JUNCTION BOX No.3 REMOVAL/INSTALLATION
id300400000800
Replacement parts
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Gasket
Quantity: 1
Location of use: Junction box No.3 side
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Gasket
Quantity: 1
Location of use: Inverter
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Warning
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<<High voltage>>
• If the necessary measures are not taken before servicing an electric vehicle, it could cause electrical shock and result in serious injury or, in the worst case, death. Before servicing the electric vehicle, refer to [HIGH VOLTAGE SERVICE CAUTIONS] in the general information and implement the necessary measures. (See
HIGH VOLTAGE SERVICE CAUTIONS.)
High Voltage Part Inspection And Removal/Installation Notes
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Warning
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<<High voltage>>
• If necessary measures such as wearing the correct protective gear are not taken when inspecting or removing/installing the high voltage parts, it could cause electrical shock and result in serious injury or, in the worst case, death.
• Before inspecting or removing/installing the high voltage parts, refer to [HIGH VOLTAGE SERVICE CAUTIONS] in the general information and [High Voltage Part Inspection and Removal/Installation Notes] of the high voltage system service cautions and implement the necessary measures and preparations. (See
HIGH VOLTAGE SERVICE CAUTIONS.) (See
HIGH VOLTAGE SYSTEM SERVICE CAUTIONS.)
1. Place the vehicle onto an auto lift and prepare it so it can be lifted up.
2. Verify that the READY indicator on the instrument cluster is not illuminated.
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• If the READY indicator is turned on, switch the main power OFF.
3. Disconnect the negative lead-acid battery terminal. (See NEGATIVE LEAD-ACID BATTERY TERMINAL DISCONNECTION/CONNECTION.)
4. Partially peel back the cover.
5. Remove the service hole cover.
6. Wear insulating gloves and remove the service plug using the following procedure.
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Warning
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<<High voltage>>
• Touching the terminal on the vehicle side can result in serious injury or death from electric shock. For this reason, after removing the service plug, cover the vehicle-side terminals with insulating tape so that they cannot be touched.
• Do not touch high voltage parts for 10 min after removing service plug. Electric charges may be stored on the condenser for 10 min after the service plug is removed, and touching high voltage parts during that time can result in serious injury or death from electric shock.
• Service plugs must be removed by workers inspecting/removing/installing high voltage parts. Keep the removed service plug on your person until inspection/removal/installation of the high voltage parts is completed to prevent other workers from accidentally installing the service plug.
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Caution
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<<High voltage>>
• After removing the service plug, cover the vehicle side terminals with insulating tape to prevent foreign matter from adhering to them.
• When you are keeping the service plug on your person, cover the service plug terminals with insulating tape to prevent damage to them.
• Do not switch the main power ON (READY on) after removing the service plug. If the main power is switched ON (READY on) after removing the service plug, the vehicle may malfunction.
- (1) Slide the lock in the direction of the arrow shown in the figure. (Do not pull out completely)
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- (2) Raise the lever.
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- (3) Press the area indicated by arrow (1) shown in the figure, release the tabs, and then raise the lever until it is perpendicular.
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- (4) Hold the lever and pull the service plug straight up.
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7. After removing the service plug, leave it for 10 min.
8. Wear insulating gloves and measure the voltage at the high voltage cable connection (junction box No.3 side) using the following procedure.
- (1) Remove the seal cover. (See SEAL COVER REMOVAL/INSTALLATION.)
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Caution
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<<High voltage>>
• Be careful not to allow foreign matter or water droplets to enter the junction box No.3. Since the junction box No.3 has a high voltage circuit, there is a risk of malfunction if foreign matter or water drops enter it.
• Remove the terminal cover by pulling it straight up. The terminal cover is fitted with an interlock switch. This interlock switch may be damaged if the terminal cover is removed while being tilted.
• Do not touch the moisture-proof seal on the terminal cover. If the seal is touched or damaged, replace the terminal cover.
- (2) Remove the terminal cover.
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- (3) Measure the voltage at the high voltage cable connection.
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Note
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• Use a voltmeter with a measurement range of
450 V DC or more.
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― Verify that the voltmeter indicates 0 V and go to the next step.
9. Remove the coolant reserve tank with the hose still connected to it, and secure it using rope or other means so that it does not interfere with work. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION.)
10. Remove the DC-DC converter with the hose and wiring harness still connected to it, and secure it using rope or other means so that it does not interfere with work. (See DC-DC CONVERTER REMOVAL/INSTALLATION.)
11. Disconnect the high voltage cable (junction box No.3 side). (See HIGH VOLTAGE CABLE REMOVAL/INSTALLATION.)
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• After disconnecting the high voltage cable, wrap the terminal part with insulating tape to insulate it.
12. Remove the bolt shown in the figure and disconnect the ground.
13. Disconnect the connector and wiring harness clip shown in the figure.
14. Remove the bolt shown in the figure.
15. Wear insulating gloves and follow the procedure below to disconnect the high voltage cable connector.
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• After disconnecting the high voltage cable connector, wear insulating gloves and wrap the terminal part with insulating tape to insulate it.
- (1) Pull out the lock tab.
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- (2) Pull out the connector while pressing on the lock lever.
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16. Wear insulating gloves and disconnect the connector and wiring harness clips shown in the figure.
17. Disconnect the wiring harness protector clip shown in the figure.
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Caution
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<<High voltage>>
• Be careful that foreign matter, water droplets, or other substance does not enter the junction box No.3. Because the junction box contains a high voltage circuit, there is the risk of malfunction if foreign matter, water droplets, or other substance enters the junction box No.3.
• Pull the terminal cover straight out toward the rear of the vehicle. Because there is an interlock switch on the terminal cover, if the terminal cover is tilted when it is removed, the interlock switch may be damaged.
18. Wear insulating gloves and remove the bolts shown in the figure, then remove the terminal cover.
19. Wear insulating gloves and remove the gasket.
20. Wear insulating gloves and remove the bolts shown in the figure, then disconnect the bus bar.
21. Wear insulating gloves and remove the bolts shown in the figure.
22. Wear insulating gloves and lift the junction box No.3 straight up to remove it.
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• After removing the junction box No.3, wear insulating gloves and wrap the exposed terminal part with insulating tape to insulate it.
23. Install in the reverse order of removal.
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Caution
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• Before connecting the service plug, check the tightness of the high voltage terminals and the connection status of the connectors.
24. Wear insulating gloves and install the service plug using the following procedure.
- (1) Insert the service plug as far as it will go.
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- (2) Depress the lever completely.
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- (3) Slide the lock in the direction of the arrow shown in the figure until the hook is engaged.
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25. Install the service hole cover.
26. Close the cover.
27. Connect the negative lead-acid battery terminal. (See NEGATIVE LEAD-ACID BATTERY TERMINAL DISCONNECTION/CONNECTION.)
