1

For supplying 12V power to the leak
detector.

Silicon Hose

1

To be used when performing leak
check (Inner Diameter: 7mm/0.3 in)

Spray Nozzle
(3M Cavity Wax Plus
Applicator Wand Kit or
general nozzle)

1

To be used with 3M Cavity Wax Plus
spray

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Bulletin Number: WRD-23; Date: 04/24/23

Page 7 of 44

Part Description

Qty

Insulated Hand Tools

1

For removing and installing bolts for
the high voltage components

1

To be used when removing and
installing the high voltage components

High Voltage Insulated
Gloves (Additional Information Provided Below)

Image

Details

For preventing static electricity from
electronic parts

Antistatic Mat
1

For preventing static electricity from
electronic parts

Antistatic Strap

Circuit Tester

1

For measuring the high voltage

Coolant Hose Cap

6

For preventing engine coolant dripping from the coolant hose

Hand Riveter

1

For installing the inverter/converter
cover

Wooden Blocks

1

To be used to support the inverter/
converter cover replacement

Continued...
Bulletin Number: WRD-23; Date: 04/24/23

Page 8 of 44

REQUIRED CHEMICALS FOR 12V TERMINAL REPLACEMENT:
Product Name

Qty

Remarks

3M Cavity Wax Plus

Appropriate
amount

For rust prevention

Three Bond 1207F (SOA868V9650)
Warranty Number SOA635336

Appropriate
amount

Sealant

Image

HIGH VOLTAGE INSULATED GLOVE INFORMATION:
•

New gloves and sleeves are marked with the date of manufacture/electrical test and are
acceptable for use 12 months from that date.

•

If new gloves are first used within 12 months of the manufacture/electrical test date, recertification must occur 6 months from first use. The first use date should be recorded.

•

If the first use date is not known, the gloves/sleeves must be retested 6 months from the
electrical test date stamped on the glove/sleeve.

•

All gloves must be inspected by the user for damage prior to each use.

•

The gloves include a stamped date indicating when the rubber insulating gloves were
“originally or last tested electrically.” Rubber insulating gloves must be re-tested electrically
by a certified lab 6 months after first use. The lab will re-stamp the gloves with the new
“tested” date.

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Bulletin Number: WRD-23; Date: 04/24/23

Page 9 of 44

SERVICE PROCEDURE FLOW CHART:

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Bulletin Number: WRD-23; Date: 04/24/23

Page 10 of 44

COMPONENT DETAILS / CONFIGURATION:

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Bulletin Number: WRD-23; Date: 04/24/23

Page 11 of 44

INSPECTION PROCEDURE:

STEP 1: Refer to the applicable Service Manual and
review: General Description > Repair Contents > Action
required before & after Battery Disconnect. Open the
rear gate Confirm the key is not inside the vehicle.
CAREFULLY disconnect the negative battery cable from
the battery.

STEP 2: Remove the rear floor mat from the cargo area.

STEP 3: Remove the service plug cover.

PRECAUTIONARY INFORMATION:
•

When working on high voltage systems, always wear high voltage insulated gloves.

•

After the service disconnect plug is removed, the inverter/converter assembly will
still contain a high voltage charge. Wait for period of ten minutes or more, prior to
proceeding with work procedures to any high voltage components, wiring, terminals and
connections.

•

To prevent any damage to the high voltage systems, DO NOT operate the ignition switch
while the service disconnect plug is removed.

•

After removing the service disconnect plug, protect the plug socket with tape to prevent
any intrusion of foreign matter such as water or dust. DO NOT touch the service
disconnect plug terminals.
Continued...

Bulletin Number: WRD-23; Date: 04/24/23

Page 12 of 44

IMPORTANT: Insulated gloves MUST be used for STEPS 3, 4, & 5.

STEP 3: Slide the lever of the service disconnect plug
toward the driver side of the vehicle.

STEP 4: Raise the lever to the vertical position.

STEP 5: Pull the lever in the upward direction and
removed the service disconnect plug.

STEP 6: Raise the vehicle using the lift manufacturer’s
specified procedures.
STEP 7: Remove the inverter/converter assembly lower
cover.

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Bulletin Number: WRD-23; Date: 04/24/23

Page 13 of 44

STEP 8: Open the terminal cap cover. Remove the
12v terminal nut. The terminal nut is a one-time use
part and must not be reused.
CAUTION: Some vehicles may have a protective
rubber boot installed in place of the terminal cap. If
found, remove and discard the rubber boot.

STEP 9: Perform a visual inspection of the High
Voltage (HV) air conditioning wire terminal for
corrosion and/or damage. See the example images
below.

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Bulletin Number: WRD-23; Date: 04/24/23

Page 14 of 44

NOTE: White Deposits found on the terminal is considered acceptable.
Inspection Result

Next Step

OK

No Corrosion, Red Rust and/or Breakage found

Proceed to Service Procedure A

NG

Corrosion, Breakage, and/or Red Rust was found

Proceed to Service Procedure B

SERVICE PROCEDURE A:
WHEN NO CORROSION, RED RUST, AND/OR BREAKAGE IS FOUND DURING
INSPECTION.
PRECAUTIONARY INFORMATION:
•

When working on high voltage systems, always wear high voltage insulated gloves.

•

During disassembly and reassembly of the inverter/converter assembly, BE CAREFUL
not to cause or induce any static electricity.

•

ALWAYS place the inverter/converter assembly and any other removed electronic
components on an antistatic work mat after removal.

•

Keep any foreign matters such as water and dust from entering the inverter/converter
assembly.

•

Be CAREFUL not to make contact with the electronic components within the inverter/
converter assembly.
Continued...

Bulletin Number: WRD-23; Date: 04/24/23

Page 15 of 44

STEP 1: Remove the inverter/converter assembly
from the body of the vehicle using the work
procedures outlined in the applicable Service
Manual. Refer to STIS: Body & Electrical/WIRING
SYSTEM > HYBRID ELECTRIC VEHICLE >
Inverter and Converter Assembly

TIP 1: ALWAYS perform the required voltage checks as outlined in the Service Manual. A zerovoltage reading at these required points is vital for confirming safe working conditions.
CAUTION: ALWAYS wear high voltage insulation gloves when performing the voltage checks.

TIP 2: Removing the ECM provides additional cable slack when working in the upper and
lower engine area during removal of the HV air conditioning cable.

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Bulletin Number: WRD-23; Date: 04/24/23

Page 16 of 44

STEP 2: CARFULLY remove the three retaining clips and the three rivets. The inverter/converter
insulation cover can then be removed.
CAUTION:
•

Release the rivets with a drill for removal. To prevent any damage to the inverter/
converter assembly, support the back side of the rivet with a trim tool or pliers.

•

The spacers attached to the cover MUST be reused. DO NOT discard the spacers.

STEP 3: Remove the two HV air condition cable
mounting bolts. Release the retaining clip and move the
HV air conditioning cable to allow room for workspace.

STEP 4: Remove and discard the terminal cap or
protective rubber boot.

STEP 5: Remove the hose clamps from the connections
indicated with yellow arrows in the right image. Remove
the two water pipe mounting bolts. Install provided rubber
caps (p.n. 9033916002) onto the aluminum pipes to
prevent any coolant drippage while working. The water
pipe can then be lowered to allow access to the inverter/
converter assembly.

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Bulletin Number: WRD-23; Date: 04/24/23

Page 17 of 44

NOTE: The following images show the water pipes removed from the inverter/converter assembly in
order to provide more detail for instructional purposes.

STEP 6: Remove the five inverter protector
mounting bolts. The inverter protector can
then be removed.

STEP 7: Place the inverter/converter
assembly on two wooden blocks.

STEP 8: Remove the two mounting bolts
for the inverter stay. The stay can then be
removed.

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Bulletin Number: WRD-23; Date: 04/24/23

Page 18 of 44

STEP 9: Remove the mounting bolts and stays
holding the rear inverter bracket. The rear bracket
assembly can then be removed.
IMPORTANT NOTE: The mounting bolts are
one-time use parts and can be discarded. The stays
are NOT to be discarded and MUST be re-used.

STEP 10: Install the NEW black painted rear
inverter bracket using the NEW mounting bolts.
Torque the mounting bolts to 18Nm (13.3ft-lbs).
CAUTION: DO NOT drop or hit the new
mounting bracket. This can cause the painted
surface to be damaged compromising its
corrosion protective strength.

STEP 11: Install the inverter stay using the two
original mounting bolts. Torque the mounting bolts
to 18Nm (13.3ft-lbs).

STEP 12: Reinstall the inverter protector with the
original mounting bolts in the following order.
1. Bolt (a)
2. Bolt (b)
3. Bolts (c)
Torque the mounting bolts in the same order to
18Nm (13.3ft-lbs).
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Bulletin Number: WRD-23; Date: 04/24/23

Page 19 of 44

STEP 13: Remove the rubber caps
(p.n. 9033916002) from the water pipe. Reinstall
the coolant hoses and clamps. Reattach the water
pipe to the inverter/converter assembly using the
original mounting bolts. Torque the bolts to 7.5Nm
(5.5ft-lbs).

STEP 14: Route the HV air conditioning cable
through the NEW rubber protective boot.

STEP 15: Secure the HV air condition cable to the
inverter/converter using the original bolts and the
new retaining clip. Torque the bolts to 7.5Nm
(5.5ft-lbs).

STEP 16: Connect the HV air conditioning cable
to the 12v terminal. Torque the NEW nut to 7.5Nm
(5.5ft-lbs).

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Bulletin Number: WRD-23; Date: 04/24/23

Page 20 of 44

STEP 17: Attach the new rubber cap to the
12v terminal.
CAUTION: Confirm the 12v terminal is
completely covered by the rubber cap.
The terminal MUST not be exposed.

STEP 18: Install the inverter/converter with
the three original retaining clips, three
original rivet spacers, and three NEW rivets.

STEP 19: Reinstall all parts in the reverse
order of disassembly.

Continued...
Bulletin Number: WRD-23; Date: 04/24/23

Page 21 of 44

SERVICE PROCEDURE B:
WHEN CORROSION, RED RUST, AND/OR BREAKAGE IS FOUND DURING
INSPECTION.
PRECAUTIONARY INFORMATION:
•

When working on high voltage systems, always wear high voltage insulated gloves.

•

During disassembly and reassembly of the inverter/converter assembly, BE CAREFULL
not to cause or induce any static electricity.

•

ALWAYS place the inverter/converter assembly and any other removed electronic
components on an antistatic work mat after removal.

•

Keep any foreign matters such as water and dust from entering the inverter/converter
assembly.

•

Be CAREFULL not to make contact with the electronic components within the inverter/
converter assembly.

STEP 1: Remove the inverter/converter assembly
from the body of the vehicle using the work procedures
outlined in the applicable Service Manual. Refer to
STIS: Body & Electrical/WIRING SYSTEM >
HYBRID ELECTRIC VEHICLE > Inverter and
Converter Assembly

TIP 1: ALWAYS perform the required voltage checks as outlined in the Service Manual. A zerovoltage reading at these required points is vital for confirming safe working conditions.

Continued...
Bulletin Number: WRD-23; Date: 04/24/23

Page 22 of 44

CAUTION: ALWAYS wear high voltage insulation gloves when performing the voltage checks.

TIP 2: Removing the ECM provides
additional cable slack when working in
the upper and lower engine area during
removal of the HV air conditioning
cable.

STEP 2: Remove the three retaining clips and the three rivets. The inverter/converter insulation cover
can then be removed.
CAUTION:
•

Release the rivets with a drill for removal. To prevent any damage to the inverter/
converter assembly, support the back side of the rivet with a trim tool or pliers.

•

The spacers attached to the cover MUST be reused. DO NOT discard the spacers.

STEP 3: Remove the two HV air condition
cable mounting bolts. Release the retaining clip
and move the HV air conditioning cable to
allow room for workspace.

Continued...
Bulletin Number: WRD-23; Date: 04/24/23