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Inverter And Converter Assembly: Installation

WARNING: This page is about a different variant/trim than selected.
WARNING: The hybrid system includes a high voltage circuit. Mishandling could cause accidents such as electric shock or leak. Refer to PRECAUTION/WARNING>Warning (HYBRID SYSTEM) .
CAUTION: Airbag system satellite safing sensor is located under the front center of the rear seat cushion. Be careful not to apply strong impact to the sensor when working with the rear seat cushion removed.
  1. Install the motor cable.
    WARNING: Be sure to wear insulated gloves and use insulated tools.
    CAUTION:
    • After the motor cable was disconnected, use caution so that foreign matter, water drops, or other substance does not enter the opening or motor cable seal.
    • Use caution so that foreign matter, water drops, or other substance does not enter the inverter with converter assembly.

    Tightening torque: 

    37.5 N.m (0.8 kgf-m, 5.5 ft-lb)

  2. Install the inhibitor terminal cover.
    WARNING: Be sure to wear insulated gloves.

    Tightening torque: 

    7.5 N.m (0.8 kgf-m, 5.5 ft-lb)

  3. Install the brackets onto the inverter with converter assembly.
    1. Place the inverter with converter assembly onto wooden blocks.
      CAUTION: Because there is the risk of damage to the inverter with converter assembly, support it at the position shown in the figure.
      G13235693Courtesy of SUBARU OF AMERICA, INC.
    2. Install the front bracket assembly - inverter and insulator - front.

      Tightening torque: 

      18 N.m (1.8 kgf-m, 13.3 ft-lb)

    3. Install the rear bracket assembly - inverter and bracket assembly - rear.

      Tightening torque: 

      18 N.m (1.8 kgf-m, 13.3 ft-lb)

    4. Install the stay COMPL - inverter.

      Tightening torque: 

      18 N.m (1.8 kgf-m, 13.3 ft-lb)

  4. Temporarily install the cover - inverter.
  5. Install the protector - inverter.
    1. Temporarily install the protector - inverter.
    2. Tighten the bolts in the order of (a) - (c).

      Tightening torque: 

      18 N.m (1.8 kgf-m, 13.3 ft-lb)

      Fig 1: Protector - Inverter Bolts Tightening Sequence
      G13235700Courtesy of SUBARU OF AMERICA, INC.
  6. Install the inverter rear water pipe COMPL.
    CAUTION:
    • So that foreign matter does not enter the engine coolant passage, place hose plugs or plastic bags onto the pipes and hoses until just before the inverter rear water pipe COMPL connection work.
    • Do not apply excessive force to the inverter inlet hose and inverter outlet hose.
    NOTE: Align hoses, clamps, etc. with the alignment mark positions.
  7. Install the main battery cable assembly.
    WARNING: Be sure to wear insulated gloves.
    CAUTION:
    • When connecting the main battery cable connector, be careful not to use excessive force or damage the connector.
    • Be careful so that foreign matter, water drops, or other substance does not enter the opening or connector seal after the terminal is disconnected.

    Tightening torque: 

    7.5 N.m (0.8 kgf-m, 5.5 ft-lb)

  8. Install the HV air conditioning wire.
    WARNING: Be sure to wear insulated gloves.
    CAUTION:
    • When connecting the HV air conditioning wire (air conditioner cable) connector, be careful not to use excessive force or damage the connector.
    • Be careful so that foreign matter, water drops, or other substance does not enter the opening or connector seal after the terminal is disconnected.

    Tightening torque: 

    7.5 N.m (0.8 kgf-m, 5.5 ft-lb)

  9. Install the cover - inverter rivets.

    Preparation tool: 

    Hand riveter

  10. Install the hose - air breather.
  11. Install the inverter with converter assembly.
    WARNING: Be sure to wear insulated gloves.
    CAUTION:
    • A helper is required to perform this work.
    • Be careful not to damage the HV air conditioning wire and main battery cable assembly.
    • When installing the inverter with converter assembly, be careful to avoid damaging surrounding parts while working. Do not grasp the inverter rear water pipe COMPL.
    • In order to prevent damage caused by static electricity, do not touch the connector terminals of the inverter with converter assembly side.
    1. Place the inverter with converter assembly onto the transmission jack.
    2. Temporarily install the inverter with converter assembly.
    3. Tighten the bolts in the order of (a) - (d).

      Tightening torque: 

      23 N.m (2.3 kgf-m, 17 ft-lb)

      Fig 2: Inverter With Converter Assembly Bolts Tightening Sequence
      G13235701Courtesy of SUBARU OF AMERICA, INC.
      NOTE: Improper tightening of mounting bolts for the inverter with converter assembly may cause abnormal noise to be produced from the inverter with converter assembly.
    4. Install the support - sub frame LH.

      Tightening torque: 

      Refer to REAR SUSPENSION>GENERAL DESCRIPTION>COMPONENT>REAR SUSPENSION .

    5. Install the electronic parking brake harness LH.

      Tightening torque: 

      Refer to PARKING BRAKE>GENERAL DESCRIPTION>COMPONENT>PARKING BRAKE LEVER & CABLE .

    6. Install the HV air conditioning wire.

      Tightening torque: 

      7.5 N.m (0.8 kgf-m, 5.5 ft-lb)

    7. Install the hose - air breather. Refer to FUEL INJECTION (FUEL SYSTEMS) (H4DO (HEV))>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE E) .
    8. Install the ground cable.

      Tightening torque: 

      7.5 N.m (0.8 kgf-m, 5.5 ft-lb)

  12. Connect the pipe COMPL - center.
    CAUTION:
    • So that foreign matter does not enter the engine coolant passage, place hose plugs or plastic bags onto the pipes and hoses until just before the inverter inlet hose and inverter outlet hose connection work.
    • Do not apply excessive force to the inverter inlet hose and inverter outlet hose.
    NOTE: Align hoses, clamps, etc. with the alignment mark positions.
  13. Remove the protector - inverter.
    1. Remove the bolts and remove the protector - inverter.
      G13235702Courtesy of SUBARU OF AMERICA, INC.
  14. Install the power cable assembly.
    WARNING: Be sure to wear insulated gloves.
    CAUTION:
    • Do not apply excessive force to the power cable assembly.
    • Because there is the risk of damaging the threads, be sure to work by hand when connecting the terminals.
    • First partially tighten all of the terminal bolts before fully tightening them.
    • When installing the power cable assembly, be careful not to scratch the terminals, connector housing, or inverter with converter assembly.
    • Replace the cover - power connector with a new part.
    • Be careful so that foreign matter, water drops, or other substance does not enter the opening or connector seal after the terminal is disconnected.

    Tightening torque: 

    Refer to HYBRID ELECTRIC VEHICLE>GENERAL DESCRIPTION>COMPONENT>POWER CABLE .

  15. Install the protector - inverter.
    1. Temporarily install the protector - inverter.
    2. Tighten the bolts in the order of (a) - (c).

      Tightening torque: 

      18 N.m (1.8 kgf-m, 13.3 ft-lb)

      Fig 3: Protector - Inverter Bolts Tightening Sequence
      G13235703Courtesy of SUBARU OF AMERICA, INC.
  16. Install the rear exhaust pipe. Refer to EXHAUST (H4DO (EXCEPT FOR HEV))>REAR EXHAUST PIPE>INSTALLATION .
  17. Install the front exhaust pipe and crossmember support - rear LH. Refer to EXHAUST (H4DO (EXCEPT FOR HEV))>FRONT EXHAUST PIPE>INSTALLATION .
  18. Install the under cover - front. Refer to EXTERIOR/INTERIOR TRIM>FRONT UNDER COVER>INSTALLATION .
  19. Install the floor under protector LH. Refer to EXTERIOR/INTERIOR TRIM>FLOOR UNDER PROTECTOR>INSTALLATION .
  20. Install the fuel tank protector and the cover of inverter with converter assembly. Refer to FUEL INJECTION (FUEL SYSTEMS) (H4DO (HEV))>FUEL TANK PROTECTOR>INSTALLATION .
  21. Lower the vehicle.
  22. Connect the HV air conditioning wire.
    WARNING: Be sure to wear insulated gloves.
    CAUTION: Make sure the connector is connected securely.

    Tightening torque: 

    7.5 N.m (0.8 kgf-m, 5.5 ft-lb)

  23. Connect the connector of inverter with converter assembly.
    WARNING: Be sure to wear insulated gloves.
    CAUTION:
    • When connecting the connector, be careful not to scratch the connector housing or the inverter with converter assembly.
    • Do not touch the connector terminals or seal.
  24. Install the cover - inverter.
    WARNING: Be sure to wear insulated gloves.
  25. Connect the main battery cable assembly.
    WARNING: Be sure to wear insulated gloves.
    CAUTION: Make sure the main battery cable assembly connector is connected securely.
  26. Install the rear seat cushion assembly and the backrest assembly LH. Refer to SEATS>REAR SEAT>INSTALLATION .
  27. Install the service disconnect plug. Refer to HYBRID ELECTRIC VEHICLE>SERVICE PLUG>INSTALLATION .
  28. Connect the battery ground terminal. Refer to REPAIR CONTENTS>REPAIR CONTENTS>NOTE>BATTERY .
  29. Fill with engine coolant (inverter assembly side). Refer to COOLING (H4DO (HEV))>ENGINE COOLANT>REPLACEMENT>FILLING OF ENGINE COOLANT .
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