Installation [08/2016 - ]: Procedure

HINT: 

Perform this procedure only when replacement of the No. 5 engine room wire is necessary.

1. Temporarily install the No. 5 engine room wire and nut to the inverter with converter assembly by hand.
2. Fully tighten the nut.

   Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

3. Close the terminal cover.

HINT: 

Perform this procedure only when replacement of a wire harness clamp bracket is necessary.

1. Install the wire harness clamp bracket to the inverter with converter assembly with the bolt.

   Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

2. Install the wire harness clamp bracket to the inverter with converter assembly with the bolt.

   Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

3. Engage each clamp to install the 2 clamps to the wire harness clamp bracket.

HINT: 

Perform this procedure only when replacement of the high voltage fuse is necessary.

1. Place the holder as shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   Use either the location shown in the illustration or another method to hold the high voltage fuse for the subsequent step.

2. Install the high voltage fuse to the holder with 2 new nuts.

   Torque: 4.2 N*m (43 kgf*cm, 37 in.*lbf) 

   NOTE:

   • Be sure to use a torque wrench to tighten the nuts.
   • Do not drop the nuts into the inverter with converter assembly.
3. Remove the 11 bolts and inverter terminal cover from the inverter with converter assembly.
   NOTE:

   • Make sure to pull the inverter terminal cover straight up, as a connector is connected to the bottom of the inverter terminal cover.
   • Do not touch the inverter terminal cover waterproof seal.
   • Do not allow any foreign matter or water to enter the inverter with converter assembly.
4. Install the holder to the inverter with converter assembly with 2 new nuts.

   Torque: 4.2 N*m (43 kgf*cm, 37 in.*lbf) 

   NOTE:

   • Be sure to use a torque wrench to tighten the nuts.
   • Do not drop the nuts into the inverter with converter assembly.
5. Temporarily install the inverter terminal cover with the 11 bolts to prevent any foreign matter or water from entering the inverter with converter assembly.
   NOTE:

   • Visually confirm that the inverter terminal cover waterproof seal is securely installed before installing the inverter terminal cover.
   • Do not touch the inverter terminal cover waterproof seal.
   • Make sure that the interlock is fully engaged.

1. Install the inverter cooling pipe to the inverter with converter assembly with the 2 bolts.

   Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Up
   *b	Front of Vehicle
   *c	2 to 7 mm (0.0787 to 0.276 in.)
   *d	Alignment Mark (Yellow)

2. Connect the inlet No. 2 inverter cooling hose to the inverter with converter assembly and slide the clip to secure it.
   NOTE:

   To prevent foreign matter from entering the inverter with converter assembly and inverter cooling system, do not remove the pieces of cloth from the pipe and disconnected hose until installation.

   HINT: 

   • Make sure that the clip is positioned as shown in the illustration.
   • Make sure to align the alignment mark of the hose with the rib of the inverter with converter assembly.

1. Install the inverter drain hose to the inverter with converter assembly and slide the clip to secure it.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Up
   *b	Front of Vehicle
   *c	2 to 7 mm (0.0787 to 0.276 in.)
   *d	Alignment Mark (Yellow)

   NOTE:

   To prevent foreign matter from entering the inverter with converter assembly and inverter cooling system, do not remove the pieces of cloth from the pipe and disconnected hose until installation.

   HINT: 

   • Make sure that the clip is positioned as shown in the illustration.
   • Make sure to align the alignment mark of the hose with the rib of the inverter with converter assembly.

1. Temporarily install the inverter with converter assembly with the 2 bolts and nut.
   NOTE:

   • Since the inverter with converter assembly is very heavy, 2 people are needed to install the inverter with converter assembly. When installing the inverter with converter assembly, be careful not to damage the parts around it.
   • To prevent damage, do not hold the inverter with converter assembly by the connectors, brackets or pipes.
   • To prevent damage due to static electricity, be careful not to touch the terminals of the disconnected connectors.
2. Fully tighten the 2 bolts and nut in the order shown in the illustration to install the inverter with converter assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

1. Engage the claw to connect the No. 5 engine room wire to the engine room relay block and junction block assembly.
2. Install the nut.

   Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 

3. Engage the 3 claws to install the No. 1 relay block cover to the engine room relay block and junction block assembly.
4. Install the No. 1 relay block cover to the No. 1 relay block cover.

1. Engage the clamp and connect the No. 2 engine room relay block.

1. Connect the outlet No. 1 inverter cooling hose to the inverter with converter assembly and lock the hose with the retainer as shown in the illustration.
   NOTE:

   • Push in the retainer until a click sound is heard.
   • Pull on the water hose to confirm that it is securely connected.
   • If there is foreign matter on the union or retainer, clean it off with water and finger scouring.
   • To prevent foreign matter from entering the cooling system, do not remove the pieces of cloth or plastic bags from the pipe and disconnected hose until installation.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Retainer

2. Connect the inlet No. 1 inverter cooling hose and outlet No. 2 inverter cooling hose to the inverter with converter assembly and slide the 2 clips to secure them.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Inlet No. 1 Inverter Cooling Hose
   *2	Outlet No. 2 Inverter Cooling Hose
   *a	Alignment Mark (White)
   *b	Alignment Mark (Yellow)
   *c	Up
   *d	LH Side
   *e	Front of Vehicle
   *f	2 to 7 mm (0.0787 to 0.276 in.)

   NOTE:

   To prevent foreign matter from entering the inverter with converter assembly and inverter cooling system, do not remove the pieces of cloth from the pipe and disconnected hose until installation.

   HINT: 

   • Make sure that the clip is positioned as shown in the illustration.
   • Make sure to align the alignment mark of the hose with the rib of the inverter with converter assembly.
3. Engage the clamp.

1. Connect the low voltage connector.
   NOTE:

   To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.

2. Connect the low voltage connector and move the lock lever as shown in the illustration to lock the connector.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.

See step  10, or see step  10, or see step  10

1. Engage the 3 clamps.
2. Connect the HV floor under wire (for HV Battery) to the inverter with converter assembly.
   NOTE:

   • Do not allow any foreign matter or water to enter the inverter with converter assembly.
   • Do not touch the connector waterproof seal or terminals.
   • Be carefull not to damage the terminals, terminal housings or inverter with converter assembly during connection.
   • Make sure that the interlock is fully engaged.
3. Temporarily install the 4 bolts to the inverter with converter assembly.
   NOTE:

   • Do not allow any foreign matter or water to enter the inverter with converter assembly.
   • To prevent the threads from being damaged, temporarily tighten the 4 bolts by hand.
4. Using an insulated tool, fully tighten the 4 bolts.

   Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

   NOTE:

   • Do not allow any foreign matter or water to enter the inverter with converter assembly.
   • Be sure to use a torque wrench to tighten the bolts.
5. Engage the clamp.
6. Connect the HV floor under wire (for Rear Motor (MGR)) to the inverter with converter assembly.
   NOTE:

   • Do not allow any foreign matter or water to enter the inverter with converter assembly.
   • Do not touch the connector waterproof seal or terminals.
   • Do not damage the terminals, terminal housings or inverter with converter assembly during connection.
7. Temporarily install the 5 bolts to the inverter with converter assembly.
   NOTE:

   • Do not allow any foreign matter or water to enter the inverter with converter assembly.
   • To prevent the threads from being damaged, temporarily tighten the 5 bolts by hand.
8. Using an insulated tool, fully tighten the 5 bolts.

   Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

   NOTE:

   • Do not allow any foreign matter or water to enter the inverter with converter assembly.
   • Be sure to use a torque wrench to tighten the bolts.

1. Connect the high voltage cable of front motor (for Motor (MG2)) to the inverter with converter assembly.
   NOTE:

   • Do not allow any foreign matter or water to enter the inverter with converter assembly.
   • Do not touch the connector waterproof seal or terminals.
   • Do not damage the terminals, terminal housings or inverter with converter assembly during connection.
2. Temporarily install the 5 bolts to the inverter with converter assembly.
   NOTE:

   • Do not allow any foreign matter or water to enter the inverter with converter assembly.
   • To prevent the threads from being damaged, temporarily tighten the 5 bolts by hand.
3. Using an insulated tool, fully tighten the 5 bolts.

   Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

   NOTE:

   • Do not allow any foreign matter or water to enter the inverter with converter assembly.
   • Be sure to use a torque wrench to tighten the bolts.
4. Connect the high voltage cable of front motor (for Generator (MG1)) to the inverter with converter assembly.
   NOTE:

   • Do not allow any foreign matter or water to enter the inverter with converter assembly.
   • Do not touch the connector waterproof seal or terminals.
   • Do not damage the terminals, terminal housings or inverter with converter assembly during connection.
5. Temporarily install the 5 bolts to the inverter with converter assembly.
   NOTE:

   • Do not allow any foreign matter or water to enter the inverter with converter assembly.
   • To prevent the threads from being damaged, temporarily tighten the 5 bolts by hand.
6. Using an insulated tool, fully tighten the 5 bolts.

   Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

   NOTE:

   • Do not allow any foreign matter or water to enter the inverter with converter assembly.
   • Be sure to use a torque wrench to tighten the bolts.

1. Connect the HV air conditioning wire to the inverter with converter assembly.
   NOTE:

   • Do not allow any foreign matter or water to enter the inverter with converter assembly.
   • Do not touch the connector waterproof seal or terminals.
   • Do not damage the terminals, terminal housings or inverter with converter assembly during connection.
2. Temporarily install the 5 bolts to the inverter with converter assembly.
   NOTE:

   • Do not allow any foreign matter or water to enter the inverter with converter assembly.
   • To prevent the threads from being damaged, temporarily tighten the 5 bolts by hand.
3. Using an insulated tool, fully tighten the 5 bolts.

   Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

   NOTE:

   • Do not allow any foreign matter or water to enter the inverter with converter assembly.
   • Be sure to use a torque wrench to tighten the bolts.

1. Check that each terminal is securely connected.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   • Make sure that the bolts and nut are fully tightened.
   • Make sure not to cross-thread the bolts.

1. Temporarily install the inverter terminal cover to the inverter with converter assembly with the 11 bolts.
   NOTE:

   • Do not touch the waterproof seal of the inverter terminal cover.
   • Do not allow any foreign matter or water to enter the inverter with converter assembly.
   • Make sure that the interlock is fully engaged.
   • Visually confirm that the inverter terminal cover waterproof seal is securely installed before installing the inverter terminal cover.
2. Fully tighten the 11 bolts in the order shown in the illustration.

   Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Temporarily install the No. 1 inverter reserve tank bracket with the 2 bolts to the inverter with converter assembly.
2. Fully tighten the 2 bolts in the order shown in the illustration.

   Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the inverter reserve tank assembly with the bolt and nut.

   Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

2. Connect the No. 1 inverter cooling hose and 2 inverter drain hoses to the inverter reserve tank assembly and slide the 3 clips to secure them.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	No. 1 Inverter Cooling Hose	*2	Inverter Drain Hose
   *a	Alignment Mark (White)	*b	Rib
   *c	Front of Vehicle	*d	Up
   *e	Left Side of Vehicle	*f	Right Side of Vehicle
   *g	2 to 6 mm (0.0787 to 0.236 in.)	*h	2 to 7 mm (0.0787 to 0.276 in.)

   NOTE:

   To prevent foreign matter from entering the inverter with converter assembly and inverter cooling system, do not remove the pieces of cloth from the pipe and disconnected hose until installation.

   HINT: 

   • Make sure that the clip are positioned as shown in the illustration.
   • Make sure to align the alignment mark of the hose with the rib of the inverter with converter assembly.
3. Connect the inverter drain hose to the clamp.

1. Install the No. 6 inverter bracket with the bolt and nut.

   Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

1. Install the No. 3 inverter bracket with the bolt and nut.

   Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

2. Engage the clamp.

Refer to INSTALLATION [10/2015 - ]

Refer to INSTALLATION [10/2015 - 03/2018] , or refer to INSTALLATION [03/2018 - ]

See step  4

See step  1

Refer to PROCEDURE - Step 85 , or refer to PROCEDURE - Step 87

Refer to PROCEDURE - Step 86 , or refer to PROCEDURE - Step 88