POWER MODULE INTELLIGENT TRANSISTOR DISASSEMBLY

REMOVE INVERTER WITH CONVERTER ASSEMBLY

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DRAIN COOLANT (for Inverter)

1. 

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

   Table 1. Text in Illustration

   *1	Protective Tape

   Note:

   Use non-residue type tape.

2. 

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

   Table 2. Text in Illustration

   *1	Coolant (for inverter) Passage

   Note:

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

   Tip:

   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. 

   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.

   Tip:
   

   • 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.

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 case with condenser, 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.

REMOVE INVERTER TERMINAL COVER

1. 

   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.

REMOVE INVERTER SIGNAL CONNECTOR COVER

1. 

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

   Table 3. Text in Illustration

   *1	Protective Tape

   Note:

   Use non-residue type tape.

2. 

   Remove the protective tape from the inverter signal connector.

   Table 4. Text in Illustration

   *1	Protective Tape

3. 

   Remove the 4 bolts and inverter signal connector cover.

   Table 5. Text in Illustration

   *1	Inverter Signal Connector Cover

   Tip:

   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.

REMOVE NO. 1 AND NO. 2 INVERTER DRAIN PLUG

1. 

   Using a screwdriver with its tip wrapped with protective tape, pry out the No. 1 and No. 2 inverter drain plugs from either side.

   Table 6. Text in Illustration

   *1	No. 1 Inverter Drain Plug
   *2	No. 2 Inverter Drain Plug

   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.

VERIFY THAT VOLTAGE OF INVERTER WITH CONVERTER IS 0 V

1. 

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

   Standard voltage
   0V

   Tip:

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

REMOVE INVERTER UNION GROMMET

1. 

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

   Table 7. Text in Illustration

   *1	Inverter Union Grommet
   *2	Coolant Pipe

   Note:

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

REMOVE INVERTER CASE WITH CONDENSER

1. 

   Disengage the 2 claws and open the terminal cover.

2. 

   Loosen the nut of the No. 2 engine room wire to secure enough space to perform work.

3. 

   Remove the 5 bolts from the bus-bars.

   Note:

   Do not touch the bus-bars.

4. 

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

   Table 8. Text in Illustration

   *1	Protective Tape

   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.

5. 

   Remove the 11 bolts.

6. 

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

   Table 9. 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.

7. Install SST to the inverter with converter assembly. (Step B)

   09891-47020

   
   
   1. 

      Apply protective tape to SST as shown in the illustration.

      Table 10. Text in Illustration

      *1	SST
      *2	Protective Tape

   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.

      Table 11. 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.

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 C)

   Table 12. Text in Illustration

   *1

   SST

   -

   -

   Note:

   Do not use air tools.

   

   Tip:

   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.

9. 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.

10. 

    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.

HOW TO PREVENT STATIC ELECTRICITY

1. 

   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).

   Tip:

   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.

REMOVE INVERTER TERMINAL WITH SENSOR SUB-ASSEMBLY

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.

   Tip:
   

   • 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. 

      For inverter with converter assembly with part number G9200-76010 or G9200-76011:

   2. 

      For inverter with converter assembly with part number other than G9200-76010 or G9200-76011:

2. 

   Remove the 6 bolts from the bus-bars.

   Note:

   Do not touch the bus-bars.

3. 

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

REMOVE MG CONTROL COMPUTER WITH BRACKET SUB-ASSEMBLY

1. 

   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.

   Table 13. Text in Illustration

   *a	Do not disconnect

2. 

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

   Tip:

   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.

4. 

   Using an 8 mm deep socket wrench, remove the 4 bolts and MG control computer with bracket sub-assembly.

REMOVE POWER MODULE INTELLIGENT TRANSISTOR KIT

1. 

   Disconnect the connector from the power module intelligent transistor kit.

2. 

   Remove the 5 bolts from the bus-bars.

   Note:

   Do not touch the bus-bars.

3. 

   Remove the 4 bolts.

4. 

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

5. 

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

   Note:

   Do not touch the circuit board.

   Table 14. Text in Illustration

   *1	Base of the coolant pipe