves.

Remove the 2 bolts and disconnect the No. 3 engine wire from the inverter with converter assembly.

Disengage the clamp.

Hide Display G922C 24.DISCONNECT OUTLET NO. 1 INVERTER COOLING HOSE

Slide the clip and disconnect the outlet No. 1 inverter cooling hose from the inverter with converter assembly.

NOTICE:: Put pieces of cloth into the pipe and disconnected hose or cover the pipe and hose with plastic bags to prevent entry of foreign matter.

Hide Display G922AA 25.DISCONNECT INLET NO. 1 INVERTER COOLING HOSE

Slide the clip and disconnect the inlet No. 1 inverter cooling hose from the inverter with converter assembly.

NOTICE:: Put pieces of cloth into the pipe and disconnected hose or cover the pipe and hose with plastic bags to prevent entry of foreign matter.

Hide Display 82121 26.DISCONNECT ENGINE WIRE

CAUTION:: Be sure to wear insulated gloves.

Disengage the clamp and disconnect the engine wire.

Hide Display 27.DISCONNECT INVERTER WITH CONVERTER ASSEMBLY

CAUTION:: Be sure to wear insulated gloves.

Remove the 4 bolts, 2 nuts to disconnect inverter with converter assembly.

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

Hide Display G9221 28.REMOVE INVERTER COVER

CAUTION:: Be sure to wear insulated gloves.

Remove the bolt and inverter cover from the hybrid vehicle transaxle assembly.

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

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.

Loosen the 2 bolts, leaving 2 to 3 threads at the tip of the bolt still engaged.

0.917,0.813 1.219,0.271 1.219,0.271 0.823,0.583 true 0.969,0.969 1.094,1.219 1.094,1.219 1.333,1.219 true 2.854,0.417 2.563,0.417 2.563,0.417 2.26,0.625 true 0.438,1.271 0.49,1.49 0.49,1.49 0.698,1.49 false 2.594,2.448 2.385,2.448 2.385,2.448 1.917,2.656 true 1.375,1.156 1.552,1.313 0.177,0.156 10 true *a 1.26,0.208 1.573,0.406 0.313,0.198 10 false *b 2.896,0.354 3.052,0.552 0.156,0.198 10 false A 0.729,1.427 0.885,1.625 0.156,0.198 10 false A 2.646,2.385 2.771,2.563 0.125,0.177 10 true B

*a	Interlock
*b	Waterproof Seal

Using the 2 bolts as guides, remove the upper inverter cover from the inverter with converter assembly.

NOTICE:

Make sure to pull the inverter cover straight out, as a connector is connected to the inside of the inverter cover.

Do not touch the waterproof seal of the inverter cover.

Do not allow any foreign matter or water to enter the inverter with converter assembly.

When removing the inverter cover, do not pull the areas (A) as they may deform.

Make sure that the interlock is installed to the inverter cover.

1.76,0.75 1.208,0.281 true 1.042,0.188 1.354,0.385 0.313,0.198 10 false *a

Screw

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

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

Hold the upper inverter cover horizontal while removing it.

HINT:: If necessary, use a screwdriver with its tip wrapped with protective tape as shown in the illustration to remove the inverter cover.

Remove the 2 bolts.

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.

Remove the bolt.

Hide Display G1148 29.DISCONNECT MOTOR CABLE

CAUTION:: Be sure to wear insulated gloves.

Remove the 6 bolts.

CAUTION:: Insulate the tool with insulating tape.

NOTICE:: Do not allow any foreign matter or water to enter the inverter with converter assembly.

0.906,3.146 1.219,3.146 1.219,3.146 1.365,2.906 true 0.729,3.063 1.042,3.26 0.313,0.198 10 false *a

*a	Waterproof Seal

Remove the 4 bolts and disconnect the motor cable from the inverter with converter assembly.

NOTICE:: ·

Do not allow any foreign matter or water to enter the inverter with converter assembly.

·

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

·

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

·

Insulate the disconnected terminals with insulating tape.

·

After disconnecting the motor cable, wrap it with a plastic bag or equivalent to protect it.

·

Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.

·

To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.

Hide Display 30.REMOVE INVERTER WITH CONVERTER ASSEMBLY

CAUTION:: Be sure to wear insulated gloves.

Remove the inverter with converter assembly.

NOTICE:: ·

When removing 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.

HINT:: Even after the coolant is drained, coolant remains in the inverter due to its internal structure. Therefore, seal or cover the pipes when removing the inverter with converter assembly so that coolant does not spill out.