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

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


PROCEDURE

Hide G9200 1.SET INVERTER WITH CONVERTER ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.


a.

Temporarily install the inverter with converter assembly.

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.

·
A512470C03
0.396,2.594 0.594,2.802 0.198,0.208 10 true *a 0.396,3.667 0.594,3.875 0.198,0.208 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.




Hide G1148 2.CONNECT MOTOR CABLE

CAUTION:

Be sure to wear insulated gloves.


NOTICE:

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


a.

Temporarily connect the motor cable to the inverter with converter assembly with the 4 bolts.

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 connection.




b.
A523910C01
2.563,2.375 2.667,2.177 2.667,2.177 2.833,2.177 true 2.875,2.094 3.188,2.25 0.313,0.156 10 false *a 2.844,1.292 2.969,1.458 0.125,0.167 10 true A 3.042,0.448 3.156,0.625 0.115,0.177 10 true 1 0.583,1.521 0.719,1.708 0.135,0.188 10 true 2 0.375,0.344 0.51,0.531 0.135,0.188 10 true 3
*a Waterproof Seal
*b 10 mm Union Nut Wrench Fulcrum Length
*c Torque Wrench Fulcrum Length


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

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


c.

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

Torque:
Specified tightening torque : 8.0 N*m (82 kgf*cm, 6 ft.*lbf)

HINT:
·

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

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION

·

When using 10 mm 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)




d.
A523712

Temporarily install the 6 bolts.

CAUTION:

Insulate the tool with insulating tape.


NOTICE:
·

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

·

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




e.

Fully tighten the 6 bolts.

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

CAUTION:

Insulate the tool with insulating tape.


NOTICE:
·

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

·

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




Hide G9221 3.INSTALL INVERTER COVER

CAUTION:

Be sure to wear insulated gloves.


a.
A523934

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


b.

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

A523935

NOTICE:

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



c.

Install the inverter cover to the inverter with converter assembly with the 2 bolts.

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

NOTICE:
·

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

·

Do not touch the waterproof seal of the inverter cover.

·

Make sure that the interlock is fully engaged.

·

Do not damage the terminals, interlock connector or inverter with converter assembly during installation.

·

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

·
A511895C01
1.76,0.75 1.208,0.281 true 1.042,0.188 1.354,0.385 0.313,0.198 10 false *a
*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.

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


Push in the inverter cover until it contacts the inverter with converter assembly.




d.

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

A523939

NOTICE:

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



e.
A523711

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

Torque:
8.0 N・m (82 kgf・cm, )


Hide G9200 4.INSTALL INVERTER WITH CONVERTER ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.


a.

Temporarily install the inverter with converter assembly with the 5 bolts and 2 nuts.

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.

·
A512470C03
0.396,2.594 0.594,2.802 0.198,0.208 10 true *a 0.396,3.667 0.594,3.875 0.198,0.208 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.



b.
A523715N01
2.365,0.313 2.521,0.51 0.156,0.198 10 true 1 0.948,0.469 1.104,0.667 0.156,0.198 10 true 3 1.719,0.229 1.875,0.427 0.156,0.198 10 true 2 2.469,2.958 2.625,3.156 0.156,0.198 10 true 4

Fully tighten the 4 bolts in the order shown in the illustration.

Torque:
55 N*m (561 kgf*cm, 41 ft.*lbf)


c.

Fully tighten the 2 nuts.

Torque:
55 N*m (561 kgf*cm, 41 ft.*lbf)


Hide 82121 5.CONNECT ENGINE WIRE

CAUTION:

Be sure to wear insulated gloves.


a.
A523710

Engage the clamp and connect the engine wire to the inverter with converter assembly.


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

a.
A523967C01
0.385,0.542 0.625,0.542 0.625,0.542 0.76,0.948 true 1.271,0.969 1.396,0.469 1.396,0.469 1.604,0.469 true 2.406,0.719 2.771,0.323 2.771,0.323 2.979,0.323 true 0.208,0.458 0.521,0.656 0.313,0.198 10 false *a 1.615,0.354 1.927,0.552 0.313,0.198 10 false *b 1.948,0.344 2.333,0.583 0.385,0.24 10 false 180° 1.073,1.542 1.385,1.74 0.313,0.198 10 false *c 2.365,0.115 2.677,0.313 0.313,0.198 10 false *d 3.042,0.875 3.354,1.073 0.313,0.198 10 false *e 3.021,0.24 3.333,0.438 0.313,0.198 10 false *a
*a Alignment Mark
*b Rib
*c 2 to 11 mm (0.0787 to 0.4331 in.)
*d Up
*e LH Side


Connect the inlet No. 1 inverter cooling hose to the inverter with converter assembly and slide the clip to secure it.

NOTICE:
·

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

·

Make sure to align the alignment mark of the hose with the alignment mark of the pipe of the inverter with converter assembly.



HINT:

Make sure that the clip is positioned as shown in the illustration.



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

a.
A523966C01
0.385,0.542 0.625,0.542 0.625,0.542 0.76,0.948 true 1.271,0.969 1.396,0.469 1.396,0.469 1.604,0.469 true 2.406,0.719 2.771,0.323 2.771,0.323 2.979,0.323 true 0.208,0.458 0.521,0.656 0.313,0.198 10 false *a 1.615,0.354 1.927,0.552 0.313,0.198 10 false *b 1.948,0.344 2.333,0.583 0.385,0.24 10 false 225° 1.073,1.542 1.385,1.74 0.313,0.198 10 false *c 2.365,0.115 2.677,0.313 0.313,0.198 10 false *d 3.042,0.875 3.354,1.073 0.313,0.198 10 false *e 3.021,0.24 3.333,0.438 0.313,0.198 10 false *a
*a Alignment Mark
*b Rib
*c 2 to 11 mm (0.0787 to 0.4331 in.)
*d Up
*e LH Side


Connect the outlet No. 1 inverter cooling hose to the inverter with converter assembly and slide the clip to secure it.

NOTICE:
·

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

·

Make sure to align the alignment mark of the hose with the rib of the inverter with converter assembly.



HINT:

Make sure that the clip is positioned as shown in the illustration.



Hide 82127D 8.CONNECT NO. 7 ENGINE WIRE

CAUTION:

Be sure to wear insulated gloves.


a.
A523707

Engage the clamp.


b.

Connect the No. 7 engine wire to the inverter with converter assembly with the 2 bolts.

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


Hide 82123 9.CONNECT NO. 3 ENGINE WIRE

a.

Engage the clamp.


b.

Engage the 2 claws to connect the engine wire to the No. 1 engine room relay block.


c.

Install the nut.

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


Hide 821H1 10.CONNECT FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves.


a.

Engage the clamps.


b.

Connect the floor under wire to the inverter with converter assembly and install the 2 bolts.

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

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 when connecting the connector.




Hide 82111 11.CONNECT 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.


a.

Connect the inverter with converter assembly connector.


b.

Engage the 3 clamps to connect the engine wire.


c.

Connect the inverter with converter assembly connector.

NOTICE:
·

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

·

Do not damage the terminals, connector housing or inverter with converter assembly when connecting the connectors.

·

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




Hide 82121 12.CONNECT 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.


a.

Engage the 2 clamps to connect the engine wire.


b.

Engage the clamp.


c.

Install the 3 nuts.

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


d.

Connect the inverter with converter assembly connector.

NOTICE:
·

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

·

Do not damage the terminals, connector housing or inverter with converter assembly when connecting the connectors.

·

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




e.

Engage the 2 claws to connect the engine wire to the No. 1 engine room relay block.


f.

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


g.

Install the No. 1 relay block cover to the No. 1 engine room relay block.


Hide 821H2 13.CONNECT HV AIR CONDITIONING WIRE

CAUTION:

Be sure to wear insulated gloves.


a.
A523962C01
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
V100137

Slide


Engage the 2 clamps.


b.

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

NOTICE:

Make sure that the connectors are connected securely.



Hide 33822 22.CONNECT FLOOR SHIFT TRANSMISSION CONTROL SELECT CABLE

a.

Install the nut to connect the floor shift transmission control select cable.

Torque:
6.0 N*m (61 kgf*cm, 53 in.*lbf)


Hide 74404A 23.INSTALL BATTERY CLAMP SUB-ASSEMBLY

a.

Install the battery clamp sub-assembly to the vehicle with the 3 bolts.

Torque:
15.4 N*m (157 kgf*cm, 11 ft.*lbf)


Hide 28. PEFOME ECU CONFIGURATION

Click hereGeneral>SETUP>WHEN REPLACING OR REMOVING/INSTALLING PARTS>ECU CONFIGURATION

HINT:

Perform this procedure only when replacement of the inverter with converter assembly.