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Home >> Toyota >> 2021 >> Mirai XLE >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Electric Motor Systems >> Hybrid Battery Control System - Service Information (1 Of 6) >> Inverter With Converter >> Installation [11/2020 - ] >> Procedure

Installation [11/2020 - ]: Procedure

  1. INSTALL HIGH VOLTAGE FUSE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.

    HINT: Perform this procedure only when replacement of the high voltage fuse is necessary.
    1. GTY1003729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the connector cover assembly.

        See step  11 [11/2020 - 11/2021], or see step  11 [11/2021 - 12/2022], or see step  11 [12/2022 - 12/2023], or see step  11 [12/2023 - ]

      2. Install the high voltage fuse with the 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.

        See step  13 [11/2020 - 11/2021], or see step  13 [11/2021 - 12/2022], or see step  13 [12/2022 - 12/2023], or see step  13 [12/2023 - ]

  2. INSTALL NO. 1 INVERTER COOLING HOSE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    Do not remove the pieces of cloth or plastic bags from the pipes until installation.

    HINT: Perform this procedure only when replacement of the No. 1 inverter cooling hose is necessary.
    1. GTY1003155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Alignment Mark - -
      1. Install the No. 1 inverter cooling hose to the inverter with converter assembly and slide the 2 hose clips to secure it.

        HINT: 

        Make sure that the 2 hose clips are positioned as shown in the illustration.

  3. INSTALL INVERTER BUS-BAR PLATE SUB-ASSEMBLY 
    1. GTY1161880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Stopper - -
      1. Temporarily install the inverter bus-bar plate sub-assembly with the nut by tightening the nut 3 or more revolutions.
        NOTE:

        If the inverter bus-bar plate sub-assembly is dropped or deformed, replace it with a new one.

        HINT: 

        When installing, align with the stopper.

      2. Install the bolt and engage the clamp.

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

      3. Tighten the nut.

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

      4. Close the terminal cover.
  4. INSTALL NO. 4 INVERTER BRACKET 
    1. Fig 1: No. 4 Inverter Bracket Tightening Sequence
      GTY1004441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Stopper *2  
      1. Temporarily install the No. 4 inverter bracket to the inverter with converter assembly with the 2 bolts.

        HINT: 

        When installing, align with the stopper.

      2. Tighten the 2 bolts in the sequence shown in the illustration.

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

  5. INSTALL INVERTER WITH CONVERTER ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. Fig 2: Inverter With Converter Assembly Tightening Sequence
      GTY1003481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Temporarily install the No. 6 inverter bracket with the 2 bolts.
        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. Temporarily install the inverter with converter assembly with the 4 bolts.
      3. Tighten the 6 bolts in the order shown in the illustration.

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

      4. Engage the clamp.
  6. INSTALL FC JUNCTION CABLE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. GTY1003925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the connector cover assembly.

        See step  11 [11/2020 - 11/2021], or see step  11 [11/2021 - 12/2022], or see step  11 [12/2022 - 12/2023], or see step  11 [12/2023 - ]

      2. Connect the FC junction cable.
        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 connectors, connector housings or inverter with converter assembly during connection.
        • Make sure that the connector is fully engaged.
      3. Secure the FC junction cable to the inverter with converter assembly with the 2 bolts.

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

      4. Engage the clamp.
      5. Temporarily install the connector cover assembly.

        See step  13 [11/2020 - 11/2021], or see step  13 [11/2021 - 12/2022], or see step  13 [12/2022 - 12/2023], or see step  13 [12/2023 - ]

  7. INSTALL FRONT COMPARTMENT MAIN WIRE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. GTY1005060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the connector cover assembly.

        See step  11 [11/2020 - 11/2021], or see step  11 [11/2021 - 12/2022], or see step  11 [12/2022 - 12/2023], or see step  11 [12/2023 - ]

      2. Connect the front compartment main 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 connectors, connector housings or inverter with converter assembly during connection.
        • Make sure that the connector is fully engaged.
      3. Temporarily install the connector cover assembly.

        See step  13 [11/2020 - 11/2021], or see step  13 [11/2021 - 12/2022], or see step  13 [12/2022 - 12/2023], or see step  13 [12/2023 - ]

      4. Connect the front compartment main wire to the inverter with converter assembly and lock the connector with the lock lever as shown in the illustration.
  8. CONNECT INVERTER BUS-BAR PLATE SUB-ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. GTY1003708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  9. INSTALL WIRE HARNESS CLAMP BRACKET 

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

  10. CONNECT NO. 3 FC INVERTER COOLING HOSE 
    1. GTY1003887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Insert *b Upper
      *c RH Side *d 120°
      *e Mark (White) *f 2.0 to 7.0 mm (0.079 to 0.275 in.)
      1. Connect the No. 3 FC inverter cooling hose to the inverter with converter assembly and slide the hose clip to secure it.
        NOTE:

        Do not remove the pieces of cloth or plastic bags from the pipe and disconnected hose until installation.

        HINT: 

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

  11. CONNECT NO. 1 FC INVERTER COOLING HOSE SUB-ASSEMBLY 
    1. GTY1003385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 2.5 mm (0.098 in.) or less - -
      1. Connect the No. 1 FC inverter cooling hose sub-assembly 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 pipe to confirm that the pipe 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.
  12. INSTALL FENDER APRON BRACE SUB-ASSEMBLY RH 

    Torque: 49 N.m (500 kgf/cm, 36 ft.lbf) 

  13. CONNECT FC CONVERTER POWER OUTLET CABLE (INVERTER WITH CONVERTER ASSEMBLY) 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. GTY1004861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. If the FC converter power outlet front holder and FC converter power outlet front gasket are removed, install them using the following procedure.
      GTY1162883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the FC converter power outlet front gasket to the housing.

        HINT: 

        Install by aligning the protrusion of the FC converter power outlet front gasket with the housing groove.

      2. Install the FC converter power outlet front holder to the housing.
        NOTE:

        Push in the FC converter power outlet front holder until a "click" sound is heard. After pushing it in, check that it is not removed.

    3. Fig 3: FC Converter Power Outlet Cable (Inverter With Converter Assembly) Tightening Sequence
      GTY1160813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Connect the FC converter power outlet cable (inverter with converter assembly) to the FC stack assembly.
      2. Tighten the 2 bolts (A) and bolt (B) in the order shown in the illustration.

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

        NOTE:

        Installing the bolts in an incorrect order may damage the FC stack assembly and FC converter power outlet cable (inverter with converter assembly).

      3. Engage the clamp.
      4. Install the bolt.

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

  14. INSTALL INVERTER MOTOR CABLE BRACKET ASSEMBLY 

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

  15. CONNECT NO. 2 BATTERY PACK WIRE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. Fig 4: No. 2 Battery Pack Wire Tightening Sequence
      GTY1004465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Temporarily install the No. 2 battery pack wire to the inverter with converter assembly with the 5 bolts.
        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, connector housings or inverter with converter assembly when connecting them.
      2. Using an insulated tool, tighten the 3 bolts (A) in the order shown in the illustration.

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

      3. Using an insulated tool, tighten the 2 bolts (B).

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

  16. CONNECT FC AIR COMPRESSOR MOTOR CABLE ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. GTY1004753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Temporarily install the FC air compressor motor cable assembly to the inverter with converter assembly with the 5 bolts.
        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, connector housings or inverter with converter assembly when connecting them.
      2. Using an insulated tool, tighten the 2 bolts (A).

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

      3. Using an insulated tool, tighten the 3 bolts (B).

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

  17. INSTALL INVERTER TERMINAL COVER 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. Fig 5: Inverter Terminal Cover Tightening Sequence
      GTY1005085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Temporarily install the inverter terminal cover to the inverter with converter assembly.
        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. Press the inverter terminal cover by hand until it is firmly attached to the inverter with converter assembly.
      3. Tighten the 3 bolts to the inverter terminal cover.

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

        NOTE:

        Tighten the 3 bolts in the sequence shown in the illustration.

  18. INSTALL CONNECTOR COVER ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.

    NOTE:
    • Visually confirm that the connector cover assembly waterproofing rubber is securely installed before installing the connector cover assembly.
    • Do not touch the connector cover assembly waterproofing rubber.
    • Make sure that the interlock is fully engaged.

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

  19. INSTALL SERVICE PLUG GRIP 

    Refer to INSTALLATION [11/2020 - 12/2022] , or refer to INSTALLATION [12/2022 - ]

  20. ADD COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 6

  21. INSPECT FOR COOLANT LEAK (for Inverter) 

    See step  1

  22. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 

    Refer to INSTALLATION [11/2020 - ]

  23. INSTALL FC STACK COVER SUB-ASSEMBLY 
  24. INSTALL LOWER RADIATOR AIR DEFLECTOR 
  25. INSTALL RADIATOR COVER PLATE 
  26. INSTALL UPPER RADIATOR SUPPORT SEAL 
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