INVERTER WITH CONVERTER INSTALLATION

PROCEDURE


  1. INSTALL HIGH VOLTAGE FUSE

    CAUTION:

    Wear insulated gloves.

    Tech Tips

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


    1. Remove the connector cover assembly.

      Click here

    2. B004B9IC01
      *A for LHD
      *B for RHD

      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.

      Click here

  2. INSTALL NO. 1 INVERTER COOLING HOSE

    Tech Tips

    Perform this procedure only when replacement of the No. 1 inverter cooling hose is necessary.


    1. Install the No. 1 inverter cooling hose to the inverter with converter assembly and slide the 2 hose clips to secure it.

      Note

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

      Tech Tips

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

      B004C95C01
      *A for LHD *B for RHD
      *a Alignment Mark - -

  3. INSTALL INVERTER BUS-BAR PLATE SUB-ASSEMBLY


    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.

      Tech Tips

      When installing, align with the stopper.

      B004B7HC01
      *A for LHD *B for RHD
      *a Stopper - -

    2. Install the bolt and attach 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. B0049SNC02
      *A for LHD
      *B for RHD
      *a Stopper

      Temporarily install the No. 4 inverter bracket to the inverter with converter assembly with the 2 bolts.

      Tech Tips

      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

    CAUTION:

    Wear insulated gloves.


    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.

      B004BNOC01
      *A for LHD *B for RHD

    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. Attach the clamp.

    5. Open the inverter bus-bar plate sub-assembly cover.

      B004AINC01
      *A for LHD *B for RHD

    6. Connect the inverter bus-bar plate sub-assembly with the nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    7. Connect the connector.

  6. INSTALL HV FLOOR UNDER WIRE

    CAUTION:

    Wear insulated gloves.


    1. Remove the connector cover assembly.

      Click here

    2. B004BOAC01
      *A for LHD
      *B for RHD

      Connect the HV floor under wire.

      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 HV floor under wire to the inverter with converter assembly with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    4. Temporarily install the connector cover assembly.

      Click here

  7. INSTALL ENGINE ROOM MAIN WIRE

    CAUTION:

    Wear insulated gloves.


    1. Remove the connector cover assembly.

      Click here

    2. B004AJWC01
      *A for LHD
      *B for RHD

      Connect the engine room main wire (air conditioning harness) 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.

      Click here

    4. B004C8EC01
      *a Torque Wrench Fulcrum Length

      for LHD:

      Install the wiring harness clamp bracket.


      1. Temporarily install the wiring harness clamp bracket with the 2 nuts.

      2. Using SST, tighten the 2 nuts.

        SST
        09961-00950
        Torque:
        Specified tightening torque
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

        Tech Tips


        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

          Click here

        • When using SST (fulcrum length of 150 mm (5.906 in.)) + torque wrench (fulcrum length of 300 mm (11.811 in.)): 5.3 N*m (54 kgf*cm, 47 in.*lbf)

    5. B0049VUC01
      *A for LHD
      *B for RHD

      Connect the engine room main wire (inverter with converter assembly connector) to the inverter with converter assembly and lock the connector with the lock lever as shown in the illustration.

  8. CONNECT NO. 4 INVERTER COOLING HOSE


    1. Connect the No. 4 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.

      Tech Tips

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

      B004CHHC01
      *A for LHD *B for RHD
      *a Insert *b Upper
      *c RH Side *d 120°
      *e Mark (Yellow) *f 2.0 to 5.0 mm (0.079 to 0.196 in.)

  9. CONNECT NO. 5 INVERTER COOLING HOSE


    1. B004C67C01
      *A for LHD
      *B for RHD

      Connect the No. 5 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.

  10. INSTALL FENDER APRON BRACE SUB-ASSEMBLY RH


    1. B004ACZ

      Install the fender apron brace sub-assembly RH with the 2 bolts.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

    2. Attach the clamp.

  11. INSTALL FENDER APRON BRACE SUB-ASSEMBLY LH


    1. B0049WW

      Install the fender apron brace sub-assembly LH with the 2 bolts.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

    2. Attach the clamp.

  12. INSTALL INVERTER MOTOR CABLE BRACKET ASSEMBLY


    1. B004BAEC01
      *A for LHD
      *B for RHD

      Install the inverter motor cable bracket assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Attach the 3 clamps.

  13. CONNECT MOTOR CABLE

    CAUTION:

    Wear insulated gloves.


    1. B004BGFC02
      *A for LHD
      *B for RHD

      Temporarily install the motor cable 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 }

  14. CONNECT GENERATOR CABLE

    CAUTION:

    Wear insulated gloves.


    1. B004CNWC02
      *A for LHD
      *B for RHD

      Temporarily install the generator cable 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 }

  15. INSTALL INVERTER TERMINAL COVER

    CAUTION:

    Wear insulated gloves.


    1. B004BR3C02
      *A for LHD
      *B for RHD

      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.

  16. INSTALL CONNECTOR COVER ASSEMBLY

    CAUTION:

    Wear insulated gloves.


    1. B004AH8C01
      *A for LHD
      *B for RHD

      Install the connector cover assembly 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 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.

  17. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  18. INSTALL CENTER COWL TOP VENTILATOR LOUVER

    Click here

  19. INSTALL WASHER GROMMET

    Click here

  20. INSTALL NO. 3 COWL TOP PANEL INSULATOR


  21. INSTALL NO. 2 COWL TOP PANEL INSULATOR


  22. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH


  23. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH


  24. INSTALL FRONT WIPER ARM HEAD CAP

    Click here

  25. INSTALL SERVICE PLUG GRIP

    Click here

  26. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Click here

  27. INSTALL NO. 2 DECK BOARD

    Click here

  28. ADD COOLANT (for Inverter)

    Click here

  29. INSPECT FOR COOLANT LEAK (for Inverter)

    Click here

  30. PERFORM RESOLVER LEARNING

    Click here