INVERTER WITH CONVERTER REMOVAL

CAUTION / NOTICE / HINT

CAUTION:


  • B000ZMO

    This vehicle has contains high voltage circuits standardized with orange colored wiring and connectors, so follow the instructions in this manual to perform the procedures correctly.

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  • If the correct procedures are not followed according to the instructions in this manual, there is a danger of electric shock from the high voltage circuits.

  • B006JFB

    Be sure to wear insulating gloves when working on high voltage wiring or components.

  • If work is performed without wearing insulating gloves, there is a danger of electric shock.

Note

When the vehicle is parked with the power switch off, if the FC control ECU judges that the FC stack temperature will go below 0 °C (32 °F), it activates the FC air compressor, hydrogen pump and FC cooling water pump for a maximum of 180 seconds and drains water from the FC stack assembly. When performing inspection or repairs with the power switch off (not On or Ready), disconnect the cable from the negative auxiliary battery terminal before performing work.

PROCEDURE


  1. CAUTIONS FOR HIGH VOLTAGE SYSTEM COMPONENTS

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  2. CAUTIONS FOR INTAKE SYSTEM COMPONENTS

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  3. REMOVE SERVICE PLUG GRIP (for EV)

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  4. REMOVE FC STACK SERVICE PLUG GRIP

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  5. REMOVE LOWER FRONT BUMPER ABSORBER

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  6. REMOVE NO. 3 REMOVE RADIATOR AIR GUIDE

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  7. DRAIN INVERTER COOLANT

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  8. REMOVE WINDSHIELD WIPER MOTOR AND LINK

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  9. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)

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  10. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

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  11. REMOVE WATER GUARD PLATE LH (for LHD)

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  12. REMOVE WATER GUARD PLATE RH (for RHD)

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  13. REMOVE COWL BODY MOUNTING REINFORCEMENT RH (for LHD)

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  14. REMOVE COWL BODY MOUNTING REINFORCEMENT RH (for RHD)

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  15. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)

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  16. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)

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  17. REMOVE COOL AIR INTAKE DUCT SEAL

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  18. REMOVE AIR CLEANER INLET

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  19. REMOVE AIR CLEANER ASSEMBLY WITH ELEMENT

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  20. REMOVE INVERTER COVER


    1. A01MGD1C03
      B006JDZ Place Hands Here
      B006JFV Remove in this Direction

      Disengage the 4 grommets and remove the inverter cover from the inverter with converter assembly and inverter protector.

      Note

      To avoid damaging the inverter cover, pull it upwards and disengage the grommet.

    2. A01MH4N

      Remove the 4 bolts from the inverter with converter assembly and inverter protector.

  21. REMOVE INVERTER TERMINAL COVER

    CAUTION:

    Wear insulated gloves.

    Note

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


    1. B000ZJX

      Disconnect the 4 connectors.

    2. B000ZS8

      Disengage the 2 clamps to separate the wire harness from the inverter terminal cover.

    3. A01MIDDC10
      *1 Interlock Connector

      Remove the 11 bolts and inverter terminal cover from the inverter with converter assembly.

      Note


      • The inverter terminal cover has an interlock connector, so pull it up perpendicularly.

      • Do not touch the rubber seal of the inverter terminal cover.

  22. CHECK TERMINAL VOLTAGE

    CAUTION:

    Wear insulated gloves.

    Note

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


    1. B000ZUU

      Using a 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.

  23. TEMPORARILY TIGHTEN INVERTER TERMINAL COVER

    CAUTION:

    Wear insulated gloves.

    Note

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


    1. A01MIDDC11
      *1 Interlock Connector
      *2 Connector Bracket

      Temporarily install the inverter cover with the 7 bolts to prevent any foreign matter or water from entering the inverter with converter assembly.

      Note


      • Make sure that the rubber seal of the inverter terminal cover is securely installed and that no foreign matter is adhering to it, then install it.

      • Do not touch the rubber seal of the inverter terminal cover.

      • Do not install the inverter terminal cover while pressing down on the connector bracket.

      • Securely connect the interlock connector.

  24. DISCONNECT WIRE HARNESS

    CAUTION:

    Wear insulated gloves.

    Note


    • To prevent damage from static electricity, do not touch the connector terminal portion.

    • To prevent contamination by foreign matter or water droplets, cover the opening of the connector with protective tape.


    1. A01MJ42C02
      *1 Lock Lever

      Lift the lock lever and disconnect the connector.

    2. Disengage the clamp to separate the wire harness from the inverter reserve tank assembly.

    3. A01MFGT

      Disconnect the 4 connectors.

    4. Disengage the 4 clamps to separate the wire harness from the FC inverter input junction cover, inverter protector and inverter reserve tank assembly.

    5. Remove the nut and separate the wire harness from the inverter protector.

  25. SEPARATE FC WATER PUMP DRAIN HOSE ASSEMBLY


    1. A01MJ0I

      Remove the bolt and separate the FC water drain hose assembly from the FC inverter input junction assembly.

  26. REMOVE FC INVERTER INPUT JUNCTION COVER

    CAUTION:

    Wear insulated gloves.


    1. A01MIADC06
      *1 Interlock Connector

      Remove the 2 bolts and FC inverter input junction cover from the FC inverter input junction assembly.

      Note


      • The FC inverter input junction cover has an interlock connector, so pull it out straight.

      • Do not touch the rubber seal of the FC inverter input junction cover.

  27. DISCONNECT FRAME WIRE

    CAUTION:

    Wear insulated gloves.


    1. A01MGUPC09
      *1 Interlock Connector

      Using an insulated tool, remove the 4 bolts and disconnect the frame wire from the FC inverter input junction assembly.

      Note


      • The frame wire has an interlock connector, so pull it out straight.

      • When disconnecting, be careful not to damage the terminal portion, connector housing, or FC inverter input junction assembly.

      • Do not touch the rubber seal or terminal portion of the frame wire.

      • Insulate the connector portion of the frame wire by wrapping it with insulating tape.

    2. A01MJ2WC06
      *a Protective Tape

      To prevent contamination by foreign matter or water droplets, cover the opening of the FC inverter input junction assembly with protective tape.

  28. REMOVE INVERTER TERMINAL COVER

    CAUTION:

    Wear insulated gloves.

    Note

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


    1. A01MIDDC12
      *1 Interlock Connector

      Remove the 11 bolts and inverter terminal cover from the inverter with converter assembly.

      Note


      • The inverter terminal cover has an interlock connector, so pull it up perpendicularly.

      • Do not touch the rubber seal of the inverter terminal cover.

  29. REMOVE FC INVERTER INPUT JUNCTION ASSEMBLY

    CAUTION:

    Wear insulated gloves.

    Note

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


    1. A01MHFTC03
      *1 Green-colored Lock

      Disengage the clamp to separate the wire harness from the FC inverter input junction assembly.

    2. As shown in the illustration, pull out the green lock of the connector, and disconnect the connector from the FC water and hydrogen pump inverter assembly.

      Note


      • Do not touch the connector terminals.

      • Insulate the opening of the connector by wrapping it with insulating tape.

    3. A01MGT0C03
      *1 Green-colored Lock

      As shown in the illustration, pull out the green lock of the connector, and disconnect the connector from the electric heater sub-assembly.

      Note


      • Do not touch the connector terminals.

      • Insulate the opening of the connector by wrapping it with insulating tape.

    4. A01MJTGC05
      *1 Interlock Connector

      Using an insulated tool, remove the 5 bolts and FC inverter input junction assembly from the inverter with converter assembly.

      Note


      • The FC inverter input junction assembly has an interlock connector, so pull it out straight.

      • During removal, make sure not to damage the terminal portion, connector housing, or inverter with converter assembly.

      • Do not touch the seal packing or terminal portion of the FC inverter input junction assembly.

      • Insulate the terminal portion of the FC inverter input junction assembly by wrapping it with insulating tape.

      If the seal packing of the FC inverter input junction assembly has any damage or deformation, replace it with a new one.

    5. A01MIWMC03
      *a Protective Tape

      To prevent contamination by foreign matter or water droplets, cover the opening of the inverter with converter assembly with protective tape.

  30. SEPARATE NO. 3 MOTOR WIRE

    CAUTION:

    Wear insulated gloves.

    Note

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


    1. A01MJC4

      Disengage the clamp to separate the No. 3 motor wire from the FC water and hydrogen pump inverter assembly.

    2. Using an insulated tool, remove the 4 bolts and separate the No. 3 motor wire from the inverter with converter assembly.

      Note


      • When disconnecting, be careful not to damage the terminal portion, connector housing, or inverter with converter assembly.

      • Do not touch the rubber seal or terminal portion of the connector

      • After disconnecting, insulate the connector portion by wrapping it with insulating tape.

    3. A01MGMGC02
      *a Protective Tape

      To prevent contamination by foreign matter or water droplets, cover the opening of the inverter with converter assembly with protective tape.

  31. DISCONNECT MOTOR CABLE

    CAUTION:

    Wear insulated gloves.

    Note

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


    1. A01MFKJ

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

      Note


      • When disconnecting, be careful not to damage the terminal portion, connector housing, or inverter with converter assembly.

      • Do not touch the rubber seal or terminal portion of the connector

      • After disconnecting, insulate the connector portion by wrapping it with insulating tape.

    2. A01MJDUC03
      *a Protective Tape

      To prevent contamination by foreign matter or water droplets, cover the opening of the inverter with converter assembly with protective tape.

  32. DISCONNECT FC AIR COMPRESSOR CABLE

    CAUTION:

    Wear insulated gloves.

    Note

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


    1. A01MJX5

      Using an insulated tool, remove the 5 bolts and disconnect the FC air compressor cable from the inverter with converter assembly.

      Note


      • When disconnecting, be careful not to damage the terminal portion, connector housing, or inverter with converter assembly.

      • Do not touch the rubber seal or terminal portion of the connector

      • After disconnecting, insulate the connector portion by wrapping it with insulating tape.

    2. A01MHJFC03
      *a Protective Tape

      To prevent contamination by foreign matter or water droplets, cover the opening of the inverter with converter assembly with protective tape.

  33. SEPARATE FC CONVERTER POWER OUTLET CABLE

    CAUTION:

    Wear insulated gloves.

    Note

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


    1. A01MI0Z

      Using an insulated tool, remove the 5 bolts and disconnect the FC converter power outlet cable from the inverter with converter assembly.

      Note


      • When disconnecting, be careful not to damage the terminal portion, connector housing, or inverter with converter assembly.

      • Do not touch the rubber seal or terminal portion of the connector

      • After disconnecting, insulate the connector portion by wrapping it with insulating tape.

    2. A01MHZPC02
      *a Protective Tape

      To prevent contamination by foreign matter or water droplets, cover the opening of the inverter with converter assembly with protective tape.

  34. TEMPORARILY TIGHTEN INVERTER TERMINAL COVER

    Click here

  35. SEPARATE WATER PIPE SUB-ASSEMBLY


    1. A01MGYO

      Remove the bolt and 2 nuts and separate the water pipe sub-assembly from the FC water and hydrogen pump inverter assembly and inverter protector.

  36. REMOVE NO. 2 INVERTER DRAIN HOSE


    1. A01MGS9

      Slide the hose clip and disconnect the No. 2 inverter drain hose from the inverter reserve tank assembly.

      Note


      • When disconnecting, be careful not to damage the hose interior surface or pipe portion.

      • Perform the procedures by hand. Do not use any tools.

    2. A01MFLMC03
      *a Plastic Bag

      To prevent contamination by foreign matter, cover the connecting portions of the No. 2 inverter drain hose and inverter reserve tank assembly with plastic bags.

    3. A01MFS9

      Disengage the 2 clamps to remove the No. 2 inverter drain hose from the inverter protector.

    4. Slide the hose clip and disconnect the No. 2 inverter drain hose from the EV water hose connector of the No. 1 inverter cooling hose.

      Note


      • When disconnecting, be careful not to damage the hose interior surface or pipe portion.

      • Perform the procedures by hand. Do not use any tools.

    5. A01MFNEC02
      *a Plastic Bag

      To prevent contamination by foreign matter, cover the connecting portions of the No. 2 inverter drain hose and No. 1 inverter cooling hose with plastic bags.

  37. DISCONNECT NO. 1 INVERTER COOLING HOSE


    1. A01MIVG

      Disengage the 2 clamps to separate the No. 1 inverter cooling hose from the inverter protector.

    2. Slide the hose clip and disconnect the No. 2 inverter cooling hose from the inverter reserve tank assembly.

      Note


      • When disconnecting, be careful not to damage the hose interior surface or pipe portion.

      • Perform the procedures by hand. Do not use any tools.

    3. A01MJZYC02
      *a Plastic Bag

      To prevent contamination by foreign matter, cover the connecting portions of the No. 2 inverter cooling hose and inverter reserve tank assembly with plastic bags.

    4. A01MGGAC02
      *1 Retainer
      *a Protective Tape
      B006JFV Pull out
      B006JHL Slowly pull out

      Using a screwdriver with its tip wrapped in protective tape, pull out the retainer of the EV water hose connector to release the lock.

    5. Slowly pull out the EV water hose connector, and disconnect the No. 1 inverter cooling hose from the inverter with converter assembly.

      Note


      • Perform the procedures by hand. Do not use any tools.

      • When pulling out the EV water hose connector, do not twist it or pull it at an angle.

      If the 2 O-rings on the inner side of the EV water hose connector are damaged or falling out, replace the EV water hose connector with a new one.

    6. A01MG6DC02
      *a Plastic Bag

      To prevent contamination by foreign matter, cover the connecting portions of the No. 1 inverter cooling hose and inverter with converter assembly with plastic bags.

  38. REMOVE INVERTER RESERVE TANK ASSEMBLY


    1. A01MG8D

      Disengage the clamp to separate the wire harness from the inverter reserve tank assembly.

    2. Remove the 2 bolts and nut and separate the inverter reserve tank assembly from the inverter with converter assembly and inverter protector.

    3. A01MFHK

      Slide the hose clip and disconnect the No. 1 inverter drain hose from the inverter reserve tank assembly.

      Note


      • When disconnecting, be careful not to damage the hose interior surface or pipe portion.

      • Perform the procedures by hand. Do not use any tools.

    4. A01MIM5C03
      *a Plastic Bag

      To prevent contamination by foreign matter, cover the connecting portions of the No. 1 inverter drain hose and inverter reserve tank assembly with plastic bags.

  39. DISCONNECT NO. 1 INVERTER COOLING INLET HOSE


    1. A01MJBJ

      Slide the hose clip and disconnect the No. 1 inverter cooling inlet hose from the inverter cooling inlet pipe.

      Note


      • When disconnecting, be careful not to damage the hose interior surface or pipe portion.

      • Perform the procedures by hand. Do not use any tools.

    2. A01MFJIC02
      *a Plastic Bag

      To prevent contamination by foreign matter, cover the connecting portions of the No. 1 inverter cooling inlet hose and inverter cooling inlet pipe with plastic bags.

  40. REMOVE INVERTER PROTECTOR


    1. A01MGHE

      Remove the 3 bolts, nut and inverter protector from the inverter with converter assembly and center frame crossmember sub-assembly.

  41. REMOVE INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Wear insulated gloves.


    1. A01MIWO

      Open the terminal cap cover.

    2. Remove the nut to disconnect the No. 2 motor compartment wire from the inverter with converter assembly.

      Note

      After disconnecting, insulate the connector portion by wrapping it with insulating tape.

    3. A01MJ4W

      Remove the bolt, 2 nuts and inverter with converter assembly from the center frame crossmember sub-assembly.

      Note


      • The inverter with converter assembly is very heavy, so when removing it from the vehicle, perform the work with 2 people and be careful not to damage any of the surrounding components.

      • When lifting up the inverter with converter assembly, to prevent damage, do not hold it by the water pipe, water hose or connector portion.

      • To prevent damage from static electricity, do not touch the connector terminal portion of the inverter with converter assembly.

      • When removing and storing the inverter with converter assembly, to prevent foreign matter or water droplets from entering, make sure that the inverter terminal cover has been installed.

      • For the openings where connectors, etc. were removed, cover them with protective tape to prevent foreign matter and water droplets from entering.

  42. REMOVE NO. 1 INVERTER DRAIN HOSE


    1. A01MGFQ

      Slide the hose clip and remove the No. 1 inverter drain hose from the inverter with converter assembly.

      Note


      • When disconnecting, be careful not to damage the hose interior surface or pipe portion.

      • Perform the procedures by hand. Do not use any tools.

    2. A01MITNC02
      *a Plastic Bag

      To prevent contamination by foreign matter, cover the connecting portions of the No. 1 inverter drain hose and inverter with converter assembly with plastic bags.

  43. REMOVE INVERTER COOLING INLET PIPE


    1. A01MFGQ

      Remove the bolt and separate the inverter cooling inlet pipe from the inverter with converter assembly.

    2. Slide the hose clip and remove the No. 2 inverter cooling inlet hose from the inverter with converter assembly.

      Note


      • When disconnecting, be careful not to damage the hose interior surface or pipe portion.

      • Perform the procedures by hand. Do not use any tools.

    3. A01MJ7VC02
      *a Plastic Bag

      To prevent contamination by foreign matter, cover the connecting portions of the No. 2 inverter cooling inlet hose and inverter with converter assembly with plastic bags.

  44. REMOVE FC CONVERTER CABLE INTER LOCK WIRE

    A01MHNN

    1. Disengage the clamp to remove the FC converter cable inter lock wire from the inverter terminal cover.

  45. REMOVE HIGH VOLTAGE FUSE

    CAUTION:

    Wear insulated gloves.

    Note

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

    Tech Tips

    This procedure is performed when the high voltage fuse must be replaced with a new one.


    1. A01MIDDC13
      *1 Interlock Connector

      Remove the 11 bolts and inverter terminal cover from the inverter with converter assembly.

      Note


      • The inverter terminal cover has an interlock connector, so pull it up perpendicularly.

      • Do not touch the rubber seal of the inverter terminal cover.

    2. A01MJQB

      Using an insulated tool, remove the 2 nuts and inverter terminal sub-assembly from the inverter with converter assembly.

      Note

      Be careful not to drop any nuts into the inverter with converter assembly.

    3. A01MIDDC14
      *1 Interlock Connector
      *2 Connector Bracket

      Temporarily install the inverter cover with the 7 bolts to prevent any foreign matter or water from entering the inverter with converter assembly.

      Note


      • Make sure that the rubber seal of the inverter terminal cover is securely installed and that no foreign matter is adhering to it, then install it.

      • Do not touch the rubber seal of the inverter terminal cover.

      • Do not install the inverter terminal cover while pressing down on the connector bracket.

      • Securely connect the interlock connector.

    4. A01MFK5

      As shown in the illustration, set the inverter terminal sub-assembly onto the inverter with converter assembly.

      Tech Tips

      It is also acceptable to secure the inverter terminal sub-assembly using other tools, instead of setting it on the inverter with converter assembly.

    5. A01MGBU

      Remove the 2 nuts and High voltage fuse from the inverter terminal sub-assembly.