Drive Motor Generator Power Inverter Module Replacement

Drive Motor Generator Power Inverter Module Replacement

Removal Procedure

Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.


The High Voltage Disabling procedure will perform the following tasks:


* Identify how to disable high voltage.

* Identify how to test for the presence of high voltage.

* Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.


Failure to follow the procedures exactly as written may result in serious injury or death.


1. Disable the high voltage system. Refer to High Voltage Disabling High Voltage Disabling.
2. Remove the power inverter module cover. Refer to Drive Motor Generator Power Inverter Module Cover Replacement Drive Motor Generator Power Inverter Module Cover Replacement.




3. Disconnect the electrical connectors (1).
4. Remove the shield circuit harness ground fasteners (2) and reposition the ground cables.
5. Disconnect the coolant pipes from the power inverter module. Refer to Drive Motor Power Inverter Module Cooling Inlet Hose Replacement Drive Motor Power Inverter Module Cooling Inlet Hose Replacement and. Drive Motor Generator Control Module Radiator Outlet Hose Replacement Drive Motor Generator Control Module Radiator Outlet Hose Replacement.




6. Remove the high voltage interlock loop connector fasteners (1) and reposition the connector.




7. Remove the three-phase cable fasteners (1) and reposition the cables.
8. Discard the cable housing seals and the cable fastener seals.




9. Remove the 300-Volt cable fasteners (1) and reposition the cables.
Note: The top cable should already be removed when the high voltage disabling was performed.

10. Discard the 300-Volt cable connector seals.




11. Remove the power inverter fasteners (1) and drive motor power inverter control module (2).





Note: Replacement power inverter module comes pre-assembled with new coolant fittings. Replace coolant fittings only if necessary.

12. Remove the coolant fitting fasteners (1) , the coolant fittings (2), and use NEW seals (3).

Installation Procedure





Note: It is possible to install the coolant fittings 180° out of position. Ensure the larger alignment tab is facing downwards.

1. Install NEW coolant tube seals (3) and the coolant fittings (2).
2. Tighten the coolant tube fasteners to 3 Nm (27 lb in).





Caution: Refer to Fastener Caution Fastener Caution.

3. Install the drive motor power inverter control module (2) and tighten the fasteners (1) to 9 Nm (80 lb in).





Note: Start the 300-Volt cable fasteners by hand.

4. Install the 300-Volt cables with NEW seals and tighten the fasteners (1) to 9 Nm (80 lb in).




5. With NEW connector housing and fastener seals, install the three-phase cables and tighten the fasteners (1) to 9 Nm (80 lb in).




6. Install the high voltage interlock loop connector fasteners (1) and tighten to 6 Nm (53 lb in).




7. Connect the coolant pipes to the power inverter module. Refer to Drive Motor Power Inverter Module Cooling Inlet Hose Replacement Drive Motor Power Inverter Module Cooling Inlet Hose Replacement and. Drive Motor Generator Control Module Radiator Outlet Hose Replacement Drive Motor Generator Control Module Radiator Outlet Hose Replacement.
8. Fill the cooling system. Refer to Drive Motor Generator Power Inverter Module Cooling System Draining and Filling Drive Motor Generator Power Inverter Module Cooling System Draining and Filling.
9. Install the ground strap fasteners (2) and tighten to 9 Nm(80 lb in).
10. Connect the electrical connectors (1).
11. Install the power inverter module cover. Refer to Drive Motor Generator Power Inverter Module Cover Replacement Drive Motor Generator Power Inverter Module Cover Replacement.
12. Enable the high voltage system. Refer to High Voltage Enabling High Voltage Enabling.
13. For control module programming and setup procedures, refer to Control Module References Programming and Relearning.