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Installation [02/2014 - 11/2016]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL NO. 2 ENGINE ROOM WIRE 

    HINT: 

    Perform this procedure only when replacement of the No. 2 engine room wire is necessary.

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

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

    3. Close the terminal cover.
    4. Install a new clamp.
  2. INSTALL WIRE HARNESS CLAMP BRACKET 

    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 2 bolts.

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

    4. Engage each clamp and install the 2 clamps to the wire harness clamp bracket.
  3. INSTALL HIGH VOLTAGE FUSE 
    WARNING:

    Wear insulated gloves.

    HINT: 

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

    1. Place the holder as shown in the illustration.
      GTY303886Courtesy 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: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

      NOTE:

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

    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 cover.
      • Do not touch the inverter terminal cover waterproofing rubber.
      • 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.

    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 waterproofing rubber is securely installed before installing the inverter terminal cover.
      • Do not touch the inverter terminal cover waterproofing rubber.
      • Make sure that the interlock is fully engaged.
  4. INSTALL INVERTER COOLING PIPE 
    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) 

      GTY439704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Upper Side
      *b Front Side
      *c 2 to 7 mm (0.0787 to 0.276 in.)
    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 cooling system, do not remove the pieces of cloth or plastic bags from the pipe and disconnected hose until installation.

      HINT: 

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

  5. INSTALL INVERTER DRAIN HOSE 
    1. Install the inverter drain hose to the inverter with converter assembly and slide the clip to secure it.
      GTY454610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Upper Side
      *b Front Side
      *c 2 to 7 mm (0.0787 to 0.276 in.)
      NOTE:

      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.

      HINT: 

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

  6. INSTALL INVERTER WITH CONVERTER ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    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.
      GTY451904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  7. INSTALL NO. 4 INVERTER BRACKET 
    1. Install the No. 4 inverter bracket with the bolt and nut.

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

    2. Engage the clamp to the No. 4 inverter bracket.
  8. CONNECT NO. 2 ENGINE ROOM WIRE 
    1. Engage the claw and connect the No. 2 engine room wire to the no. 1 engine room relay block and No. 1 junction block assembly.
    2. Install the nut to the No. 2 engine room wire.

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

    3. Engage the 4 claws to install the No. 1 relay block cover to the no. 1 engine room relay block and No. 1 junction block assembly.
    4. Install the No. 1 relay block cover to the No. 1 relay block cover.
  9. CONNECT NO. 2 ENGINE ROOM RELAY BLOCK ASSEMBLY 
    1. Engage the clamp and connect the No. 2 engine room relay block assembly.
  10. CONNECT WATER HOSE 
    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 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.
      GTY425706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
    2. Connect the inlet No. 1 inverter cooling hose and No. 2 inverter cooling hose to the inverter with converter assembly and slide the 2 clips to secure them.
      GTY450160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Inlet No. 1 Inverter Cooling Hose
      *2 No. 2 Inverter Cooling Hose
      *a Alignment Mark (White)
      *b Alignment Mark (Yellow)
      *c Upper Side
      *d LH Side
      *e Front Side
      *f 2 to 7 mm (0.0787 to 0.276 in.)
      NOTE:

      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.

      HINT: 

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

    3. Engage the clamp.
  11. CONNECT MG ECU CONNECTOR 
    WARNING:

    Wear insulated gloves.

    1. Connect the MG ECU connector.
    2. Connect the MG ECU connector to the inverter with converter assembly and move the lock lever as shown in the illustration to lock the connector.
      GTY303439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. CONNECT NO. 3 ENGINE ROOM RELAY BLOCK 
    1. Engage the clamp and connect the No. 3 engine room relay block.
  13. REMOVE INVERTER TERMINAL COVER 

    See step  9

  14. CONNECT NO. 6 FLOOR WIRE 
    WARNING:

    Wear insulated gloves.

    1. Engage the 3 clamps.
    2. Connect the No. 6 floor 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 waterproofing rubber or terminals.
      • Do not 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 by hand.
      NOTE:

      Do not allow any foreign matter or water to enter the inverter with converter assembly.

    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 No. 6 floor 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 waterproofing rubber 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 by hand.
      NOTE:

      Do not allow any foreign matter or water to enter the inverter with converter assembly.

    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.
  15. CONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR 
    WARNING:

    Wear insulated gloves.

    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 waterproofing rubber 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 by hand.
      NOTE:

      Do not allow any foreign matter or water to enter the inverter with converter assembly.

    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 waterproofing rubber 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 by hand.
      NOTE:

      Do not allow any foreign matter or water to enter the inverter with converter assembly.

    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.
  16. CONNECT NO. 4 ENGINE WIRE 
    WARNING:

    Wear insulated gloves.

    1. Connect the No. 4 engine 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 waterproofing rubber 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 by hand.
      NOTE:

      Do not allow any foreign matter or water to enter the inverter with converter assembly.

    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.
  17. CHECK HIGH VOLTAGE CABLE CONNECTION 
    WARNING:

    Wear insulated gloves.

    NOTE:

    Do not allow any foreign matter or water to enter the inverter with converter assembly.

    1. Check that each terminal is firmly connected.
      GTY303888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure that the bolts and nut are fully tightened.
      • Make sure not to cross-thread the bolts.
  18. INSTALL INVERTER TERMINAL COVER 
    WARNING:

    Wear insulated gloves.

    1. Temporarily install the inverter terminal cover to the inverter with converter assembly with the 11 bolts.
      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.
    2. Fully tighten the 11 bolts in the order shown in the illustration.

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

      GTY431413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL NO. 1 INVERTER RESERVE TANK BRACKET 
    1. Install the No. 1 inverter reserve tank bracket with the 2 bolts to the inverter with converter assembly.

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

  20. INSTALL INVERTER RESERVE TANK ASSEMBLY 
    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.
      GTY446282Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Inverter Cooling Hose *2 Inverter Drain Hose
      *a Alignment Mark (White) *b Alignment Mark (Pink)
      *c Rib *d Upper Side
      *e Front Side *f LH Side
      *g RH Side *h 2 to 7 mm (0.0787 to 0.276 in.)
      *i 2 to 6 mm (0.0787 to 0.236 in.) - -
      NOTE:

      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.

      HINT: 

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

    3. Connect the inverter drain hose to the clamp.
  21. INSTALL NO. 3 INVERTER BRACKET 
    1. Install the No. 3 inverter bracket with the bolt and nut.

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

  22. INSTALL AIR CLEANER ASSEMBLY 

    Refer to INSTALLATION [02/2014 - 11/2016]

  23. INSTALL SERVICE PLUG GRIP 

    Refer to INSTALLATION [02/2014 - ] 

  24. ADD COOLANT (for Inverter) 

    See step  3

  25. INSPECT FOR COOLANT LEAK (for Inverter) 

    See step  1

  26. INSTALL NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 78 (INSTALLATION [02/2014 - 11/2015])

    Refer to PROCEDURE - Step 77 (INSTALLATION [11/2015 - 11/2016])

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