DC-DC CONVERTER REMOVAL/INSTALLATION
id301700000600
-
Warning
-
<<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
-
Warning
-
<<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. Verify that the READY indicator on the instrument cluster is not illuminated.
-
• If the READY indicator is turned on, switch the main power OFF.
2. Disconnect the negative lead-acid battery terminal. (See NEGATIVE LEAD-ACID BATTERY TERMINAL DISCONNECTION/CONNECTION.)
3. Partially peel back the cover.
4. Remove the service hole cover.
5. Wear insulating gloves and remove the service plug using the following procedure.
-
Warning
-
<<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.
-
Caution
-
<<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)
-
- (2) Raise the lever.
-
- (3) Press the area indicated by arrow (1) shown in the figure, release the tabs, and then raise the lever until it is perpendicular.
-
- (4) Hold the lever and pull the service plug straight up.
-
6. After removing the service plug, leave it for 10 min.
7. 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.)
-
-
Caution
-
<<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.
-
- (3) Measure the voltage at the high voltage cable connection.
-
-
Note
-
• Use a voltmeter with a measurement range of
450 V DC or more.
-
― Verify that the voltmeter indicates 0 V and go to the next step.
• Verify that the waterproof rubber on the terminal cover is securely installed.
• Be careful not to damage the interlock, and install it securely.
- (4) Install the terminal cover.
-
8. Remove front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)
9. Drain the coolant. (See COOLANT REPLACEMENT.)
10. Remove the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION.)
11. Remove the bolts shown in the figure and remove the bracket.
12. Wear insulating gloves and follow the procedure below to disconnect the high voltage cable connector.
-
• 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.
-
- (2) Pull out the connector while pressing on the lock lever.
-
13. Detach the wiring harness clips shown in the figure.
14. Remove using the procedure shown in the figure.
|
1
|
Water hose
|
|
2
|
Battery wiring harness
|
|
3
|
Electric motor wiring harness
|
|
4
|
DC-DC converter
|
15. Install in the reverse order of removal.
-
Caution
-
• Before connecting the service plug, check the tightness of the high voltage terminals and the connection status of the connectors.
16. Wear insulating gloves and install the service plug using the following procedure.
- (1) Insert the service plug as far as it will go.
-
- (2) Depress the lever completely.
-
- (3) Slide the lock in the direction of the arrow shown in the figure until the hook is engaged.
-
17. Install the service hole cover.
18. Close the cover.
19. Connect the negative lead-acid battery terminal. (See NEGATIVE LEAD-ACID BATTERY TERMINAL DISCONNECTION/CONNECTION.)
20. Add coolant and perform air bleeding. (See COOLANT REPLACEMENT.)
21. Inspect to confirm that there is no coolant leakage at any part. (See COOLANT LEAKAGE INSPECTION.)
Water Hose Installation Note
1. Install with the marking on the water hose aligned with the projection on the DC-DC converter as shown in the figure.
