Inverter - Rear Drive Unit (Remove and Replace)

Correction code 4020060240200602
  • 1130479-00-A Skt, 3/8in Dr, 10EP Torx Plus External
  • 1140311-00-ALever Lock, HV Connector, Model 3

SPECIAL TOOLS

Skt, 3/8in Dr, 10EP Torx Plus External (1130479-00-A)
Lever Lock, HV Connector, Model 3 (1140311-00-A)
Parent topic: 4020 - Rear Drive Inverter

Remove

  1. Use Toolbox to open the Rear Drive Inverter - Remove and Replace Autodiag, and click Run Network.
  2. In the Rear Drive Inverter - Remove and Replace Autodiag, run PROC_DI_X_STORE-DATA-APP to store the application data and run PROC_PM_X_STORE-DATA-BOOT to store the bootloader data.
  3. Follow the instructions in the Rear Drive Inverter - Remove and Replace Autodiag to perform the rest of this procedure.
  4. Remove the laptop from the vehicle, but do not close Toolbox 3.
  5. Remove the rear subframe assembly. See Subframe Assembly - Rear (Remove and Install).
  6. Remove the LH rear drive unit mount. See Mount - Rear Drive Unit - LH (Remove and Replace).
  7. Release the clips that attach the upper cooler hose to the rear drive unit.
  8. Disconnect the electrical harness from the inverter low voltage connector.
  9. Release the clip, disconnect the rear drive unit inlet hose from the inverter coolant inlet, and then plug the inlet.
  10. Release the clip that attaches the rear drive unit inlet hose to the HV harness bracket, and then remove the hose from the rear drive unit.
  11. Remove the bolt that attaches the HV harness bracket to the inverter.
  12. Slide the release to unlock the HV harness connector.
  13. Lift the handle on HV harness connector, disconnect the harness from the inverter connector, and then remove the harness from the rear drive unit.
  14. Secure an ESD strap to the inverter housing.
  15. Remove the 3-phase access label.
  16. Remove the bolts (x2) that attach the 3-phase access cover to the rear drive unit.
  17. Remove and discard the 3-phase access cover.
  18. Remove and discard the bolts (x3) that attach the 3-phase terminals to the inverter assembly.
  19. Remove and discard the bolts (x12) that attach the inverter to the gearbox assembly.
  20. Carefully remove the inverter assembly from the rear drive unit and allow the coolant to drain.
  21. Remove and discard the inverter gasket.
1Use Toolbox to open the Rear Drive Inverter - Remove and Replace Autodiag, and click Run Network.
2In the Rear Drive Inverter - Remove and Replace Autodiag, run PROC_DI_X_STORE-DATA-APP to store the application data and run PROC_PM_X_STORE-DATA-BOOT to store the bootloader data.
3Follow the instructions in the Rear Drive Inverter - Remove and Replace Autodiag to perform the rest of this procedure.
4Remove the laptop from the vehicle, but do not close Toolbox 3.
5Remove the rear subframe assembly. See Subframe Assembly - Rear (Remove and Install).
6Remove the LH rear drive unit mount. See Mount - Rear Drive Unit - LH (Remove and Replace).
7Release the clips that attach the upper cooler hose to the rear drive unit.
8Disconnect the electrical harness from the inverter low voltage connector.
9Release the clip, disconnect the rear drive unit inlet hose from the inverter coolant inlet, and then plug the inlet.
10Release the clip that attaches the rear drive unit inlet hose to the HV harness bracket, and then remove the hose from the rear drive unit.
11Remove the bolt that attaches the HV harness bracket to the inverter.
12Slide the release to unlock the HV harness connector.
13Lift the handle on HV harness connector, disconnect the harness from the inverter connector, and then remove the harness from the rear drive unit.
14Secure an ESD strap to the inverter housing.
15Remove the 3-phase access label.
16Remove the bolts (x2) that attach the 3-phase access cover to the rear drive unit.
17Remove and discard the 3-phase access cover.
18Remove and discard the bolts (x3) that attach the 3-phase terminals to the inverter assembly.
19Remove and discard the bolts (x12) that attach the inverter to the gearbox assembly.
20Carefully remove the inverter assembly from the rear drive unit and allow the coolant to drain.
21Remove and discard the inverter gasket.

Install

  1. Secure the ESD strap to the replacement inverter housing.
  2. Inspect the condition of the gap pad on the inverter PCB. Replace the gap pad if it does not fulfill these criteria.
    • New and undamaged condition.
    • Fully covers the discharge resistor array and that no resistors are visible.
    • Clean and free of debris.
    • Evenly adhered to the inverter PCB.
  3. Install a new inverter gasket.
  4. Use an IPA wipe to clean the HV mating surfaces of the motor and inverter 3-phase terminals.
  5. Carefully align the inverter to the 2 pins in the rear drive unit, and then install the inverter to the rear drive unit. Make sure that the 3-phase terminals align during installation.
    Caution:
    Avoid damage to the printed circuit board of the inverter.
  6. Hand-tighten the new bolts (x12) that attach the inverter to the gearbox assembly.
  7. Torque the bolts in the sequence shown.
    Torque 5 Nm +20 deg
  8. Install the new bolts (x3) that attach the 3 phase cable to the inverter assembly.
    1. Tighten the bolts to this specification.
      Torque 11.5 Nm
    2. Loosen the bolts 180 degrees.
    3. Tighten the bolts to this specification.
      Torque 5 Nm +40 deg
  9. Apply a film of ATF-9 fluid to the walls of the gear case bores, and then install the new 3-phase access cover.
  10. Install the bolts (x2) that attach the 3-phase access cover to the rear drive unit assembly.
    Torque 7.5 Nm
  11. Perform an inverter air leak test. See Inverter Air Leak Test.
  12. Apply a new 3-phase access label.
  13. Remove the ESD wrist strap.
  14. Fully raise the handle on the rear drive unit HV electrical harness.
  15. Attach the HV connector lever lock onto the back of the HV electrical harness.
  16. Firmly connect the HV electrical harness to the inverter connector.
    Caution:
    Make sure that the harness fits the connector squarely and tightly.
  17. While pressing the harness to the connector, remove the HV connector lever lock.
  18. While pressing the harness to the connector, fully lower the handle.
  19. Slide the release to lock the HV electrical harness.
  20. Install the bolt that attaches the HV harness bracket to the inverter.
    Torque 6 Nm
  21. Connect the rear drive unit inlet hose to the inverter coolant inlet, and then fasten the clip.
    Caution:
    Perform a push-pull test to verify that the hose is fully seated.
  22. Fasten the clip that attaches the rear drive unit inlet hose to the HV harness bracket.
  23. Connect the electrical harness to the inverter low voltage connector.
  24. Install the LH rear drive unit mount. See Mount - Rear Drive Unit - LH (Remove and Replace).
  25. Fasten the clips that attach the upper cooler hose to the rear drive unit.
  26. Install the rear subframe assembly. See Subframe Assembly - Rear (Remove and Install).
  27. Refill the cooling system. See Powertrain Coolant (Drain and Refill).
    Note: Perform the refill before the installation of the front RH wheel liner.
  28. Within Toolbox, return to the Rear Drive Inverter - Remove and Replace Autodiag, and run PROC_PM_X_RESTORE-DATA-BOOT to restore the bootloader data and run PROC_PM_X_WRITE-DRIVE-TYPE to configure the Usage ID.
  29. Use the Rear Drive Inverter - Remove and Replace Autodiag to:
    1. Redeploy the current firmware to the new inverter.
    2. Restore the required data to the new inverter.
    3. Perform the resolver learn process.
      Caution:
      This process requires the vehicle wheels to be spinning at 55 mph (90 kph) while elevated on a lift.
    4. Perform the thermal performance self-test.
  30. Perform a four wheel alignment. See Four Wheel Alignment (Check and Adjust).
1Secure the ESD strap to the replacement inverter housing.
2Inspect the condition of the gap pad on the inverter PCB. Replace the gap pad if it does not fulfill these criteria.
  • New and undamaged condition.
  • Fully covers the discharge resistor array and that no resistors are visible.
  • Clean and free of debris.
  • Evenly adhered to the inverter PCB.
3Install a new inverter gasket.
4Use an IPA wipe to clean the HV mating surfaces of the motor and inverter 3-phase terminals.
5Carefully align the inverter to the 2 pins in the rear drive unit, and then install the inverter to the rear drive unit. Make sure that the 3-phase terminals align during installation.
Caution:
Avoid damage to the printed circuit board of the inverter.
6Hand-tighten the new bolts (x12) that attach the inverter to the gearbox assembly.
7Torque the bolts in the sequence shown.
Torque 5 Nm +20 deg
8Install the new bolts (x3) that attach the 3 phase cable to the inverter assembly.
  1. Tighten the bolts to this specification.
    Torque 11.5 Nm
  2. Loosen the bolts 180 degrees.
  3. Tighten the bolts to this specification.
    Torque 5 Nm +40 deg
9Apply a film of ATF-9 fluid to the walls of the gear case bores, and then install the new 3-phase access cover.
10Install the bolts (x2) that attach the 3-phase access cover to the rear drive unit assembly.
Torque 7.5 Nm
11Perform an inverter air leak test. See Inverter Air Leak Test.
12Apply a new 3-phase access label.
13Remove the ESD wrist strap.
14Fully raise the handle on the rear drive unit HV electrical harness.
15Attach the HV connector lever lock onto the back of the HV electrical harness.
16Firmly connect the HV electrical harness to the inverter connector.
Caution:
Make sure that the harness fits the connector squarely and tightly.
17While pressing the harness to the connector, remove the HV connector lever lock.
18While pressing the harness to the connector, fully lower the handle.
19Slide the release to lock the HV electrical harness.
20Install the bolt that attaches the HV harness bracket to the inverter.
Torque 6 Nm
21Connect the rear drive unit inlet hose to the inverter coolant inlet, and then fasten the clip.
Caution:
Perform a push-pull test to verify that the hose is fully seated.
22Fasten the clip that attaches the rear drive unit inlet hose to the HV harness bracket.
23Connect the electrical harness to the inverter low voltage connector.
24Install the LH rear drive unit mount. See Mount - Rear Drive Unit - LH (Remove and Replace).
25Fasten the clips that attach the upper cooler hose to the rear drive unit.
26Install the rear subframe assembly. See Subframe Assembly - Rear (Remove and Install).
27Refill the cooling system. See Powertrain Coolant (Drain and Refill).
Note: Perform the refill before the installation of the front RH wheel liner.
28Within Toolbox, return to the Rear Drive Inverter - Remove and Replace Autodiag, and run PROC_PM_X_RESTORE-DATA-BOOT to restore the bootloader data and run PROC_PM_X_WRITE-DRIVE-TYPE to configure the Usage ID.
29Use the Rear Drive Inverter - Remove and Replace Autodiag to:
  1. Redeploy the current firmware to the new inverter.
  2. Restore the required data to the new inverter.
  3. Perform the resolver learn process.
    Caution:
    This process requires the vehicle wheels to be spinning at 55 mph (90 kph) while elevated on a lift.
  4. Perform the thermal performance self-test.
30Perform a four wheel alignment. See Four Wheel Alignment (Check and Adjust).