MOTOR GENERATOR CONTROL COMPUTER 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 motor generator control ECU kit removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure Necessary Procedures Effect/Inoperative Function when Necessary Procedure not Performed Link
Auxiliary battery terminal is disconnected/reconnected Memorize steering angle neutral point Lane departure alert system (w/ Steering Control)

Click here

Intelligent clearance sonar system*1
Simple intelligent parking assist system*1
Pre-crash safety system
Parking assist monitor system

Click here

Initialize back door lock Power door lock control system

Click here

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

Click here


    for SFI system (w/ Canister Pump Module)

  • Replacement of ECM

 Perform Vehicle Identification Number (VIN) registration MIL comes on

Click here


    for SFI system (w/o Canister Pump Module)

  • Replacement of ECM

 Perform Vehicle Identification Number (VIN) or frame number registration

Click here

*1: When performing learning using the GTS.
Click here Click here

CAUTION:


  • B004PF2

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

    Click here

  • B004Q03

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

Note


  • If metal shavings are created when bolts are removed from the inverter with converter assembly, remove them using tape or equivalent.

  • Use non-residue type tape.

B004PK5

Tech Tips

When replacing the motor generator control computer kit, make sure to check the part number label on the inverter upper cover and replace the motor generator control computer kit with the appropriate part.

B004PW7C01
*a Part Number Label
Part Number Compatibility Table
Part Number Motor Generator Control ECU Kit Number

G9200-47240

G9200-47260

 04899-47100(Number of Connectors:21)

If the part number is not listed above, refer to the parts catalog.

PROCEDURE


  1. REMOVE INVERTER WITH CONVERTER ASSEMBLY

    Click here

  2. REMOVE WIRE HARNESS CLAMP BRACKET

    Click here

  3. VERIFY THAT VOLTAGE OF INVERTER WITH CONVERTER IS 0 V

    CAUTION:

    Wear insulating gloves.

    Note

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


    1. B004OTEC01
      *a Tape

      Remove the protective tape from the HV floor under wire opening.

    2. B004P2EC01
      *a Voltage Measurement Position

      Using a voltmeter, measure the voltage between the high voltage cable connector terminals.

      Standard voltage
      0V

      Tech Tips


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

      • If it is confirmed that high-voltage is not being applied to the inverter with converter assembly, the following procedures can be performed without using insulated tools or gloves.

    3. Apply protective tape to the area that was exposed.

      Note

      Use non-residue type tape.

  4. CLEAN INVERTER WITH CONVERTER ASSEMBLY


    1. Using a piece of cloth, clean the outside of the inverter with converter assembly and around the bolts.

      Note

      To prevent foreign matter from entering the inverter with converter assembly, make sure that the protective tape is not partially removed.

  5. HOW TO PREVENT STATIC ELECTRICITY

    SST
    09890-47010

    Note


    • Static electricity should be eliminated when removing/installing the inverter with converter assembly.

    • Do not touch the electronic components of a circuit board.

    • Keep clothes away from electronic components.

    • Place the inverter with converter assembly and any removed electronic components on SST (antistatic mat).


    1. B004Q9ZN03

      Wear an antistatic wrist strap.

    2. Connect the ground clip of the antistatic mat securely to a ground point provided in the workshop or on a workbench (anchor bolt).

      Tech Tips

      If the ground clip cable is too short, use an extension cable.

    3. Connect the ground clip of the antistatic wrist strap securely to the specified point of the antistatic mat.

    4. When handling internal components of the inverter with converter assembly, use only antistatic gloves or bare hands to prevent damage from static electricity or the entry of foreign matter.

  6. REMOVE INVERTER UPPER COVER


    1. B004QFS

      Remove the 10 bolts.

    2. Using a screwdriver with its tip wrapped with protective tape, bend the 2 flanges of the inverter upper cover inward.

      B004ORUC01
      *a A-A Cross Section *b Protective Tape

    3. Using a screwdriver with its tip wrapped with protective tape, remove the inverter upper cover from the inverter with converter assembly.

      B004PBGC01
      *a Protective Tape - -

      Note


      • Do not damage the sealing surfaces of the inverter with converter assembly.

      • Do not touch or allow grease or oil to contact the sealing surfaces of the inverter with converter assembly.

      • Be careful not to damage the sealing surfaces of the inverter with converter assembly.

      • To prevent internal components of the inverter with converter assembly from being damaged, do not insert the screwdriver excessively.

  7. REMOVE SEAL PACKING FROM INVERTER WITH CONVERTER ASSEMBLY

    Note


    • Do not allow any removed seal packing to enter the inverter with converter assembly.

    • Do not touch the circuit board.

    • Do not allow any moisture to come into contact.


    1. Using a finger, remove any seal packing that has seeped into the inverter with converter assembly.

      Tech Tips

      Make sure to remove any seal packing which has seeped toward the inside of inverter with converter assembly before installing the seal packing removal cover, otherwise the seal packing may be pushed into the inverter with converter assembly.

    2. B004OUX

      Break off the seal packing removal cover and scraper at each break off line.

    3. Set the seal packing removal cover on the inverter with converter assembly and secure it by lightly pressing it at the 2 areas shown in the illustration.

      B004QCLC01
      *a A-A Cross Section *b B-B Cross Section
      B004PFI Push - -

      Note

      Make sure that the seal packing removal cover is in secure contact with the inside surface of the inverter with converter assembly without any gaps.

    4. B004P37C01
      *a MG Connector Opening

      Place the inverter with converter assembly on its side on an antistatic mat as shown in the illustration.

      Note


      • Make sure that the MG connector opening in the inverter with converter assembly is facing upward.

      • Make sure that the inverter with converter assembly is oriented correctly, otherwise seal packing may enter the inverter with converter assembly.

    5. Using a scraper, remove any remaining seal packing from the inverter with converter assembly.

      Note


      • It is not necessary to remove small amounts of seal packing which are not easily scraped off.

        B004OKNC02
        *a Correct *b Incorrect
        *c Width of Sealing Surface *d Difficult to Remove Seal Packing
        *e Peeled Off Seal Packing *f Seal Packing Remaining on Full Width of Sealing Surface
      • B004P3P

        Make sure to use the scraper supplied with the seal packing removal cover.

      Tech Tips

      Use the small end of the scraper to remove seal packing from small areas such as bolt holes.

    6. Using a clean piece of cloth, clean the sealing surfaces of the inverter with converter assembly.

      Note


      • Do not use compressed air or a vacuum cleaner to clean the sealing surfaces of the inverter with converter assembly.

      • Do not use non-residue solvent to clean the sealing surfaces of the inverter with converter assembly.

    7. B004OWP

      Remove the seal packing removal cover.

      Note

      Make sure that the inverter with converter assembly is oriented correctly, otherwise seal packing may enter the inverter with converter assembly when removing the seal packing removal cover.

    8. Check for and remove any foreign matter which has entered the inverter with converter assembly.

    9. Set the inverter with converter assembly upright.

    10. Clean the seal packing removal cover.

      Tech Tips

      As the seal packing removal cover will be reused, it is necessary to clean it to prevent foreign matter from entering the inverter with converter assembly and prevent damage.

  8. REMOVE MOTOR GENERATOR CONTROL ECU KIT

    CAUTION:

    To prevent foreign matter from entering the inverter with converter assembly, once the seal packing removal cover has been removed, work cannot be suspended until the motor generator control ECU kit is reinstalled.

    Note


    • Do not touch the circuit board.

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


    1. Install the seal packing removal cover to the inverter with converter assembly.

      Tech Tips

      The seal packing removal cover is installed to help prevent the motor generator control computer kit from being damaged if a part or tool is dropped on it.

    2. B004QL2

      Install the 2 guide pins by hand at the positions shown in the illustration.

      Note

      Make sure that the guide pins are tightened securely.

    3. B004QQ4

      Remove the seal packing removal cover.

    4. B004Q5XC01
      B004P9H Unlock
      B004PYE Rib

      Check that the 4 clips of the circuit board replacement jig are unlocked, and then while holding the circuit board replacement jig by the ribs, align it with the guide pins and set it on the inverter with converter assembly.

      Tech Tips

      Make sure that circuit board replacement jig is perfectly level with the sealing surface.

    5. B004QT5C04
      *a Locked
      *b Locked Position
      B004PRK Bolt
      B004P9H Lock

      Secure the circuit board replacement jig with 2 inverter upper cover installation bolts.

    6. Lock the 4 clips as shown in the illustration to secure the circuit board replacement jig to the circuit board.

      Note

      When locking the clips of the circuit board replacement jig, do not apply excessive force to the clips, otherwise the circuit board replacement jig may be damaged.

      Tech Tips

      Make sure that the clips of the circuit board replacement jig are securely locked.

    7. B004PW7C01
      *a Part Number Label

      Check the part number label on the inverter upper cover.

      Tech Tips

      The number of vibration dampening connectors on the motor generator control ECU kit differs according to the part number.

      Type Part Number Number of Vibration Dampening Connectors
      A

      for Inverter with Converter Assembly with Part Number


      • G9200-47240

        G9200-47260

      		 21
      B

      for Inverter with Converter Assembly with Part Number Other Than


      • G9200-47240

        G9200-47260

      		 20

    8. Type A:


      1. B004POQC02
        *a Connected Vibration Dampening Connector
        *b Disconnected Vibration Dampening Connector
        *c Stopper of The Circuit Board Replacement Jig

        Using SST, release the lock of each vibration dampening connector and raise the 21 vibration dampening connectors until they reach the stopper of the circuit board replacement jig.

        SST
        09905-00040

        Note

        When disconnecting the vibration dampening connectors, release the lock of each connector with SST and then carefully lift the connector the specified amount.

        Tech Tips


        • To prevent the vibration dampening connectors from being pulled up excessively, use both hands to raise them slowly as shown in the illustration.

        • The position of the lock will vary depending on the position of the vibration dampening connector. Refer to the arrows on the circuit board replacement jig.

        B004QXXC02

    9. Type B:


      1. B004PP5C01
        *a Connected Vibration Dampening Connector
        *b Disconnected Vibration Dampening Connector
        *c Stopper of The Circuit Board Replacement Jig

        Using SST, release the lock of each vibration dampening connector and raise the 20 vibration dampening connectors until they reach the stopper of the circuit board replacement jig.

        SST
        09905-00040

        Note

        When disconnecting the vibration dampening connectors, release the lock of each connector with SST and then carefully lift the connector the specified amount.

        Tech Tips


        • To prevent the vibration dampening connectors from being pulled up excessively, use both hands to raise them slowly as shown in the illustration.

        • The position of the lock will vary depending on the position of the vibration dampening connector. Refer to the arrows on the circuit board replacement jig.

        B004QXXC02
    10. B004PT1C01
      B004PRK Bolt (A)
      B004P9H Bolt (B)

      Remove the 3 bolts (A).

      Tech Tips

      If the bolts are difficult to remove from the circuit board replacement jig, use a magnet hand.

    11. Remove the 12 bolts (B).

      Tech Tips

      If the bolts are difficult to remove from the circuit board replacement jig, use a magnet hand.

    12. Remove the 2 inverter upper cover installation bolts.

    13. B004PB6C01
      B004PYE Rib

      While holding the circuit board replacement jig by the ribs, evenly lift the circuit board replacement jig and circuit board straight up and remove it.

    14. B004PF8

      Place the circuit board replacement jig upside down on a clean workbench.

    15. Check that the terminals of the inverter with converter assembly are not bent or damaged and that it is free of foreign matter.

      B004OJLC01
      *a Correct *b Incorrect
      *c Terminal - -

      Note


      • Do not touch the terminals.

      • If any of the terminals are bent, replace the inverter with converter assembly with a new one. Do not attempt to repair the terminals.

    16. Unlock the 4 circuit board replacement jig clips, and then while holding the sides of the circuit board or the top and bottom of the circuit board at the areas shown in the illustration, lift the circuit board to remove it from the circuit board replacement jig.

      B004QR8C02
      *a Hold here *b Do not hold here
      *c Circuit Board *d Circuit Board Replacement Jig
      B004PRK Unlock - -

      Note

      Be careful not to touch any part of the circuit board other than the specified areas.