Inverter With Converter: Installation: Installation

HINT: 

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

1. Remove the 9 bolts and inverter cover.
   NOTE:

   Make sure to pull the inverter cover straight up, as a connector is connected to the bottom of the cover.

2. Install the high voltage fuse with the 2 bolts.
   Fig 1: Identifying High Voltage Fuse And Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *a	CORRECT
   *b	INCORRECT

   Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

   NOTE:

   • Be sure to use a torque wrench to tighten the bolts.
   • The fuse should be installed with its orientation as shown in the illustration.
3. Temporarily install the inverter cover with the 9 bolts to prevent any foreign matter or water from entering the inverter with converter assembly.

1. Temporarily install the motor cable bracket with the 2 bolts.
2. Tighten the 2 bolts in the order shown in the illustration.
   Fig 2: Identifying Motor Cable Bracket Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Temporarily install the inverter with converter assembly with the 3 bolts.
   Fig 3: Identifying Inverter With Converter Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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. Tighten bolt A.

   Torque: 12 N*m (122 kgf*cm, 8 ft.*lbf) 

3. Tighten the 2 bolts.

   Torque: 12 N*m (122 kgf*cm, 8 ft.*lbf) 

1. Connect the No. 6 inverter cooling hose to the inverter with converter assembly and lock the hose with the retainer.
   Fig 4: Connecting Retainer To Water Hose And Inverter

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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.

1. Connect the No. 1 inverter cooling hose to the inverter with converter assembly and lock the hose with the retainer.
   Fig 5: Connecting Water Hose

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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.

1. Disconnect the No. 2 engine room wire from the protector.
2. Connect the No. 2 engine room wire with the bolt and 2 claws.

   Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) 

   NOTE:

   Pass the No. 2 engine room wire under the two cooling hoses that pass beside the inverter.

3. Install the No. 1 relay block cover and 2 clamps.
4. Install the relay block cover.

1. Remove the 9 bolts and inverter cover.
   NOTE:

   Make sure to pull the inverter cover straight up, as a connector is connected to the bottom of the cover.

1. Temporarily install the No. 2 engine wire (high voltage cables of the air conditioning) and 4 bolts to the inverter assembly by hand.
   Fig 6: Identifying No. 2 Engine Wire

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using an insulated tool, fully tighten the 4 bolts.

   Bolt A 

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

   Bolt B 

   Torque: 9.2 N*m (94 kgf*cm, 81 in.*lbf) 

   NOTE:

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

3. Connect the harness clamp.

1. Temporarily install the high voltage cable of the motor cable (MG2) and 5 bolts to the inverter assembly by hand.
   Fig 7: Identifying Inverter Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using an insulated tool, fully tighten the 5 bolts.

   Bolt A 

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

   Bolt B 

   Torque: 9.2 N*m (94 kgf*cm, 81 in.*lbf) 

   NOTE:

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

3. Connect the harness clamp.

1. Temporarily install the high voltage cable of the generator cable (MG1) and 5 bolts to the inverter assembly by hand.
   Fig 8: Identifying High Voltage Cable

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using an insulated tool, fully tighten the 5 bolts.

   Bolt A 

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

   Bolt B 

   Torque: 9.2 N*m (94 kgf*cm, 81 in.*lbf) 

   NOTE:

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

3. Install the generator cable and cover.
   Fig 9: Installing The Generator Cable And Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *a	Alignment Mark

   NOTE:

   Close the cover so that the alignment marks are not visible.

1. Temporarily install the frame wire (high voltage cables of the hybrid battery) and 4 bolts to the inverter assembly by hand.
   Fig 10: Identifying Bolts & Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *1	Interlock
   *2	High voltage cables of hybrid battery
   *a	Front view of frame wire connector

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

   Bolt A 

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

   Bolt B 

   Torque: 9.2 N*m (94 kgf*cm, 81 in.*lbf) 

   NOTE:

   • Be sure to use a torque wrench to tighten the bolts.
   • Make sure that the interlock are fully engaged.
3. Connect the harness clamp.

1. Check that each connector and terminal is firmly installed.
   Fig 11: Identifying Inverter And Converter Assembly Terminals

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   Make sure that the bolts are fully tightened.

1. Install the inverter cover with the 9 bolts to the inverter with converter assembly.
   Fig 12: Identifying Terminal Cover Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *1

   Interlock

   Torque: 11 N*m (112 kgf*cm, 8 ft.*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. Connect the engine wire to the engine room main wire.
   Fig 13: Connecting Engine Wire And Engine Room Main Wire

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the connector to the inverter with converter assembly and lock the connector with the lock lever.
   Fig 14: Locking Connector With Lock Lever

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the bolt, clamp and clip, and connect the engine room main ware.

   Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

4. Install the 2 bolts.
   Fig 15: Identifying Bolts, Clamp & Clip

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Bolt A 

   Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

   Bolt B 

   Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 

1. Temporarily install the No. 1 inverter bracket with the 3 bolts.
   Fig 16: Identifying No. 1 Inverter Bracket & Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Tighten the 3 bolts in the order shown in the illustration.

   Torque: 14 N*m (138 kgf*cm, 10 ft.*lbf) 

Refer to INSTALLATION .