FUEL PRESSURE PULSATION DAMPER REMOVAL

Tech Tips

When viewed from the rear of the engine assembly, Bank 1 is on the left side and Bank 2 is on the right side.

Note

While the auxiliary battery is connected, even if the power switch is off, the brake control system activates when the brake pedal is depressed or the door courtesy switch turns on. Therefore during servicing of the brake system components, do not operate the brake pedal and open / close the doors while the battery is connected.


  1. DISCHARGE FUEL SYSTEM PRESSURE

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  2. REMOVE INTAKE MANIFOLD

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  3. REMOVE COWL TOP VENTILATOR LOUVER RH (for LHD)


    1. A01GXQ9

      Remove the 4 clips and hood to cowl top seal.

    2. Remove the 6 clips and cowl top ventilator louver RH.

  4. REMOVE MOTOR CABLE COVER RH (for LHD)


    1. A01GX1K

      Remove the 2 clips and motor cable cover RH.

  5. REMOVE INVERTER COVER ASSEMBLY RH (for LHD)


    1. A01H0NS

      Detach the 2 clips and remove the inverter cover assembly RH.

  6. REMOVE CONNECTOR COVER ASSEMBLY (for LHD)

    CAUTION:

    Wear insulating gloves.


    1. A01GXYO

      Using an insulated tool, remove the 2 bolts and connector cover assembly.

      Note


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

      • Do not touch the high voltage connectors or terminals for 10 minutes after the service plug grip is removed.

  7. CHECK TERMINAL VOLTAGE (for LHD)

    CAUTION:

    Wear insulating gloves.


    1. A01H1SR

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

      Standard voltage
      0 V

      Tech Tips

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

  8. INSTALL CONNECTOR COVER ASSEMBLY (for LHD)

    CAUTION:

    Wear insulating gloves.


    1. A01GXYO

      Using an insulated tool, install the connector cover assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  9. REMOVE COWL TOP VENTILATOR LOUVER LH (for RHD)


    1. A01GZEK

      Remove the 4 clips and hood to cowl top seal.

    2. Remove the 6 clips and cowl top ventilator louver LH.

  10. REMOVE MOTOR CABLE COVER LH (for RHD)


    1. A01GW49

      Remove the 2 clips and motor cable cover LH.

  11. REMOVE INVERTER COVER ASSEMBLY LH (for RHD)


    1. A01H09U

      Detach the 2 clips and remove the inverter cover assembly LH.

  12. REMOVE CONNECTOR COVER ASSEMBLY (for RHD)

    CAUTION:

    Wear insulating gloves.


    1. A01GX3O

      Using an insulated tool, remove the 2 bolts and connector cover assembly.

      Note


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

      • Do not touch the high voltage connectors or terminals for 10 minutes after the service plug grip is removed.

  13. CHECK TERMINAL VOLTAGE (for RHD)

    CAUTION:

    Wear insulating gloves.


    1. A01GX6G

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

      Standard voltage
      0 V

      Tech Tips

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

  14. INSTALL CONNECTOR COVER ASSEMBLY (for RHD)

    CAUTION:

    Wear insulating gloves.


    1. A01GX3O

      Using an insulated tool, install the connector cover assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  15. REMOVE INVERTER TERMINAL COVER (for LHD)

    CAUTION:

    Wear insulating gloves.

    Note

    Lift the inverter terminal cover horizontally so that it will not tilt. Failure to do so may break the inverter cover guide pins.


    1. A01GYJRE01

      Using an insulated tool, remove the 2 bolts.

    2. Insert and gradually rotate a screwdriver between the inverter terminal cover and inverter case near bolt hole A to raise the terminal cover by approximately 2 mm (0.08 in.). (*1)

      Note

      Tape the screwdriver tip before use.

    3. Insert and gradually rotate a screwdriver between the inverter terminal cover and inverter case near bolt hole B to raise the terminal cover by approximately 2 mm (0.08 in.). (*2)

      Note

      Tape the screwdriver tip before use.

      Tech Tips

      Repeat the preceding steps (*1) and (*2) until the inverter cover can be easily removed by hand.

    4. Remove the inverter terminal cover by hand.

      Note


      • Do not allow any foreign objects to enter the waterproofed parts of the removed inverter terminal cover.

      • Do not touch the waterproofed parts.

      • When removing the inverter terminal cover, do not bend the connector terminals around the interlock part.

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

  16. DISCONNECT MOTOR CABLE (for LHD)

    CAUTION:

    Wear insulating gloves.


    1. A01GY2R

      Remove the 3 bolts and separate the motor cable bracket.

    2. A01GZJI

      Using an insulated tool, remove the 5 bolts and pull out the motor cable from the inverter with converter assembly.

      Note


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

      • When removing the bolts that secure the cable, do not damage anything inside the inverter with converter assembly.

  17. DISCONNECT GENERATOR CABLE (for LHD)

    CAUTION:

    Wear insulating gloves.


    1. A01H1LV

      Using an insulated tool, remove the 5 bolts and pull out the generator cable from the inverter with converter assembly.

      Note


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

      • When removing the bolts that secure the cable, do not damage anything inside the inverter with converter assembly.

  18. DISCONNECT INLET INVERTER COOLING PIPE (for LHD)


    1. A01H1AA

      Remove the 2 bolts and disconnect the inlet inverter cooling pipe.

  19. DISCONNECT FRAME WIRE (for LHD)


    1. Remove the No. 1 relay block cover.

    2. A01H1CR

      Remove the 2 nuts from the frame wire.

    3. Detach the 2 claws to disconnect the frame wire from the No. 1 relay block.

  20. REMOVE INVERTER TERMINAL COVER (for RHD)

    CAUTION:

    Wear insulating gloves.

    Note

    Lift the inverter terminal cover horizontally so that it will not tilt. Failure to do so may break the inverter cover guide pins.


    1. A01GWMTE01

      Using an insulated tool, remove the 2 bolts.

    2. Insert and gradually rotate a screwdriver between the inverter terminal cover and inverter case near bolt hole A to raise the terminal cover by approximately 2 mm (0.08 in.). (*1)

      Note

      Tape the screwdriver tip before use.

    3. Insert and gradually rotate a screwdriver between the inverter terminal cover and inverter case near bolt hole B to raise the terminal cover by approximately 2 mm (0.08 in.). (*2)

      Note

      Tape the screwdriver tip before use.

      Tech Tips

      Repeat the preceding steps (*1) and (*2) until the inverter cover can be easily removed by hand.

    4. Remove the inverter terminal cover by hand.

      Note


      • Do not allow any foreign objects to enter the waterproofed parts of the removed inverter terminal cover.

      • Do not touch the waterproofed parts.

      • When removing the inverter terminal cover, do not bend the connector terminals around the interlock part.

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

  21. DISCONNECT MOTOR CABLE (for RHD)

    CAUTION:

    Wear insulating gloves.


    1. A01H281

      Remove the 3 bolts and separate the motor cable bracket.

    2. A01H1MQ

      Using an insulated tool, remove the 5 bolts and pull out the motor cable from the inverter with converter assembly.

      Note


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

      • When removing the bolts that secure the cable, do not damage anything inside the inverter with converter assembly.

  22. DISCONNECT GENERATOR CABLE (for RHD)

    CAUTION:

    Wear insulating gloves.


    1. A01H0UQ

      Using an insulated tool, remove the 5 bolts and pull out the generator cable from the inverter with converter assembly.

      Note


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

      • When removing the bolts that secure the cable, do not damage anything inside the inverter with converter assembly.

  23. DISCONNECT FRAME WIRE (for RHD)


    1. Remove the No. 1 relay block cover.

    2. A01H138

      Remove the 2 nuts from the frame wire.

    3. Detach the 2 claws to disconnect the frame wire from the No. 1 relay block.

  24. REMOVE INVERTER COOLING PIPE BRACKET (for RHD)


    1. A01GWAY

      Detach the 2 clamps to disconnect the air conditioning harness from the No. 1 relay block.

    2. A01GWKO

      Detach the clamp of the No. 2 inlet inverter cooling hose from the inverter cooling pipe bracket.

    3. Remove the bolt, and then remove the inverter cooling pipe bracket from the inverter with converter assembly.

    4. A01H037

      Detach the clamp of the frame wire and the clamp of the air conditioning harness. Then remove the inverter cooling pipe bracket.

  25. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01H2BZE01

      Remove the engine oil level dipstick.

    2. Remove the bolt and engine oil level dipstick guide.

    3. Remove the O-ring from the engine oil level dipstick guide.

  26. REMOVE ENGINE COVER SUB-ASSEMBLY RH


    1. A01GXYYE01

      Remove the 4 nuts and engine cover RH.

  27. REMOVE NO. 5 COVER SUB-ASSEMBLY


    1. Remove the No. 5 cover.

  28. REMOVE ENGINE COVER SUB-ASSEMBLY LH


    1. A01GZYBE01

      Remove the 4 nuts and engine cover LH.

  29. REMOVE NO. 6 COVER SUB-ASSEMBLY


    1. Remove the No. 6 cover.

  30. DISCONNECT NO. 1 FUEL HOSE

    A01H19YE01

    1. Lift up the retainer to release its lock.

    2. Pinch the tube connector and then pull out the fuel pipe.

      Note


      • Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.

      • Do not use any tools to separate the pipe and connector.

      • Do not forcefully bend or twist the nylon tube.

      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.

      • Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.

      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the pipe.

  31. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY


    1. A01GYCME03

      Disconnect the 2 delivery pipe connectors from the delivery pipe.

    2. A01GYHSE01

      Disconnect the 3 fuel hoses.

    3. A01GXSIE02

      Using SST, remove the 2 fuel pressure pulsation dampers.

      SST
      09612-24014   ( 09617-24011 )
    4. A01GY7X

      Remove the 2 clamp bolts shown in the illustration.

    5. Remove the 2 pulsation dampers, 4 gaskets and No. 1 fuel pipe.