Installation [10/2014 - ]: Procedure

HINT: 

Perform this procedure only when replacement of the inverter tray bracket sub-assembly.

1. Temporarily install the inverter tray bracket sub-assembly to the body with the 4 bolts.
   Fig 1: Inverter Tray Bracket Sub-Assembly Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   Temporarily tighten the bolt (1) first.

2. Install the 4 bolts in the order shown in the illustration.

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

1. Temporarily install the No. 3 engine room wire to the inverter with converter assembly with the nut.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Tighten the nut.

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

3. Close the cover.

HINT: 

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

1. Connect the No. 1 inverter cooling hose to the inverter with converter assembly and lock the hose with the retainer.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *1

   Retainer

   NOTE:

   • Insert 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 pipes and disconnected hoses until installation.
2. Install the No. 1 inverter cooling hose to the inverter with converter assembly.

1. Install the No. 2 motor cable bracket to the inverter with converter assembly with the 2 bolts.

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

1. Install the No. 1 motor cable bracket to the inverter with converter assembly with the 2 bolts.

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

1. Temporarily install the No. 3 inverter bracket to the inverter with converter assembly with the 2 bolts.
2. Tighten the 2 bolts in the order shown in the illustration.
   Fig 2: No. 3 Inverter Bracket Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Temporarily install the No. 2 inverter bracket to the inverter with converter assembly with the 2 bolts.
2. Tighten the 2 bolts in the order shown in the illustration.
   Fig 3: No. 2 Inverter Bracket Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Temporarily install the No. 1 inverter bracket to the inverter with converter assembly with the 2 bolts.
2. Tighten the 2 bolts in the order shown in the illustration.
   Fig 4: No. 1 Inverter Bracket Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Install the air cleaner bracket to the inverter with converter assembly with the bolt.

   Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

1. Install the air cleaner bracket to the inverter with converter assembly with the bolt.

   Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

HINT: 

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

1. Remove the bolt and connector cover assembly from the inverter with converter assembly.
   NOTE:

   • Make sure to pull the connector cover assembly straight up, as a connector is connected to the bottom of the cover.
   • Do not allow any foreign matter or water to enter the inverter with converter assembly.
2. Install the high voltage fuse to the inverter with converter assembly with 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.

3. Temporarily install the connector cover assembly with the bolt to prevent any foreign matter or water from entering 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, 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. Fully tighten the 2 bolts and nut in the order shown in the illustration.
   Fig 5: Inverter With Converter Assembly Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Connect the No. 1 inverter cooling hose assembly to the inverter with converter assembly and lock the hose with the retainer.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *1

   Retainer

   NOTE:

   • Insert 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.

1. Connect the No. 4 inverter cooling hose to the inverter with converter assembly and lock the hose with the retainer.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   TEXT IN ILLUSTRATION
   
   

   *1

   Retainer

   NOTE:

   • Insert 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.

1. Connect the wire harness clamp to the engine room relay block and junction block assembly.
2. Install the No. 3 engine room wire to the engine room relay block and junction block assembly with the nut.

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

3. Install the No. 1 relay block cover to the engine room relay block and junction block assembly.

1. Connect the 3 low voltage connectors and lock the connector with the lock lever.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   • Do not allow any foreign matter or water to enter the inverter with converter assembly.
   • Make sure that the connectors are fully engaged.

See step  19

1. Connect the No. 4 floor wire and wire harness clamp to the inverter with converter assembly.
2. Secure the No. 4 floor wire to the inverter with converter assembly with the bolt.

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

1. Connect the No. 4 engine wire to the inverter with converter assembly.
2. Connect the wire harness clamp to the No. 2 motor cable bracket.

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:

   • Make sure that the interlock is fully engaged.
   • Do not allow any foreign matter or water to enter the inverter with converter assembly.

1. Install the No. 3 motor cable bracket to the inverter with converter assembly with the 2 bolts.

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

2. Connect the hose clamp to the No. 3 motor cable bracket.

1. Connect the motor cable to the inverter with converter assembly.
2. Connect the 3 wire harness clamps.
3. Using an insulated tool, secure the motor cable to the inverter with converter assembly with the 3 bolts.

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

   NOTE:

   • The terminals should be connected securely.
   • The bolts should be tightened securely.

1. Install the upper inverter cover (motor cable side) to the inverter with converter assembly with the 2 bolts.

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

   NOTE:

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

1. Connect the generator cable to the inverter with converter assembly.
2. Connect the 2 wire harness clamps.
3. Using an insulated tool, secure the generator cable to the inverter with converter assembly with the 3 bolts.

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

   NOTE:

   • The terminals should be connected securely.
   • The bolts should be tightened securely.

1. Install the upper inverter cover (generator cable side) to the inverter with converter assembly with the 2 bolts.

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

   NOTE:

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

1. Temporarily install the No. 4 inverter bracket with the 3 bolts.
2. Tighten the 3 bolts in the order shown in the illustration.
   Fig 6: No. 4 Inverter Bracket Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Temporarily install the No. 5 inverter bracket with the 2 bolts.
2. Tighten the 2 bolts in the order shown in the illustration.
   Fig 7: No. 5 Inverter Bracket Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Refer to PROCEDURE - Step 62

Refer to PROCEDURE - Step 63

Refer to PROCEDURE - Step 3

Refer to PROCEDURE - Step 65

Refer to PROCEDURE - Step 3 and PROCEDURE - Step 3

(Refer to INSTALLATION [10/2014 - ] )

See step  2

See step  1