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Installation [06/2015 - ]: Procedure

  1. INSTALL HIGH VOLTAGE FUSE 
    NOTE:

    Do not allow foreign matter or water droplets to enter the FC inverter input junction assembly.

    HINT: 

    Perform this procedure when the high voltage fuse must be replaced.

    1. Temporarily install the 2 high voltage fuses to the FC inverter input junction assembly with 4 new nuts.
      Fig 1: High Voltage Fuses To FC Inverter Input Junction Assembly Nuts Tightening Sequence
      GTY586873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tighten the 4 nuts in the order shown in the illustration.

      Torque: 4.5 N*m (46 kgf*cm, 40 in.*lbf) 

    3. Remove all of the old seal packing remaining on the sealing surface between the junction block service cover and FC inverter input junction assembly, and using non-residue solvent, clean and degrease the sealing surface.
      NOTE:

      Do not scratch or damage the sealing surface between the junction block service cover and FC inverter input junction assembly.

    4. Using Seal Packing 1282B or equivalent, apply an unbroken bead 2.0 to 4.0 mm in diameter to the FC inverter input junction assembly in the location shown in the illustration.
      GTY541839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Packing 1282B

      Seal Packing

      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

      NOTE:

      After applying the Seal Packing 1282B or equivalent, install the junction block service cover within 3 minutes, and tighten the bolts within 15 minutes.

    5. Install the junction block service cover to the FC inverter input junction assembly with the 9 bolts.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

  2. INSTALL PACKING SEAL 

    HINT: 

    Perform this procedure when the packing seal must be replaced.

    1. Install the packing seal to the FC inverter input junction assembly.
  3. REMOVE INVERTER TERMINAL COVER 

    Refer to PROCEDURE - Step 17 [06/2015 - 11/2018] , or refer to PROCEDURE - Step 17 [11/2018 - ]

  4. INSTALL FC INVERTER INPUT JUNCTION ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    NOTE:

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

    1. To prevent contamination by foreign matter or water droplets, remove the protective tape from the opening of the inverter with converter assembly immediately before performing the procedure.
    2. Temporarily install the FC inverter input junction assembly to the inverter with converter assembly with the 5 bolts.
      GTY603078Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Interlock Connector
      NOTE:
      • To prevent damage to the threaded portion, be sure to perform the work by hand.
      • If the packing seal of the FC inverter input junction assembly has any damage or deformation, replace it with a new one.
      • Do not touch the packing seal or terminal portion of the FC inverter input junction assembly.
      • When installing, do not damage or scratch the terminal portions, connector housing, or inverter with converter assembly.
      • Securely connect the interlock connector.

      HINT

      Item Bolt Head Shape
      Bolt A Flange Bolt
      Bolt B Bolt with Washer
    3. Using an insulated tool, tighten the 3 bolts A.

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

    4. Using an insulated tool, tighten the 2 bolts B.

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

    5. Connect the connector to the electric heater sub-assembly and press in the green lock to securely fix the connector in place as shown in the illustration.
      GTY568004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Green-colored Lock
      NOTE:
      • Do not touch the connector terminals.
      • Check that the connector is securely connected.
    6. Connect the connector to the FC water and hydrogen pump inverter assembly and press in the green lock to securely fix the connector in place as shown in the illustration.
      GTY546369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Green-colored Lock
      NOTE:
      • Do not touch the connector terminals.
      • Check that the connector is securely connected.
    7. Engage the clamp to connect the wire harness to the FC inverter input junction assembly.
  5. INSTALL INVERTER TERMINAL COVER 

    Refer to PROCEDURE - Step 19

  6. CONNECT FRAME WIRE 
    WARNING:

    Wear insulated gloves.

    1. To prevent contamination by foreign matter or water droplets, remove the protective tape from the openings of the FC inverter input junction assembly immediately before performing the procedure.
    2. Temporarily install the frame wire to the FC inverter input junction assembly with the 4 bolts.
      GTY549695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Interlock Connector
      NOTE:
      • To prevent damage to the threaded portion, be sure to perform the work by hand.
      • Do not touch the rubber seal or terminal portion of the frame wire.
      • When connecting, do not damage or scratch the terminal portions, connector housing, or FC inverter input junction assembly.
      • Securely connect the interlock connector.

      HINT

      Item Bolt Head Shape
      Bolt A Flange Bolt
      Bolt B Bolt with Washer
    3. Using an insulated tool, tighten the 2 bolts A.

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

    4. Using an insulated tool, tighten the 2 bolts B.

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

  7. INSTALL FC INVERTER INPUT JUNCTION COVER 
    WARNING:

    Wear insulated gloves.

    1. Install the FC inverter input junction cover to the FC inverter input junction assembly with the 2 bolts.

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

      NOTE:
      • Do not touch the rubber seal of the FC inverter input junction cover.
      • Securely connect the interlock connector.
    2. Engage the clamp to connect the wire harness from the FC inverter input junction cover.
    3. Connect the FC inverter input junction cover connector.
  8. INSTALL FC WATER PUMP DRAIN HOSE ASSEMBLY 
    1. Install the FC water pump drain hose assembly to the FC inverter input junction assembly with the bolt.

      Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

  9. INSTALL INVERTER COVER 

    Refer to PROCEDURE - Step 62

  10. INSTALL AIR CLEANER SUPPORT 
    1. Install the air cleaner support to the FC inverter input junction assembly.
  11. INSTALL AIR CLEANER WITH ELEMENT ASSEMBLY 

    Refer to PROCEDURE - Step 64

  12. INSTALL AIR CLEANER INLET 

    Refer to PROCEDURE - Step 65

  13. INSTALL COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 2 [06/2015 - 11/2018] , or refer to PROCEDURE - Step 2 [11/2018 - ]

  14. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 12 [06/2015 - 11/2018] , or refer to PROCEDURE - Step 12 [11/2018 - ]

  15. INSTALL COWL BODY MOUNTING REINFORCEMENT RH 

    Refer to PROCEDURE - Step 13 [06/2015 - 11/2018] , or refer to PROCEDURE - Step 13 [11/2018 - ]

  16. INSTALL WATER GUARD PLATE LH 

    Refer to PROCEDURE - Step 14 [06/2015 - 11/2018] , or refer to PROCEDURE - Step 14 [11/2018 - ]

  17. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL 

    Refer to PROCEDURE - Step 15 [06/2015 - 11/2018] , or refer to PROCEDURE - Step 15 [11/2018 - ]

  18. INSTALL WINDSHIELD WIPER MOTOR AND LINK 

    Refer to INSTALLATION [06/2015 - ]

  19. INSTALL FC STACK SERVICE PLUG GRIP 

    Refer to INSTALLATION [06/2015 - 11/2018] , or refer to INSTALLATION [11/2018 - ] 

  20. INSTALL SERVICE PLUG GRIP (for EV) 

    Refer to INSTALLATION [06/2015 - 11/2018] , or refer to INSTALLATION [11/2018 - ]

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