ELECTRIC VEHICLE CONVERTER DISASSEMBLY

CAUTION / NOTICE / HINT

Note

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

A01V12Q

Tech Tips

Prepare 2 tubes of thermal grease X-23-7884-4 when replacing the hybrid vehicle converter kit.


  • For Europe : 08887-83080

  • For except Europe : 08887-02809

PROCEDURE


  1. REMOVE INVERTER WITH CONVERTER ASSEMBLY

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  2. DRAIN COOLANT (for Inverter)

    CAUTION:

    Wear insulating gloves.


    1. B0040WNE02
      Text in Illustration
      *1 Protective Tape

      Apply protective tape to the areas shown in the illustration without leaving any gaps between the tape and part.

      Note

      Use non-residue type tape.

    2. B00411IE01
      Text in Illustration
      *1 Coolant (for inverter) Passage

      Tilt the inverter with converter assembly back and forth to drain the coolant (for inverter).

      Note

      Do not hold the inverter with converter assembly by the coolant pipes or inverter signal connector.

      Tech Tips

      The coolant (for inverter) passage is designed as shown in the illustration. Tilt the inverter with converter assembly back and forth repeatedly to drain the coolant (for inverter) completely.

    3. A01V1TP

      Blow compressed air into the inverter with converter assembly until most all of the coolant (for inverter) is blown out.

      Note

      Do not damage the coolant pipes.

      Tech Tips


      • Use a piece of cloth as shown in the illustration to prevent the coolant (for inverter) from spraying.

      • Cover the air inlet port with a piece of cloth to minimize air leakage.

  3. CLEAN INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Wear insulating gloves.


    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.

    2. Turn the inverter with converter assembly over and clean around the bolts.

      Note

      Do not hold the inverter with converter assembly by the coolant pipes.

  4. REMOVE INVERTER TERMINAL COVER

    CAUTION:

    Wear insulated gloves.


    1. B00414WE01
      Text in Illustration
      *1 Interlock Connector

      Remove the 2 bolts and inverter terminal cover.

      CAUTION:

      An interlock connector is installed to the inverter terminal cover. Make sure to remove the inverter terminal cover before removing the inverter cover.

      Note

      Make sure to pull the inverter terminal cover straight up, as a connector is connected to the bottom of the cover.

  5. REMOVE INVERTER COVER

    CAUTION:

    Wear insulating gloves.


    1. B00415J

      Remove the 7 bolts and inverter cover.

      Note

      An interlock connector is installed to the inverter terminal cover. Make sure to remove the inverter terminal cover before removing the inverter cover.

  6. REMOVE INVERTER SIGNAL CONNECTOR COVER

    CAUTION:

    Wear insulating gloves.


    1. B0040VUE03
      Text in Illustration
      *1 Protective Tape

      Apply protective tape to the area that was exposed when the inverter terminal cover was removed.

      Note

      Use non-residue type tape.

    2. B00410YE01
      Text in Illustration
      *1 Protective Tape

      Remove the protective tape from the inverter signal connector.

    3. B004160E01
      Text in Illustration
      *1 Inverter Signal Connector Cover

      Remove the 4 bolts and inverter signal connector cover.

      Tech Tips

      As there will be dust and dirt around the inverter signal connector cover gasket, before removing the inverter signal connector cover, clean the area around the inverter signal connector cover with a piece of cloth to prevent foreign matter from entering the inverter with converter assembly.

  7. REMOVE NO. 1 AND NO. 2 INVERTER DRAIN PLUG

    CAUTION:


    • Wear insulating gloves.

    • Wear protective goggles.


    1. B0040URE01
      Text in Illustration
      *1 No. 1 Inverter Drain Plug
      *2 No. 2 Inverter Drain Plug

      Using a screwdriver with its tip wrapped with protective tape, remove the No. 1 and No. 2 inverter drain plugs.

      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 case with condenser.

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

      A01V13X
      Standard voltage
      0V

      Tech Tips

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

  9. REMOVE INVERTER UNION GROMMET


    1. B00412YE01
      Text in Illustration
      *1 Inverter Union Grommet
      *2 Coolant Pipe

      Using a screwdriver with its tip wrapped with protective tape, remove the 2 inverter union grommets from the inverter with converter assembly.

      Note

      Pull the grommet straight out without applying any force to the coolant pipes.

  10. REMOVE NO. 2 ENGINE ROOM WIRE


    1. B00410U

      Disengage the 2 claws and open the terminal cover.

    2. B004107

      Remove the nut.

    3. Disengage the clamp and remove the No. 2 engine room wire from the inverter with converter assembly.

  11. REMOVE INVERTER CASE WITH CONDENSER


    1. B00413J

      Remove the 5 bolts.

      Note

      Do not touch the bus-bars.

    2. B0040W2E03
      Text in Illustration
      *1 Protective Tape

      Apply protective tape to the installation holes of the No. 1 and No. 2 inverter drain plugs as shown in the illustration.

      Note


      • Use non-residue type tape.

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

    3. B00416M

      Remove the 11 bolts.

    4. Apply protective tape to the coolant pipe as shown in the illustration.

      B0040U0E03
      Text in Illustration
      *1 Protective Tape *2 Coolant Pipe

      Note


      • Do not apply excessive force to the coolant pipe.

      • Do not damage the coolant pipe.

      • Use non-residue type tape.

    5. Install SST to the inverter with converter assembly. (Step A)

      SST
      09891-47020

      1. B0040YME01
        Text in Illustration
        *1 SST
        *2 Protective Tape

        Apply protective tape to SST as shown in the illustration.

      2. Insert SST into the inverter union grommet installation hole and tighten the bolt (A) of SST to install SST to the inverter with converter assembly as shown in the illustration.

        B0040ZEE02
        Text in Illustration
        *1 SST *2 Inverter Case with Condenser
        *3 Hybrid Vehicle Converter Kit - -
        *a Tip - -

        Note


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

        • Do not apply excessive force to the coolant pipe.

      3. Check that the tips of SST are not in contact with the grommet sealing surface of the inverter with converter assembly.

    6. While supporting SST by hand, tighten the bolt A of SST to separate the inverter case with condenser and hybrid vehicle converter kit as shown in the illustration. (Step B)

      B00410NE01
      Text in Illustration
      *1 SST - -

      Note

      Do not use air tools.

    7. Remove SST from the inverter with converter assembly, and then insert SST into the inverter union grommet installation hole on the opposite side of the inverter with converter assembly and tighten the bolt (A) of SST to install SST to the inverter with converter assembly as shown in the illustration. (Step C)

      B004124E01
      Text in Illustration
      *1 SST *2 Inverter Case with Condenser
      *3 Hybrid Vehicle Converter Kit - -
      *a Tips - -

    8. While supporting SST by hand, tighten the bolt A of SST to separate the inverter case with condenser and hybrid vehicle converter kit as shown in the illustration. (Step D)

      B004122E01
      Text in Illustration
      *1 SST - -

      Note

      Do not use air tools.

    9. Perform steps A, B, C and D on the opposite side of the inverter with converter assembly and remove the inverter case with condenser from the hybrid vehicle converter kit.

    10. A01UXN3

      Place the inverter case with condenser on a clean piece of cloth.

      Note


      • Do not touch the bus-bars.

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

  12. 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 parts removed from the inverter with converter assembly on an antistatic mat.


    1. A01V1QJ

      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. After removing the inverter case with condenser, perform work with bare hands to prevent damage from static electricity and entry of foreign matter.

  13. REMOVE INVERTER TERMINAL WITH SENSOR SUB-ASSEMBLY

    Note


    • If metal shavings are created, remove them using tape or equivalent.

    • Do not touch the circuit board.

    • Do not allow any moisture to come into contact with the inverter terminal with sensor sub-assembly.

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


    1. B00416L

      Disconnect the 3 connectors from the MG control computer with bracket sub-assembly.

      Note

      Do not move a pen sheet out of position when disconnecting the connectors.

      Tech Tips


      • If the pen sheet is moved out of position, return it to its original position when connecting the connectors.

    2. B0040WX

      Remove the 6 bolts.

      Note

      Do not touch the bus-bars.

    3. B0040ZH

      Remove the 4 bolts and inverter terminal with sensor sub-assembly.

  14. REMOVE MG CONTROL COMPUTER WITH BRACKET SUB-ASSEMBLY

    Note


    • If metal shavings are created, remove them using tape or equivalent.

    • Do not touch the circuit board.

    • Do not allow any moisture to come into contact with the MG control computer with bracket sub-assembly.


    1. B0040V0E01
      Text in Illustration
      *a Do not disconnect

      While disengaging the white resin lock claws of the connector, disconnect the flat cable from the power module intelligent transistor kit.

      Note


      • Do not disconnect the flat cable from the MG control computer with bracket sub-assembly.

      • Do not use any tools.

    2. B00411H

      Disconnect the 2 connectors.

      Note

      Do not move a pen sheet out of position when disconnecting the connectors.

    3. B0040UA

      Disconnect the connector.

    4. Disengage the 2 wire harnesses from the 4 clamps.

      A01V0OQ
    5. B0040Y1

      Remove the 4 bolts and MG control computer with bracket sub-assembly.

  15. REMOVE POWER MODULE INTELLIGENT TRANSISTOR KIT

    Note


    • If metal shavings are created, remove them using tape or equivalent.

    • Do not touch the circuit board.

    • Do not allow any moisture to come into contact with the power module intelligent transistor kit.


    1. B00415R

      Remove the 3 bolts.

      Note

      Do not touch the bus-bars.

    2. B004126

      Remove the 4 bolts.

    3. A01V1WA

      Using a screwdriver with its tip wrapped with protective tape, lift the power module intelligent transistor kit.

    4. B00412UE03
      Text in Illustration
      *1 Base of the coolant pipe

      While holding the base of the coolant pipes, remove the power module intelligent transistor kit.

      Note

      Do not touch the circuit board.