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Inverter With Converter: Installation

  1. INSTALL W/CONVERTER INVERTER ASSEMBLY 
    CAUTION: Wear insulating gloves.
    1. Install the w/ converter inverter assembly with the 2 nuts and bolt.

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

      Fig 1: Locating W/ Converter Inverter Assembly Nuts And Bolt
      G05201753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: 2 people are needed to install the w/ converter inverter assembly.
  2. INSTALL INVERTER BRACKET No. 4 
    1. Install the inverter bracket No. 4 with the 2 bolts.

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

      Fig 2: Locating Inverter Bracket No. 4 Bolts
      G05201755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL ENGINE ROOM RELAY BLOCK ASSEMBLY 
    1. Install the engine room relay block assembly.
      Fig 3: Locating Engine Room Relay Block Assembly
      G05201756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE INVERTER COVER 
    1. Remove the 2 bolts and inverter cover to the w/ converter inverter assembly.
  5. CONNECT No. 3 WIRE FRAME 
    CAUTION: Wear insulating gloves.
    NOTE:
    • Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly (See PRECAUTION ).
    • Do not allow any foreign objects or waterdrops to enter the w/ converter inverter assembly.
      Fig 4: Locating Inverter Cover Bolts
      G05201750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. After connecting the connector, press the lever down to connect the No. 3 wire frame and install the bolt to the w/ converter inverter assembly.

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

      Fig 5: Pressing Lever
      G05201758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the No. 3 wire frame (high voltage cable of the rear motor) with the 5 bolts to the w/ converter inverter assembly, (for 4WD)

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

      Fig 6: Locating No. 3 Wire Frame Bolts
      G05201748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. CONNECT MG ECU CONNECTOR 
    CAUTION: Wear insulating gloves.
    NOTE:
    • Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly (See PRECAUTION ).
    • Do not allow any foreign objects or waterdrops to enter the w/ converter inverter assembly.
    1. Connect the 2 connectors and 2 grommets to the w/ converter inverter assembly.
      2. Fig 7: Locating Connectors And Grommets
      G05201760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. CONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR 
    CAUTION: Wear insulating gloves.
    NOTE:
    • Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly (See PRECAUTION ).
    • Do not allow any foreign objects or waterdrops to enter the w/ converter inverter assembly.
    1. Connect the high voltage cable of the Generator with the 5 bolts to the w/ converter inverter assembly.

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

      Fig 8: Locating High Voltage Cable Bolts
      G05201746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the high voltage cable of the Motor with the 5 bolts to the w/ converter inverter assembly.

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

      Fig 9: Locating High Voltage Cable Bolts
      G05201745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. CONNECT ENGINE WIRE No. 4 
    CAUTION: Wear insulating gloves.
    NOTE:
    • Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly (See PRECAUTION ).
    • Do not allow any foreign objects or waterdrops to enter the w/ converter inverter assembly.
    1. Connect the engine wire No. 4 with the connector, clamp and grommet to the w/ converter inverter assembly.
    2. Connect the engine wire No. 4 with the bolt to the w/ converter inverter assembly.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      Fig 10: Locating Engine Wire No. 4 To W/ Converter Inverter Assembly
      G05201744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. CHECK HIGH VOLTAGE CABLE CONNECTION 
    CAUTION: Wear insulating gloves.
    NOTE:
    • Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly (See PRECAUTION ).
    • Do not allow any foreign objects or waterdrops to enter the w/ converter inverter assembly.
    1. Check that each connector and terminal is firmly installed.
      NOTE:
      • Make sure that the connectors are fully engaged.
      • Make sure that the bolts are fully tightened.
        Fig 11: Locating High Voltage Cable Bolts
        G05201764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL INVERTER COVER 
    1. Install the inverter cover with the 12 bolts to the w/ converter inverter assembly.

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

      Fig 12: Locating Inverter Cover Bolts
      G05201742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the interlock bracket with the bolt to the w/ converter inverter assembly.

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

      Fig 13: Identifying Interlock Bracket
      G05201740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL POWER STEERING ECU BRACKET 
    1. Install the power steering ECU bracket with the bolt to the w/ converter inverter assembly.

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

      Fig 14: Locating Power Steering ECU Bracket Bolt
      G05201739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. CONNECT WATER HOSE 
    1. Connect the water hose with the clamp to the w/ converter inverter assembly.
      Fig 15: Locating Water Hose With Clamp
      G05201768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL INVERTER RESERVE TANK SUB-ASSEMBLY 
    1. Connect the 2 water hoses with the 2 clamps to the inverter reserve tank sub-assembly.
      Fig 16: Connecting Water Hoses To Inverter Reserve Tank Sub-Assembly
      G05201737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the inverter reserve tank with the 2 bolts to the w/ converter inverter assembly.

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

      Fig 17: Locating Inverter Reserve Tank Bolts
      G05201736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. CONNECT ENGINE ROOM WIRE No. 2 
    1. Connect the engine room wire No. 2 with the nut.

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

      Fig 18: Locating Engine Room Wire No. 2 With Nut
      G05201771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. CONNECT CIRCUIT BREAKER SENSOR No. 1 
    1. Connect the circuit breaker sensor No. 1 connector.
      2. Fig 19: Locating Circuit Breaker Sensor No. 1 Connector
      G05201772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL POWER STEERING ECU ASSEMBLY  (See INSTALLATION )
  17. INSTALL INVERTER BRACKET No. 5  (See INSTALLATION )
  18. INSTALL AIR CLEANER W/RESONATOR  (See INSTALLATION )
  19. INSTALL AIR CLEANER CAP W/INLET  (See INSTALLATION )
  20. INSTALL FRONT SUSPENSION BRACE SUB-ASSEMBLY UPPER CENTER  (See INSTALLATION )
  21. INSTALL SERVICE PLUG GRIP  (See INSTALLATION )
  22. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  23. ADD COOLANT  (See COOLANT )
  24. INSPECT FOR COOLANT LEAK 
  25. INSTALL ENGINE ROOM SIDE LH COVER No. 2  (See INSTALLATION )
  26. PERFORM INITIALIZATION 
    1. Some systems need initialization when disconnecting the cable from the negative battery terminal. (See INITIALIZATION )
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