RM38T0EC _51 Engine / Hybrid System _144957 HYBRID / BATTERY CONTROL _0604245 INVERTER WITH CONVERTER A

HYBRID / BATTERY CONTROL  INVERTER WITH CONVERTER  REMOVAL  


CAUTION / NOTICE / HINT

COMPONENTS (REMOVAL)
A523062N01
6.385,0.208 6.76,0.208 false 6.448,0.688 6.823,0.688 false 1.958,1.229 2.333,1.229 false 6.198,0.073 7.146,0.563 0.948,0.49 18 false 1 1.74,1.115 2.688,1.604 0.948,0.49 18 false 2 6.229,0.573 6.74,0.969 0.51,0.396 18 false 3

Procedure Part Name Code
Z101186

Z101188

Z101187

1 PRECAUTION - (Click here) - -
2 SERVICE PLUG GRIP G3834 - - -
3 COOLANT (for Inverter) - - (Click here) -

A548690N01
3.417,0.583 4.417,0.75 1,0.167 3.219,0.917 3.25,0.667 3.25,0.667 3.417,0.667 false 6.448,0.271 6.781,0.271 false 3.948,2.146 4.208,2.146 false 3.333,1.219 3.417,1.052 3.417,1.052 3.542,1.052 false 3.927,1.302 4.24,1.458 0.313,0.156 10 false x2 4.531,2 4.813,2.354 0.281,0.354 18 false 7 6.219,0.104 6.5,0.458 0.281,0.354 18 false 5 3.479,0.583 4.51,0.875 1.031,0.292 8 false 2.0 (20, 18 in.*lbf) 3.958,0.885 4.51,1.208 0.552,0.323 18 false 4, 6

Procedure Part Name Code
Z101186

Z101188

Z101187

4 REMOVE CONNECTOR COVER ASSEMBLY - - - -
5 TERMINAL VOLTAGE - (Click here) - -
6 TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY - (Click here) - -
7 FLOOR UNDER WIRE 821H1 (Click here) - -

V100146

N*m (kgf*cm, ft.*lbf): Specified torque - -

A521673N01
4.563,1.333 5.01,1.333 false 1.958,1.25 2.323,1.25 false 1.448,4.365 1.563,4.604 1.563,4.604 1.698,4.604 false 5.948,2.26 6.115,2.115 6.115,2.115 6.26,2.115 false 6.24,3.146 6.604,3.146 false 0.781,0.917 1,0.75 1,0.75 1.167,0.75 false 2.177,2.052 2.542,2.052 false 2.51,2.865 2.875,2.865 false 6.042,4.094 6.406,4.094 false 4.083,2.802 4.531,2.802 false 5.083,1.156 5.635,1.51 0.552,0.354 18 false 16 6.354,1.927 6.906,2.281 0.552,0.354 18 false 14 6.646,3.01 7.063,3.417 0.417,0.406 18 false 12 2.979,2.74 3.531,3.094 0.552,0.354 18 false 10 2.625,1.906 3.177,2.26 0.552,0.354 18 false 9 2.427,1.115 2.979,1.469 0.552,0.354 18 false 8 2.198,2.354 2.75,2.708 0.552,0.354 10 false x3 1.26,0.625 1.646,0.979 0.385,0.354 18 false 11 1.948,4.531 2.333,4.885 0.385,0.354 18 false 13 5.688,3.938 6.24,4.292 0.552,0.354 18 false 15 4.635,2.677 5.188,3.031 0.552,0.354 18 false 17

Procedure Part Name Code
Z101186

Z101188

Z101187

8 AIR CLEANER CAP SUB-ASSEMBLY 17705 - - -
9 AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 17801 - - -
10 AIR CLEANER CASE SUB-ASSEMBLY 17701 - - -
11 NO. 1 AIR CLEANER HOSE 17881 - - -
12 ECM 89661 - - -
13 HIGH VOLTAGE AIR CONDITIONING WIRE 821H2A (Click here) - -
14 NO.2 RELAY BLOCK COVER 82662B - - -
15 NO.3 ENGINE WIRE 82123 - - -
16 VACUUM SWITCHING VALVE ASSEMBLY 17650 - - -
17 TRANSMISSION CONTROL CABLE ASSEMBLY 33820B - - -

A521674N01
1.156,2.323 1.281,1.771 1.281,1.771 1.417,1.771 false 2.604,1.458 2.729,1.458 2.729,1.458 2.948,1.688 false 2.781,0.802 3.031,0.271 3.031,0.271 3.167,0.271 false 4.76,1.042 5.104,1.042 false 6.094,1.344 6.198,1.031 6.198,1.031 6.333,1.031 false 4.177,0.667 4.49,0.865 0.313,0.198 10 false x3 6.635,0.896 7.042,1.229 0.406,0.333 18 false 18 5.375,0.885 5.781,1.219 0.406,0.333 18 false 19 3.438,0.146 3.844,0.479 0.406,0.333 18 false 20 1.698,1.635 2.104,1.969 0.406,0.333 18 false 21 2.313,1.344 2.719,1.677 0.406,0.333 18 false 22 2.625,1.969 2.938,2.167 0.313,0.198 10 false x2

Procedure Part Name Code
Z101186

Z101188

Z101187

18 ENGINE ROOM MAIN WIRE 82111 (Click here) - -
19 ENGINE WIRE 82121 (Click here) - -
20 OUTLET NO. 1 INVERTER COOLING HOSE G922C (Click here) - -
21 INLET NO. 1 INVERTER COOLING HOSE G922AA (Click here) - -
22 NO. 7 ENGINE, WIRE 82127D (Click here) - -

A521675N01
3.271,0.635 3.198,0.323 3.198,0.323 3.031,0.323 false 3.677,2.677 3.635,2.844 3.635,2.844 3.542,2.844 false 5.021,2.542 5.354,2.542 false 2.25,0.208 3.052,0.563 0.802,0.354 18 false 23, 26 3.76,0.542 4.052,0.708 0.292,0.167 10 false x4 2.75,0.635 3.042,0.802 0.292,0.167 10 false x 2 5.667,2.448 6.219,2.802 0.552,0.354 18 false 24 3.229,2.729 3.781,3.083 0.552,0.354 18 false 25 5.313,3.375 5.604,3.542 0.292,0.167 10 false x3 2.042,0.688 2.333,0.854 0.292,0.167 10 false x2 4.854,2.198 5.146,2.365 0.292,0.167 10 false x4 4.552,2.354 4.844,2.521 0.292,0.167 10 false x6

Procedure Part Name Code
Z101186

Z101188

Z101187

23 SEPARATE INVERTER WITH CONVERTER ASSEMBLY G9200 (Click here) - -
24 UPPER INVERTER COVER G9221 (Click here) - -
25 MOTOR CABLE G1148 (Click here) - -
26 REMOVE INVERTER WITH CONVERTER ASSEMBLY G9200 (Click here) - -

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during hybrid motor control inverter assembly 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
Replacement of hybrid motor control inverter 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)

CAUTION:
·
A340386

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

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID CONTROL SYSTEM>PRECAUTION

·
A340358

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



HINT:

When the cable is disconnected/reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

·

Learning completes when vehicle is driven.

Effect/Inoperative Function When Necessary Procedures are not Performed Necessary Procedures Link
Front Camera System Drive the vehicle straight ahead at 15 km/h (10 mph) or more for 1 second or more. (Click here)

·

Learning completes when vehicle is operated normally

Effect/Inoperative Function When Necessary Procedures are not Performed Necessary Procedures Link
Power door lock control system
·

Back door opener


Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch. (Click here)
Power back door system Fully close the back door by hand.
HINT:

Initialization is not necessary if the above procedures are performed while the back door is closed.


(Click here)
Air conditioning system After the ignition switch is turned to ON, the servo motor standard position is recognized. -



PROCEDURE

Hide 1. PRECAUTION

Z101186

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal.

Click here(Click here)



Hide 4.REMOVE CONNECTOR COVER ASSEMBLY

Z101186

CAUTION:

Wear insulated gloves.



a.
A523031C01
3.958,0.323 4.177,0.51 0.219,0.188 10 true *b 3.063,1.229 3.281,1.417 0.219,0.188 10 true *a 2.281,0.094 2.688,0.385 0.406,0.292 18 true i, ii
*a Bolt (A) *b Bolt (B)


i.

Remove the bolt (A).


ii.

Using a T20 "TORX" socket wrench, remove the bolt (B) and connector cover assembly from the hybrid motor control inverter assembly.

NOTICE:
·

Do not touch the connector cover assembly waterproof seal.

·

Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.





Hide 5.CHECK TERMINAL VOLTAGE

Z101186

CAUTION:

Wear insulated gloves.


NOTICE:

Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.



a.
A537194C01
4.865,1.594 5.469,2.083 5.469,2.083 5.146,1.594 true 1.354,0.677 1.552,0.99 0.198,0.313 18 true i 5.531,2.01 5.76,2.24 0.229,0.229 10 true *a
*a Terminal - -


i.

Measure the voltage between the terminals of the high voltage DC line.

Specified Voltage:

0 V


HINT:
·

Set the tester to the DC 750 V range or higher to measure the voltage.

·

Perform the measurement while holding the tips of the tester probes against the terminals as shown in the illustration.





Hide 6.TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

Z101186

CAUTION:

Wear insulated gloves.


NOTICE:

Do not touch the waterproof seal of the connector cover assembly.



a.
A528497N01
2.219,0.063 2.385,0.354 0.167,0.292 18 true i

i.

Using a T20 "TORX" socket wrench, temporarily install the connector cover assembly to the hybrid motor control inverter assembly with the bolt.

Torque:
2.0 N*m (20 kgf*cm, 18 in.*lbf)



Hide 821H1 7.DISCONNECT FLOOR UNDER WIRE

Z101186

CAUTION:

Wear insulated gloves.


NOTICE:

Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.


NOTICE:
·

Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.

·

Do not touch the waterproof seal or terminals of the connector.

·

Do not damage the terminals, connector housing or hybrid motor control inverter assembly during disconnection.

·

Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.

·

Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.

·

Insulate the disconnected terminals with insulating tape.




a.
A528498C01
3.448,2.135 3.323,1.99 true 3.167,1.792 3.479,1.99 0.313,0.198 10 false *a 1.708,0.125 2.115,0.448 0.406,0.323 18 true i, ii
*a Waterproof Seal - -


i.

Remove the bolt, 2 nuts and disconnect the floor under wire from the inverter with converter assembly.


ii.

Disengage the 2 clamps.



Hide 17705 8.REMOVE AIR CLEANER CAP SUB-ASSEMBLY

a.
A537193


Hide 17701 10.REMOVE AIR CLEANER CASE SUB-ASSEMBLY

a.
A528503


Hide 17881 11.REMOVE NO. 1 AIR CLEANER HOSE

a.
A521682


Hide 89661 12.REMOVE ECM

Z101186

Click here(Click here)

Hide 821H2A 13.DISCONNECT HIGH VOLTAGE AIR CONDITIONING WIRE

Z101186

CAUTION:

Wear insulated gloves.


NOTICE:
·

Do not damage the terminals, connector housing or hybrid motor control inverter assembly during disconnection.

·

Insulate the disconnected terminals with insulating tape.




a.
A521677C01
1.458,1.281 1.292,1.281 1.292,1.281 1.188,1.021 true 1.531,1.208 1.844,1.365 0.313,0.156 10 false *a 0.844,0.094 1.26,0.396 0.417,0.302 18 false i, ii
*a Green-colored Lock - -
V100138

Slide - -


i.

Disengage the 2 clamps.


ii.

Slide the green-colored lock of the connector as shown in the illustration to release it and disconnect the high voltage air conditioning wire.



Hide 82661A 14.REMOVE NO.2 RELAY BLOCK COVER

a.
A521680


Hide 82123 15.DISCONNECT NO.3 ENGINE WIRE

a.
A521681


Hide 25860 16.REMOVE VACUUM SWITCHING VALVE ASSEMBLY

a.
A521683


Hide 33820B 17.DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

a.
A521685


Hide 82111 18.DISCONNECT ENGINE ROOM MAIN WIRE

Z101186

CAUTION:

Wear insulated gloves.


NOTICE:

Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.



a.
A521679N01
2.323,0.063 2.573,0.313 0.25,0.25 18 false ii 1.719,0.052 1.969,0.302 0.25,0.25 18 false i

i.

Disengage the clamp and disconnect the connector.


ii.

Move the lock lever while pushing the lock on the connector, and disconnect the hybrid motor control inverter assembly connector.

NOTICE:
·

Do not damage the terminals, connector housing or hybrid motor control inverter assembly during disconnection.

·

Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.

·

Insulate the disconnected terminals with insulating tape.

·

Do not touch the waterproof seal or terminals of the connector.





Hide 82121 19.DISCONNECT ENGINE WIRE

Z101186

CAUTION:

Be sure to wear insulated gloves.


NOTICE:

Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.



a.
A548691N01
0.74,0.052 2.01,0.323 1.271,0.271 18 false i, ii, iii, iv, v

i.

Move the lock lever while pushing the lock on the connector, and disconnect the hybrid motor control inverter assembly connector.

NOTICE:
·

Do not damage the terminals, connector housing or hybrid motor control inverter assembly during disconnection.

·

Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.

·

Insulate the disconnected terminals with insulating tape.

·

Do not touch the waterproof seal or terminals of the connector.




ii.

Disconnect the connector.


iii.

Disengage the 2 claws.


iv.

Remove the 3 nuts.


v.

Disengage the 2 clamps.



Hide G922C 20.DISCONNECT OUTLET NO. 1 INVERTER COOLING HOSE

Z101186

NOTICE:

Put pieces of cloth into the pipe and disconnected hose or cover the pipe and hose with plastic bags to prevent entry of foreign matter.



a.
A521687


Hide G922AA 21.DISCONNECT INLET NO. 1 INVERTER COOLING HOSE

Z101186

NOTICE:

Put pieces of cloth into the pipe and disconnected hose or cover the pipe and hose with plastic bags to prevent entry of foreign matter.



a.
A521688


Hide 82127D 22.DISCONNECT NO. 7 ENGINE, WIRE

a.
A521686


Hide G9200 23.SEPARATE INVERTER WITH CONVERTER ASSEMBLY

Z101186

CAUTION:

Be sure to wear insulated gloves.


NOTICE:

To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.



a.
A524806


Hide G9221 24.REMOVE UPPER INVERTER COVER

Z101186

CAUTION:

Wear insulated gloves.



a.
A521690N01
0.24,0.063 0.521,0.417 0.281,0.354 18 false i 4,0.042 4.198,0.323 0.198,0.281 18 true ii 0.427,1.688 0.656,1.969 0.229,0.281 18 true iii 0.406,3.333 0.635,3.615 0.229,0.281 18 true iv

i.

Remove the bolt and inverter cover from the hybrid vehicle transaxle assembly.


ii.

To prevent the inverter with converter assembly from falling, temporarily install the bolt in the location shown in the illustration.


iii.

Shift the position of the inverter with converter assembly and temporarily set it on top of the stud bolts as shown in the illustration.

NOTICE:

When lifting, make sure not to apply force to the motor cable.



iv.

Loosen the 2 bolts, leaving 2 to 3 threads at the tip of the bolt still engaged.



b.
A521691C01
5.073,0.979 5.104,0.417 5.104,0.417 5.219,0.417 false 6.396,1.135 6.531,1.135 6.531,1.135 6.594,0.75 false 5.573,0.948 5.646,1.26 5.646,1.26 5.802,1.26 true 5.396,0.625 5.771,0.365 5.771,0.365 5.5,0.823 true 5.271,0.323 5.427,0.521 0.156,0.198 10 false A 6.25,1.042 6.406,1.24 0.156,0.198 10 false A 5.844,1.177 6.042,1.365 0.198,0.188 10 true *a 5.823,0.24 6.104,0.479 0.281,0.24 10 false *b 2.188,0.042 2.667,0.354 0.479,0.313 18 true i, ii
*a Interlock *b Waterproof Seal


i.

Using the 2 bolts as guides, remove the upper inverter cover from the inverter with converter assembly.

NOTICE:
·

Make sure to pull the upper inverter cover straight out, as a connector is connected to the inside of the upper inverter cover.

·

Do not touch the waterproof seal of the upper inverter cover.

·

Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.

·

When removing the upper inverter cover, do not pull the areas (A) as they may deform.

·

Make sure that the interlock is installed to the upper inverter cover.

·
A521692C01
2.094,1.885 2.698,1.427 2.698,1.427 2.073,1.26 true 1.052,0.24 1.323,0.24 1.323,0.24 1.708,0.688 true 0.865,0.104 1.177,0.302 0.313,0.198 10 false *a 2.771,1.354 3.083,1.552 0.313,0.198 10 false *1
*1 Inverter Cover
*a Screw


Do not remove or excessively tighten the screw of the upper inverter cover.

·

Although the inverter cover may feel loose, this is not due to a malfunction.

·
A521693

Hold the upper inverter cover horizontal while removing it.



HINT:
A521694

If necessary, use a screwdriver with its tip wrapped with protective tape as shown in the illustration to remove the upper inverter cover.



ii.

Remove the 2 bolts.



c.
A521695N01
0.406,0.073 0.563,0.385 0.156,0.313 18 true i 3.74,0.052 3.958,0.375 0.219,0.323 18 false ii

i.

Shift the position of the inverter with converter assembly and temporarily set it on the hybrid vehicle transaxle assembly as shown in the illustration.

NOTICE:

When lifting, make sure not to apply force to the motor cable.



ii.

Remove the bolt.



Hide G1148 25.DISCONNECT MOTOR CABLE

Z101186

CAUTION:

Wear insulated gloves.



a.
A521696C01
4.656,1.833 4.521,1.708 true 0.396,0.042 0.552,0.365 0.156,0.323 18 true i 3.969,0.042 4.135,0.333 0.167,0.292 18 true ii 4.365,1.552 4.677,1.75 0.313,0.198 10 false *a
*a Waterproof Seal - -


i.

Using an insulated tool, remove the 6 bolts.

NOTICE:
·

Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.

·

Do not touch the waterproof seal or terminals of the connector.




ii.

Remove the 4 bolts and disconnect the motor cable from the hybrid motor control inverter assembly.

NOTICE:
·

Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.

·

Do not touch the waterproof seal or terminals of the connector.

·

Do not damage the terminals, connector housing or hybrid motor control inverter assembly during disconnection.

·

Insulate the disconnected terminals with insulating tape.

·

Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.

·
A521697

To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.





Hide G9200 26.REMOVE INVERTER WITH CONVERTER ASSEMBLY

Z101186

CAUTION:

Be sure to wear insulated gloves.


NOTICE:
·

When removing the hybrid motor control inverter assembly, be careful not to damage the parts around it.

·

To prevent damage, do not hold the hybrid motor control inverter assembly by the connectors, brackets or cooling pipes.

·

To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.




a.
A521698

i.

Even after the coolant is drained, coolant remains in the inverter due to its internal structure. Therefore, seal or cover the pipes when removing the hybrid motor control inverter assembly so that coolant does not spill out.