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INVERTER WITH CONVERTER INSTALLATION

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PROCEDURE


  1. Click here

    INSTALL HIGH VOLTAGE FUSE

    CAUTION:

    Wear insulated gloves.

    Tip:

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


    1. Remove the connector cover assembly.

      Click here

    2. B004T7UC01
      *A for LHD
      *B for RHD

      Install the high voltage fuse with the 2 new nuts.

      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.

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  2. Click here

    INSTALL NO. 1 INVERTER COOLING HOSE

    Tip:

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


    1. B004VP4C01
      *A for LHD *B for RHD
      *a Alignment Mark - -

      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.

      Tip:

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

  3. Click here

    INSTALL INVERTER BUS-BAR PLATE SUB-ASSEMBLY


    1. B004RMDC01
      *A for LHD *B for RHD
      *a Stopper - -

      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.

      Tip:

      When installing, align with the stopper.

    2. Install the bolt and Engage the clamp.

      8.0 N*m 82 kgf*cm 71 in.*lbf

    3. Tighten the nut.

      18 N*m 184 kgf*cm 13 ft.*lbf

    4. Close the terminal cover.

  4. Click here

    INSTALL NO. 4 INVERTER BRACKET


    1. B004R7CC02
      *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.

      Tip:

      When installing, align with the stopper.

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

      8.0 N*m 82 kgf*cm 71 in.*lbf
  5. Click here

    INSTALL INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Wear insulated gloves.


    1. B004SWKC02
      *A for LHD *B for RHD

      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.

      8.0 N*m 82 kgf*cm 71 in.*lbf

    4. Engage the clamp.

    5. B004R9EC01
      *A for LHD *B for RHD

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

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

      8.0 N*m 82 kgf*cm 71 in.*lbf

    7. Connect the connector.

  6. Click here

    INSTALL HV FLOOR UNDER WIRE

    CAUTION:

    Wear insulated gloves.


    1. Remove the connector cover assembly.

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    2. B004T25C01
      *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.

      8.0 N*m 82 kgf*cm 71 in.*lbf

    4. Temporarily install the connector cover assembly.

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  7. Click here

    INSTALL ENGINE ROOM MAIN WIRE

    CAUTION:

    Wear insulated gloves.


    1. Remove the connector cover assembly.

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    2. B004XV7C01
      *A for LHD
      *B for RHD

      Connect the engine room main wire (HV air conditioning 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.

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    4. B004Y5GC01
      *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.

        09961-00950
        Specified tightening torque
        8.0 N*m 82 kgf*cm 71 in.*lbf
        Tip:

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

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        • 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. B004WVWC01
      *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. Click here

    CONNECT NO. 4 INVERTER COOLING HOSE


    1. B004WZ9C01
      *A for LHD *B for RHD
      *a Insert *b Upper
      *c RH Side *d LH Side
      *e 120° *f Mark (Yellow)
      *g 2.0 to 7.0 mm (0.079 to 0.276 in.) - -

      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.

      Tip:

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

  9. Click here

    CONNECT NO. 5 INVERTER COOLING HOSE


    1. B004VR6C01
      *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. Click here

    INSTALL FENDER APRON BRACE SUB-ASSEMBLY RH (for LHD)


    1. B004V2V

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

      49 N*m 500 kgf*cm 36 ft.*lbf

    2. Engage the clamp.

  11. Click here

    INSTALL FENDER APRON BRACE SUB-ASSEMBLY LH (for RHD)


    1. B004VDX

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

      49 N*m 500 kgf*cm 36 ft.*lbf

    2. Engage the clamp.

  12. Click here

    INSTALL INVERTER MOTOR CABLE BRACKET ASSEMBLY


    1. B004X3CC01
      *A for LHD
      *B for RHD

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

      8.0 N*m 82 kgf*cm 71 in.*lbf

    2. Engage the 3 clamps.

  13. Click here

    CONNECT MOTOR CABLE

    CAUTION:

    Wear insulated gloves.


    1. B004WV0C02
      *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.

      8.0 N*m 82 kgf*cm 71 in.*lbf

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

      8.0 N*m 82 kgf*cm 71 in.*lbf
  14. Click here

    CONNECT GENERATOR CABLE

    CAUTION:

    Wear insulated gloves.


    1. B004U0IC02
      *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.

      8.0 N*m 82 kgf*cm 71 in.*lbf

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

      8.0 N*m 82 kgf*cm 71 in.*lbf
  15. Click here

    INSTALL INVERTER TERMINAL COVER

    CAUTION:

    Wear insulated gloves.


    1. B004SG7C02
      *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.

      8.0 N*m 82 kgf*cm 71 in.*lbf
      Note:

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

  16. Click here

    INSTALL CONNECTOR COVER ASSEMBLY

    CAUTION:

    Wear insulated gloves.


    1. B004T22C01
      *A for LHD
      *B for RHD

      Install the connector cover assembly to the inverter with converter assembly with the 2 bolts.

      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.

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    INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

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  18. Click here

    INSTALL INVERTER COVER ASSEMBLY RH (for LHD)


    1. B004UVM

      Engage the clip and 2 claws to install the inverter cover assembly RH.

  19. Click here

    INSTALL INVERTER COVER ASSEMBLY LH (for RHD)


    1. B004W1K

      Engage the clip and 2 claws to install the inverter cover assembly LH.

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    INSTALL LOWER RADIATOR AIR DEFLECTOR

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  21. Click here

    INSTALL RADIATOR COVER PLATE

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  22. Click here

    INSTALL UPPER RADIATOR SUPPORT SEAL

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  23. Click here

    INSTALL SERVICE PLUG GRIP

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  24. Click here

    CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

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    Note:

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

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  25. Click here

    INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY

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  26. Click here

    ADD COOLANT (for Inverter)

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  27. Click here

    INSPECT FOR COOLANT LEAK (for Inverter)

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    PERFORM RESOLVER LEARNING

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