ELECTRIC VEHICLE CONVERTER REMOVAL

Note


  • A01JBY7

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

Tech Tips

Prepare 2 tubes of thermal grease X-23-7884-4 (08887-02809) when replacing the hybrid converter kit.


  1. REMOVE INVERTER WITH CONVERTER ASSEMBLY

    Click here

  2. DRAIN COOLANT (for Inverter)

    CAUTION:

    Wear insulating gloves.


    1. A01J9J8E02
      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. A01JCGNE02
      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. A01J9NJ

      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 case with condenser 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 insulating gloves.


    1. A01JC1N

      Remove the 9 bolts and inverter terminal 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 SIGNAL CONNECTOR COVER

    CAUTION:

    Wear insulating gloves.


    1. A01JADKE01
      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. A01J96KE02
      Text in Illustration
      *1 Protective Tape

      Remove the protective tape from the inverter signal connector.

    3. A01JAZ2E01
      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.

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

    CAUTION:


    • Wear insulating gloves.

    • Wear protective goggles.


    1. A01JB8QE01
      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, pry out the No. 1 and No. 2 inverter drain plugs from either side.

      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.

  7. 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.

      A01J8YG
      Standard voltage
      0V

      Tech Tips

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

  8. REMOVE INVERTER UNION GROMMET


    1. A01JBX1E01
      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.

  9. REMOVE NO. 2 ENGINE ROOM WIRE


    1. A01JDB6

      Disengage the 2 claws and open the terminal cover.

    2. A01J994

      Remove the nut from the No. 2 engine room wire.

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

  10. REMOVE INVERTER CASE WITH CONDENSER


    1. A01JBR6

      Remove the 5 bolts from the bus-bars.

      Note

      Do not touch the bus-bars.

    2. A01J9LOE01
      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. A01JAJG

      Remove the 11 bolts.

    4. Apply protective tape to the coolant pipe as shown in the illustration. (Step A)

      A01J9QWE01
      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 B)

      SST
      09891-47020

      1. A01J8STE01
        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.

        A01J8EPE01
        Text in Illustration
        *1 SST *2 Inverter Case with Condenser
        *3 Hybrid Vehicle Converter Kit - -
        *a Tips - -

        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 C)

      A01J9YXE01
      Text in Illustration
      *1 SST - -

      Note

      Do not use air tools.

      Tech Tips

      Tighten the bolt (A) of SST and listen for 3 cracking sounds from the inverter case with condenser. After hearing the sounds, use a screwdriver with its tip wrapped with protective tape to pry between the parts at the area (B) shown in the illustration and separate them. If it is difficult to separate the parts, further tighten the bolt (A) of SST and pry between the parts again.

      Do not pry between the parts excessively or the case rib (B) may be deformed or damaged.

      A01JAU3E01

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

    8. A01J9MX

      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.

  11. 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. A01JBNB

      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.

  12. 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.

    • For inverter with converter assembly with part number G9200-47140, G9200-47141, G9200-47180 or G9200-47181: Make sure to replace the inverter current sensor sub-assembly and inverter wire sub-assembly at the same time when replacing the MG control computer with bracket sub-assembly Click here.


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

      Note

      If a pen sheet is provided, do not move it out of position when disconnecting the connectors.

      Tech Tips


      • The location of the connectors varies depending on the part number of the inverter with converter assembly. Confirm the part number before performing work.

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


      1. A01JAHP

        For inverter with converter assembly with part number G9200-47140, G9200-47141, G9200-47180 or G9200-47181:

      2. A01JC80

        For inverter with converter assembly with part number other than G9200-47140, G9200-47141, G9200-47180 or G9200-47181:

    2. A01JD5X

      Remove the 6 bolts from the bus-bars.

      Note

      Do not touch the bus-bars.

    3. A01J9K8

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

  13. 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. A01JDB4E01
      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. A01JCSP

      Disconnect the 2 connectors from the MG control computer with bracket sub-assembly.

      Tech Tips

      If a pen sheet is provided, do not move it out of position when disconnecting the connectors.

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

      A01JB4L
    4. A01J939

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

  14. 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. A01J9ZY

      Disconnect the connector from the power module intelligent transistor kit.

    2. A01JB6T

      Remove the 5 bolts from the bus-bars.

      Note

      Do not touch the bus-bars.

    3. A01JCAI

      Remove the 4 bolts.

    4. A01JC0I

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

    5. A01JBPBE01
      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.