Installation [01/2017 - 05/2023]: Procedure

HINT: 

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

1. Remove the connector cover assembly.

   See step  14

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

   Torque: 4.0 N.m (41 kgf/cm, 35 in.lbf) 

   NOTE:

   Be sure to use a torque wrench to tighten the nuts.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

3. Temporarily install the connector cover assembly.

   See step  16

HINT: 

Perform this procedure only when replacement of the No. 1 inverter cooling hose is necessary.

1. Install the No. 1 inverter cooling hose to the inverter with converter assembly and slide the 2 hose clips to secure it.
   NOTE:

   Do not remove the pieces of cloth or plastic bags from the pipes until installation.

   HINT: 

   Make sure that the 2 hose clips are positioned as shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Alignment Mark

1. Temporarily install the inverter bus-bar plate sub-assembly with the nut by tightening the nut 3 or more revolutions.
   NOTE:

   If the inverter bus-bar plate sub-assembly is dropped or deformed, replace it with a new one.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Stopper

   HINT: 

   When installing, align with the stopper.

2. Install the bolt and attach the clamp.

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

3. Tighten the nut.

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

4. Close the terminal cover.

1. Temporarily install the No. 4 inverter bracket to the inverter with converter assembly with the 2 bolts.
   Fig 1: No. 4 Inverter Bracket Bolts Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Stopper

   HINT: 

   When installing, align with the stopper.

2. Tighten the 2 bolts in the sequence shown in the illustration.

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

1. Temporarily install the No. 6 inverter bracket with the 2 bolts.
   Fig 2: Inverter With Converter Assembly Bolts Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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, do not damage the parts around it.
   • To prevent damage, do not hold the inverter with converter assembly by the connectors.
   • To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.
2. Temporarily install the inverter with converter assembly with the 4 bolts.
3. Tighten the 6 bolts in the order shown in the illustration.

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

4. Attach the clamp.
5. Open the inverter bus-bar plate sub-assembly cover.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

6. Connect the inverter bus-bar plate sub-assembly with the nut.

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

7. Connect the connector.

1. Remove the connector cover assembly.

   See step  14

2. Connect the HV floor under wire.
   NOTE:

   • Do not allow any foreign matter or water to enter the inverter with converter assembly.
   • Do not touch the connector waterproofing rubber or terminals.
   • Do not damage the connectors, connector housings or inverter with converter assembly during connection.
   • Make sure that the connector is fully engaged.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

3. Secure the HV floor under wire to the inverter with converter assembly with the bolt.

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

4. Temporarily install the connector cover assembly.

   See step  16

1. Remove the connector cover assembly.

   See step  14

2. Connect the engine room main wire (air conditioning harness) 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 waterproofing rubber or terminals.
   • Do not damage the connectors, connector housings or inverter with converter assembly during connection.
   • Make sure that the connector is fully engaged.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

3. Temporarily install the connector cover assembly.

   See step  16

4. Temporarily install the wiring harness clamp bracket with the 2 nuts.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Torque Wrench Fulcrum Length

5. Using SST, tighten the 2 nuts.
   • SST: 09961-00950 

   Specified tightening torque 

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

   HINT: 

   • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

     Refer to PRECAUTION [01/2017 - 05/2023]

   • When using SST (fulcrum length of 150 mm (5.906 in.)) + torque wrench (fulcrum length of 300 mm (11.811 in.)): 5.3 N.m (54 kgf/cm, 47 in.lbf)
6. Connect the engine room main wire (inverter with converter assembly connector) to the inverter with converter assembly and lock the connector with the lock lever as shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Connect the No. 4 inverter cooling hose to the inverter with converter assembly and slide the hose clip to secure it.
   NOTE:

   Do not remove the pieces of cloth or plastic bags from the pipe and disconnected hose until installation.

   HINT: 

   Make sure that the hose clip is positioned as shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Insert
   *b	Upper
   *c	RH Side
   *d	120°
   *e	Mark (Yellow)
   *f	2.0 to 5.0 mm (0.079 to 0.196 in.)

1. Connect the No. 5 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 hose to confirm that the hose is securely connected.
   • If there is foreign matter on the union or the O-ring, clean it 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

1. Install the fender apron brace sub-assembly RH with the 2 bolts.

   Torque: 49 N.m (500 kgf/cm, 36 ft.lbf) 

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Attach the clamp.

1. Install the inverter motor cable bracket assembly with the 2 bolts.

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Attach the 3 clamps.

1. Temporarily install the motor cable to the inverter with converter assembly with the 5 bolts.
   NOTE:

   • Do not allow any foreign matter or water to enter the inverter with converter assembly.
   • Do not touch the connector waterproofing rubber or terminals.
   • Do not damage the terminals, connector housings or inverter with converter assembly when connecting them.
   Fig 3: Motor Cable Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using an insulated tool, tighten the 3 bolts (A) in the order shown in the illustration.

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

3. Using an insulated tool, tighten the 2 bolts (B).

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

1. Temporarily install the generator cable to the inverter with converter assembly with the 5 bolts.
   NOTE:

   • Do not allow any foreign matter or water to enter the inverter with converter assembly.
   • Do not touch the connector waterproofing rubber or terminals.
   • Do not damage the terminals, connector housings or inverter with converter assembly when connecting them.
   Fig 4: Generator Cable Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using an insulated tool, tighten the 3 bolts (A) in the order shown in the illustration.

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

3. Using an insulated tool, tighten the 2 bolts (B).

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

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

   • Do not touch the inverter terminal cover waterproofing rubber.
   • Do not allow any foreign matter or water to enter the inverter with converter assembly.
   • Make sure that the interlock is fully engaged.
   Fig 5: Inverter Terminal Cover Bolts Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Press the inverter terminal cover by hand until it is firmly attached to the inverter with converter assembly.
3. Tighten the 3 bolts to the inverter terminal cover.

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

   NOTE:

   Tighten the 3 bolts in the sequence shown in the illustration.

1. Install the connector cover assembly to the inverter with converter assembly with the 2 bolts.

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

   NOTE:

   • Visually confirm that the connector cover assembly waterproofing rubber is securely installed before installing the connector cover assembly.
   • Do not touch the connector cover assembly waterproofing rubber.
   • Make sure that the interlock is fully engaged.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Refer to PROCEDURE - Step 10

Refer to PROCEDURE - Step 11

Refer to PROCEDURE - Step 12

Refer to PROCEDURE - Step 13

Refer to PROCEDURE - Step 14

Refer to PROCEDURE - Step 23

Refer to PROCEDURE - Step 24

Refer to PROCEDURE - Step 25

Refer to INSTALLATION [01/2017 - 05/2023]

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 13 [01/2017 - 01/2021] , or refer to PROCEDURE - Step 13 [01/2021 - 05/2023]

Refer to PROCEDURE - Step 3

See step  1

Refer to UTILITY [01/2017 - ]