Removal And Installation
DC/DC-J/B
Removal and Installation
WARNING:
- Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are handled incorrectly. Be sure to follow the correct work procedures when performing inspection and maintenance.
- Be sure to remove the service plug in order to disconnect the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.
- To prevent the removed service plug from being connected by mistake during the procedure, always carry it in your pocket or put it in the tool box.
- Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses before beginning work on the high voltage system.
- Clearly identify the persons responsible for high voltage work and ensure that other persons do not touch the vehicle. When not working, cover high voltage parts with an insulating cover sheet or similar item to prevent other persons from contacting them.
- Refer to "High Voltage Precautions" High Voltage Precautions.
CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do so in the Service Manual.
REMOVAL
WARNING:
Disconnect high voltage. Refer to "How to Disconnect High Voltage" Service and Repair.
1.Check voltage in high voltage circuit. (Check that condenser are discharged.)
a.Lift up the vehicle and remove the Li-ion battery under covers. Refer to "Removal and Installation" Service and Repair (without Li-ion battery heater models), "Removal and Installation" Service and Repair (with Li-ion battery heater models).
b.Disconnect high voltage harness connector from front side of Li-ion battery. Refer to "Removal and Installation" Service and Repair (without Li-ion battery heater models), "Removal and Installation" Service and Repair (with Li-ion battery heater models).
c.Measure voltage between high voltage harness connector terminals.
DANGER:
Touching high voltage components without using the appropriate protective equipment will cause electrocution.
Standard: 5 V or less
CAUTION:
For voltage measurements, use a tester which can measure to 500 V or higher.
2.Drain coolant from radiator. Refer to "Draining and Refilling" Coolant Draining And Refilling.
3.Drain heater fluid. Refer to "Draining and Refilling" Draining And Refilling.
4.Remove traction motor inverter. Refer to "Removal and Installation" 5.Remove cowl top extension. Refer to "Exploded View" Exploded View.
6.Disconnect water hoses from the locations indicated below.
a.Disconnect water hose (1) below the floor.
WARNING:
To prevent electric shock hazards, be sure to put on insulating protective gear before beginning work on the high voltage system.
CAUTION:
- Take care that coolant does not contact the high voltage harness connectors.
- If coolant contacts a high voltage harness connector, immediately dry the high voltage connector completely with an air blow gun.
b.Disconnect water hose (1) at DC/DC-J/B IN side (top left).
WARNING:
To prevent electric shock hazards, be sure to put on insulating protective gear before beginning work on the high voltage system.
CAUTION:
- Take care that coolant does not contact the high voltage harness connectors.
- If coolant contacts a high voltage harness connector, immediately use an air blow and fully remove the liquid.
c.Disconnect water hose (1) between electric water pump 2 and water pipe.
WARNING:
To prevent electric shock hazards, be sure to put on insulating protective gear before beginning work on the high voltage system.
CAUTION:
- Take care that coolant does not contact the high voltage harness connectors.
- If coolant contacts a high voltage harness connector, immediately dry the high voltage connector completely with an air blow gun.
7.Remove the 2 water pipe mounting screws so that water pipe is free. Refer to "Exploded View" Exploded View.
8.Disconnect 12V system connector and harness clips (A).
WARNING:
To prevent electric shock hazards, be sure to put on insulating protective gear before beginning work on the high voltage system.
9.Disconnect 14V output terminal.
WARNING:
To prevent electric shock hazards, be sure to put on insulating protective gear before beginning work on the high voltage system.
10.Disconnect high voltage connector from the following 5 locations at DC/DC-J/B.
a.From below the vehicle, disconnect high voltage harness connector (1) from Li-ion battery.
WARNING:
-To prevent electric shock hazards, be sure to put on insulating protective gear before beginning work on the high voltage system.
- Protect the terminals of disconnected high voltage harness connector with insulation tape so that they are not exposed.
b.Disconnect high voltage harness connector (1) for vehicle leftside on board charger.
WARNING:
-To prevent electric shock hazards, be sure to put on insulating protective gear before beginning work on the high voltage system.
- Protect the terminals of disconnected high voltage harness connector with insulation tape so that they are not exposed.
c.Disconnect high voltage harness connector (A) for vehicle frontside electric compressor, high voltage harness connector (B) for
PTC elements heater, and high voltage harness connector (C)
for quick charge port.
WARNING:
-To prevent electric shock hazards, be sure to put on insulating protective gear before beginning work on the high voltage system.
- Protect the terminals of disconnected high voltage harness connector with insulation tape so that they are not exposed.
i.When disconnecting high voltage harness connector for electric compressor, disconnect it by inserting a suitable tool into inspection hole in traction motor inverter member.
WARNING:
-To prevent electric shock hazards, be sure to put on insulating protective gear before beginning work on the high voltage system.
- Protect the terminals of disconnected high voltage harness connector with insulation tape so that they are not exposed.
ii.For high voltage harness connector for PTC elements heater and high voltage harness connector for quick charge port, check their positions from the inspection hole and remove by reaching in and feeling with your hand.
WARNING:
-To prevent electric shock hazards, be sure to put on insulating protective gear before beginning work on the high voltage system.
- Protect the terminals of disconnected high voltage harness connector with insulation tape so that they are not exposed.
- Follow steps shown below to remove a 2-step type high voltage connector.
- Follow steps shown below to remove a 3-step type high voltage connector.
11.Disconnect 2 brake tubes (1). Refer to "FRONT : Exploded View" Exploded View.
WARNING:
-To prevent electric shock hazards, be sure to put on insulating protective gear before beginning work on the high voltage system.
- Protect the terminals of disconnected high voltage harness connector with insulation tape so that they are not exposed.
12.Disconnect heater hose (1) and move it out of the way to left side of vehicle.
CAUTION:
- Take care that coolant does not contact the high voltage harness connectors.
- If coolant contacts a high voltage harness connector, immediately dry the high voltage connector completely with an air blow gun.
13.Remove DC/DC-J/B fastening nut (A) and fastening bolt (B).
WARNING:
To prevent electric shock hazards, be sure to put on insulating protective gear before beginning work on the high voltage system.
14.Move DC/DC-J/B to rear of vehicle. Then remove DC/DC-J/B, keeping the side on left of vehicle raised so that it does not contact high voltage harness connector for quick charge port or inverter member.
WARNING:
To prevent electric shock hazards, be sure to put on insulating protective gear before beginning work on the high voltage system.
INSTALLATION
Pay attention to the following and install by following the procedure for removal in the reverse order.
WARNING:
To prevent electric shock hazards, be sure to put on insulating protective gear before beginning work on the high voltage system.
CAUTION:
- Be sure to reinstall high voltage harness clips in their original positions. If a clip is damaged, replace it with a new clip before installing.
- Be sure to perform correct air bleeding after adding coolant. Refer to "Draining and Refilling" Coolant Draining And Refilling.
- If DC/DC-J/B was replaced, apply high voltage warning label at position (A), with the top facing in the direction of the arrow.
- Before applying label, verify that there is no dust or dirt on surface of DC/DC-J/B.
- Follow the procedure below and connect the 2-step type high voltage harness connector.
- Follow the procedure below and connect the 3-step type high voltage harness connector.
- After all parts are installed, be sure to check the equipotential.
- DC/DC-J/B: Refer to "Inspection" Inspection.
- Traction motor inverter: Refer to "Inspection and Adjustment"