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Installation [11/2015 - ]: Procedure

  1. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install the wire harness clamp bracket to the inverter with converter assembly with the bolt.

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

    3. Install the 2 wire harness clamp brackets to the inverter with converter assembly with the 2 bolts.

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

  2. INSTALL NO. 2 INVERTER BRACKET 
    1. Set the inverter with converter assembly on wooden blocks.
      GTY594376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
      NOTE:

      Make sure to support the inverter with converter assembly at the positions shown in the illustration, otherwise it may be damaged.

      GTY586919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the No. 2 inverter bracket to the inverter with converter assembly with the 2 bolts.
    3. Fully tighten the 2 bolts in the order shown in the illustration.

      Torque: 15 N.m (153 kgf.cm, 11 ft/lbf) 

  3. INSTALL NO. 1 INVERTER BRACKET 
    1. Temporarily install the No. 1 inverter bracket to the inverter with converter assembly with the 2 bolts.
      GTY587617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
    2. Fully tighten the 2 bolts in the order shown in the illustration.

      Torque: 15 N.m (153 kgf.cm, 11 ft/lbf) 

  4. INSTALL INVERTER WITH CONVERTER ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. Temporarily install the inverter with converter assembly with the 5 bolts and 2 nuts.
      NOTE:
      • 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 cooling pipes.
      • To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.
      • Make sure that the inverter with converter assembly is positioned so that the stud bolts are in contact with the base of the U-shaped portions of the No. 1 inverter bracket.
        GTY591719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Correct
        *b Incorrect

      HINT: 

      If the bolts and nuts are not tightened appropriately, the inverter with converter assembly may make an abnormal noise.

    2. Fully tighten the bolt (A).

      Torque: 25 N.m (255 kgf.cm, 18 ft/lbf) 

      GTY568571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Fully tighten the 3 bolts (B).

      Torque: 25 N.m (255 kgf.cm, 18 ft/lbf) 

    4. Fully tighten the bolt (C).

      Torque: 25 N.m (255 kgf.cm, 18 ft/lbf) 

    5. Fully tighten the 2 nuts (D).

      Torque: 25 N.m (255 kgf.cm, 18 ft/lbf) 

  5. CONNECT MOTOR CABLE 
    WARNING:

    Wear insulated gloves.

    NOTE:

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

    1. Temporarily connect the motor cable to the inverter with converter assembly with the 4 bolts.
      NOTE:
      • Do not touch the waterproof seal or terminals of the connector.
      • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
    2. Fully tighten the bolt (A).
      GTY545411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal

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

    3. Fully tighten the 3 bolts in the order shown in the illustration to connect the motor cable to the inverter with converter assembly.

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

    4. Temporarily install the 6 bolts.
      NOTE:
      • To prevent the threads from being damaged, temporarily tighten the 6 bolts by hand.
      • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
      GTY542955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using an insulated tool, fully tighten the 6 bolts.

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

      NOTE:
      • Do not touch the waterproof seal or terminals of the connector.
      • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
      • Be sure to use a torque wrench to tighten the bolts.
  6. INSTALL INVERTER COVER 
    WARNING:

    Wear insulated gloves.

    1. Install the inverter cover 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 inverter cover waterproof seal is securely installed before installing the inverter cover.
      • Do not touch the waterproof seal of the inverter cover.
      • Make sure that the interlock is fully engaged.
      • Do not damage the terminals, interlock connector or inverter with converter assembly during installation.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Do not remove or excessively tighten the screw of the inverter cover.
        GTY596586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Inverter Cover
        *a Screw
      • Although the inverter cover may feel loose, this is not due to a malfunction.
      • Push in the inverter cover until it contacts the inverter with converter assembly.
        GTY607007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a No Gap
  7. CONNECT INLET NO. 1 INVERTER COOLING HOSE 
    1. Connect the inlet No. 1 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.
      GTY566692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Alignment Mark (Light Blue)
      *b Rib
      *c 2 to 11 mm (0.0787 to 0.433 in.)
      *d Up
      *e LH Side
  8. CONNECT OUTLET NO. 1 INVERTER COOLING HOSE 
    1. Connect the outlet No. 1 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.
      GTY548810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Alignment Mark (Pink)
      *b Rib
      *c 2 to 11 mm (0.0787 to 0.433 in.)
  9. CONNECT NO. 3 ENGINE WIRE 
    WARNING:

    Wear insulated gloves.

    1. Engage the clamp and connect the No. 3 engine wire to the inverter with converter assembly.
      GTY542938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the nut.
      NOTE:

      To prevent the threads from being damaged, temporarily tighten the nut by hand.

    3. Fully tighten the nut.

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

    4. Engage the 2 claws to close the No. 3 engine wire terminal cover.
    5. Connect the No. 3 engine wire to the inverter with converter assembly with the bolt.
      GTY542937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    6. Connect the No. 3 engine wire to the inverter with converter assembly with the bolt.
      GTY542944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  10. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install the wire harness clamp bracket to the inverter with converter assembly with the nut.

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

  11. CONNECT AIR CONDITIONING WIRE 
    WARNING:

    Wear insulated gloves.

    1. Engage the clamp.
    2. Connect the air conditioning wire to the inverter with converter assembly and install the 2 bolts.
      GTY552145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.
      • Do not touch the waterproof seal or terminals of the connector.
      • Do not damage the terminals, connector housing or inverter with converter assembly when connecting the connector.
  12. CONNECT HV FLOOR UNDER WIRE 
    WARNING:

    Wear insulated gloves.

    1. Engage the 2 clamps.
    2. Connect the HV floor under wire to the inverter with converter assembly and install the 2 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.
      • Do not touch the waterproof seal or terminals of the connector.
      • Do not damage the terminals, connector housing or inverter with converter assembly when connecting the connector.
      GTY600528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. CONNECT ENGINE WIRE 
    WARNING:

    Wear insulated gloves.

    NOTE:

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

    1. Engage the 2 clamps to connect the engine wire.
    2. Install the bolt.

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

    3. Install the inverter protector to the inverter with converter assembly with the bolt.

      Torque: 9.5 N.m (97 kgf.cm, 84 in/lbf) 

    4. Engage the 2 clamps.
    5. Connect the 2 inverter with converter assembly connectors and move each lock lever as shown in the illustration.
      GTY543048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.
      • Do not damage the terminals, connector housing or inverter with converter assembly when connecting the connectors.
      • Do not touch the waterproof seal or terminals of the connectors.
    6. Engage the 2 claws.
    7. Connect the 3 No. 1 engine room relay block and No. 1 junction block assembly connectors.
    8. Install the No. 1 relay block cover.
  14. INSTALL BATTERY CLAMP SUB-ASSEMBLY 
    1. Install the battery clamp sub-assembly with the 3 bolts.

      Torque: 15.4 N.m (157 kgf.cm, 11 ft/lbf) 

  15. INSTALL ECM 

    Refer to INSTALLATION [11/2015 - ]

  16. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 14 [11/2015 - 12/2018] , or refer to PROCEDURE - Step 16 [12/2018 - ]

  17. INSTALL COWL BODY MOUNTING REINFORCEMENT LH 

    Refer to PROCEDURE - Step 15 [11/2015 - 12/2018] , or refer to PROCEDURE - Step 17 [12/2018 - ]

  18. INSTALL WATER GUARD PLATE LH 

    Refer to PROCEDURE - Step 16 [11/2015 - 12/2018] , or refer to PROCEDURE - Step 18 [12/2018 - ]

  19. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL 

    Refer to PROCEDURE - Step 17 [11/2015 - 12/2018] , or refer to PROCEDURE - Step 19 [12/2018 - ]

  20. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to INSTALLATION [11/2015 - ]

  21. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 72 [11/2015 - 08/2016] , or refer to PROCEDURE - Step 72 [08/2016 - 12/2018] , or refer to PROCEDURE - Step 72 , or refer to PROCEDURE - Step 72

  22. INSTALL SERVICE PLUG GRIP 

    Refer to INSTALLATION [11/2015 - ]

  23. INSTALL AUXILIARY BATTERY 

    Refer to INSTALLATION [11/2015 - 12/2018] , or refer to INSTALLATION [12/2018 - ]

  24. CONNECT ENGINE WIRE 
    1. Connect the battery state sensor assembly connector.
    2. Engage the 2 claws to connect the engine wire to the battery current sensor holder.
  25. ADD COOLANT (for Inverter) 

    See step  3

  26. INSPECT FOR COOLANT LEAK (for Inverter) 

    See step  1

  27. INSTALL REAR MOTOR UNDER COVER LH 

    See step  5

  28. PERFORM RESOLVER LEARNING 
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