INVERTER WITH CONVERTER INSTALLATION

PROCEDURE

INSTALL NO. 2 ENGINE ROOM WIRE
Tech Tips

Perform this procedure only when replacement of the No. 2 engine room wire is necessary.
1. Engage the clamp to Install the No. 2 engine room wire to the inverter with converter assembly.
2. Install the nut to the No. 2 engine room wire.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
3. Engage the 2 claws and close the terminal cover.
INSTALL HIGH VOLTAGE FUSE

CAUTION:

Wear insulating gloves.

Tech Tips

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. Text in Illustration
  
  *a CORRECT
  
  *b INCORRECT
  
  Install the high voltage fuse with the 2 bolts.
  
  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.
INSTALL MOTOR CABLE BRACKET
1. Temporarily install the motor cable bracket with the 2 bolts.
2. Tighten the 2 bolts in the order shown in the illustration.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSTALL INVERTER WITH CONVERTER ASSEMBLY
CAUTION:

Wear insulating gloves.
1. Temporarily install the inverter with converter assembly with the 3 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. 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 }
CONNECT WATER HOSE
1. Connect the water hose to the inverter with converter assembly and lock the hose with the retainer.
  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.
2. Connect the water hose to the inverter with converter assembly and lock the hose with the retainer.
  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.
CONNECT NO. 2 ENGINE ROOM WIRE
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.
REMOVE INVERTER COVER

CAUTION:

Wear insulating gloves.
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.
CONNECT NO. 2 ENGINE WIRE
CAUTION:

Wear insulating gloves.

Note

Do not allow any foreign matter or water to enter the inverter with converter assembly.
1. Temporarily install the No. 2 engine wire (high voltage cables of the air conditioning) and 4 bolts to the inverter assembly by hand.
2. Fully tighten the 4 bolts.
  
  Torque:
  
  Bolt A
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  
  Bolt B
  
  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.
CONNECT MOTOR CABLE
CAUTION:

Wear insulating gloves.

Note

Do not allow any foreign matter or water to enter the inverter with converter assembly.
1. Temporarily install the high voltage cable of the motor (MG2) and 5 bolts to the inverter assembly by hand.
2. Fully tighten the 5 bolts.
  
  Torque:
  
  Bolt A
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  
  Bolt B
  
  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.
CONNECT GENERATOR CABLE
CAUTION:

Wear insulating gloves.

Note

Do not allow any foreign matter or water to enter the inverter with converter assembly.
1. Temporarily install the high voltage cable of the generator cable (MG1) and 5 bolts to the inverter assembly by hand.
2. Fully tighten the 5 bolts.
  
  Torque:
  
  Bolt A
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  
  Bolt B
  
  9.2 N*m { 94 kgf*cm, 81 in.*lbf }
  
  Note
  
  Be sure to use a torque wrench to tighten the bolts.
3. Text in Illustration
  
  *a Align Mark
  
  Install the generator cable and cover.
  
  Note
  
  Close the cover so that the matchmarks are not visible.

Text in Illustration
*a	CORRECT
*b	INCORRECT

Text in Illustration
*a	Align Mark

CONNECT FRAME WIRE

CAUTION:

Wear insulating gloves.

Note

Make sure that the interlock is fully engaged.
Do not allow any foreign matter or water to enter the inverter with converter assembly.

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

Temporarily install the frame wire (high voltage cables of the hybrid battery) and 4 bolts to the inverter assembly by hand.

Fully tighten the 4 bolts.

Torque:

Bolt A

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

Bolt B

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.
Connect the 2 harness clamps.

CHECK HIGH VOLTAGE CABLE CONNECTION
CAUTION:

Wear insulating gloves.

Note

Do not allow any foreign matter or water to enter the inverter with converter assembly.
1. Check that each connector and terminal is firmly installed.
  
  Note
  
  Make sure that the bolts are fully tightened.
INSTALL INVERTER COVER

CAUTION:

Wear insulating gloves.
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. Text in Illustration
  
  *1 Interlock
  
  Install the inverter cover with the 9 bolts to the inverter with converter assembly.
  
  Torque:
  
  11 N*m { 112 kgf*cm, 8 ft.*lbf }
INSTALL ENGINE ROOM MAIN WIRE
Note
- Make sure that the connectors are fully engaged.
- Do not allow any foreign matter or water to enter the inverter with converter assembly.
1. Install the bolt, clamp and clip, and connect the engine room main wire.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
2. Install the bolt.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
3. Connect the engine wire to the engine room main wire.
4. Connect the connector to the inverter with converter assembly and lock the connector with the lock lever.
INSTALL NO. 1 INVERTER BRACKET
1. Temporarily install the No. 1 inverter bracket with the 3 bolts.
2. Tighten the 3 bolts in the order shown in the illustration.
  
  Torque:
  
  14 N*m { 138 kgf*cm, 10 ft.*lbf }
INSTALL SERVICE PLUG GRIP

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ADD COOLANT (for Inverter)

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INSPECT FOR COOLANT LEAK (for Inverter)

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INSTALL NO. 1 ENGINE UNDER COVER
INSTALL INVERTER COVER ASSEMBLY LH (w/ Cover)
1. Engage the claw and install the inverter cover assembly LH.
2. Install the 2 clips.
INSTALL RADIATOR SUPPORT OPENING COVER

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