INVERTER WITH CONVERTER(for LHD) INSTALLATION

PROCEDURE


  1. INSTALL HIGH VOLTAGE FUSE


    1. A000XJL

      Install the high voltage fuse with 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.

      Tech Tips

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

  2. INSTALL INVERTER COOLING PIPE BRACKET


    1. A000YHR

      Install the inverter cooling pipe bracket to the inverter with converter assembly with the bolt.

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

  3. INSTALL NO. 6 INVERTER BRACKET


    1. A000V5V

      Install the No. 6 inverter bracket to the inverter with converter assembly with the bolt.

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

  4. INSTALL NO. 3 INVERTER BRACKET


    1. A000VCC

      Install the No. 3 inverter bracket to the inverter with converter assembly with the 2 bolts.

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

  5. INSTALL NO. 2 INVERTER BRACKET


    1. A000YVM

      Install the No. 2 inverter bracket to the inverter with converter assembly with the 2 bolts.

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

  6. INSTALL NO. 1 INVERTER COOLING HOSE ASSEMBLY


    1. A000TXQ

      Install the No. 1 inverter cooling hose assembly and No. 1 inverter cooling inlet hose to the inverter with converter assembly with the 2 clips and clamp.

      Note


      • Do not deform, bend or scratch the pipes of the inverter with converter assembly. The pipes are made of aluminum and must remain undamaged to maintain proper seal with the rubber hoses.

      • The inverter hose is connected to the cooling system built into the inverter. Do not apply excessive force to the inverter hose, or the inverter cooling system may be damaged.

    2. Connect the hose clamp.

  7. INSTALL INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Wear insulating gloves.


    1. A000VPQ

      Install the inverter with converter assembly with the bolt, 3 nuts and inverter bracket.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

      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. A000TFS

      Connect the 3 wire harness clamps.

    3. A000YSX

      Connect the low voltage connector of the inverter with converter assembly and lock the connector with the lock lever.

    4. Connect the wire harness clamp.

    5. A000ZFC

      Connect the 2 inverter hoses with the 2 clips.

  8. CONNECT AIR CONDITIONING HARNESS

    CAUTION:

    Wear insulating gloves.


    1. A000VGZ

      Connect the air conditioning harness to the inverter with converter assembly.

  9. CONNECT FRAME WIRE

    CAUTION:

    Wear insulating gloves.


    1. A001020

      Using an insulated tool, connect the frame wire to the inverter with converter assembly with the bolt.

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

  10. CONNECT GENERATOR CABLE

    CAUTION:

    Wear insulating gloves.


    1. A000WBU

      Using an insulated tool, connect the generator cable to the inverter with converter assembly.

    2. Secure the generator cable to the inverter with converter assembly with the 5 bolts.

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

      Note


      • When installing the bolts that secure the cable, do not damage anything inside the inverter with converter assembly.

      • Make sure that no foreign matter is present on the terminal block.

      • Be sure to tighten the bolt to the specified torque. Failure to do so may damage the bolt.

  11. CONNECT MOTOR CABLE

    CAUTION:

    Wear insulating gloves.


    1. A000X0Q

      Using an insulated tool, connect the motor cable to the inverter with converter assembly.

    2. Secure the motor cable to the inverter with converter assembly with the 5 bolts.

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

      Note


      • When installing the bolts that secure the cable, do not damage anything inside the inverter with converter assembly.

      • Make sure that no foreign matter is present on the terminal block.

      • Be sure to tighten the bolt to the specified torque. Failure to do so may damage the bolt

    3. A000ZPQ

      Install the motor cable bracket with the 3 bolts.

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

  12. INSTALL INVERTER TERMINAL COVER

    CAUTION:

    Wear insulating gloves.


    1. A000VPXE02
      *1 Guide Pin

      Set the inverter terminal cover to the inverter with converter assembly.

      Note


      • Check that the sealing rubber is securely installed to the inverter terminal cover before installing the cover.

      • Making sure that there are no foreign objects on the waterproofed parts before installing the inverter terminal cover.

      • Install the inverter terminal cover while inserting the guide pins on both sides of the cover into guide pin holes of the inverter case.

      • When removing the inverter terminal cover, do not bend the connector terminals around the interlock part.

    2. Push in both ends of the inverter terminal cover horizontally by hand.

      Note


      • Insert the inverter terminal cover horizontally to prevent it from tilting. Failure to do so may damage the inverter terminal cover guide pins.

      • Make sure that both the inverter terminal cover bolt holes are aligned and in contact with the holes in the inverter case.

    3. Using an insulated tool, secure the inverter terminal cover to the inverter with converter assembly with the 2 bolts.

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

  13. INSTALL CONNECTOR COVER ASSEMBLY

    CAUTION:

    Wear insulating gloves.


    1. A000Z7Y

      Using an insulated tool, install the connector cover assembly with the 2 bolts.

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

  14. INSTALL SERVICE PLUG GRIP

    Click here

  15. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

  16. INSTALL BATTERY SERVICE HOLE COVER LH

    Click here

  17. INSTALL DECK TRIM SIDE BOARD LH (w/o Spare Tire)

    Click here

  18. INSTALL DECK BOARD ASSEMBLY (w/o Spare Tire)

    Click here

  19. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY (w/ Spare Tire)

    Click here

  20. ADD COOLANT (for Inverter)

    Click here

  21. INSPECT FOR COOLANT LEAK (for Inverter)

    Click here

  22. INSTALL FRONT CENTER FLOOR COVER

    Click here

  23. INSTALL INVERTER COVER ASSEMBLY RH


    1. A000XZD

      Align the locating hole of the inverter cover assembly RH with the locating pin of the inverter with converter assembly. Set the inverter cover assembly RH to the inverter with converter assembly.

    2. Press the positions where the clips are to secure the inverter cover assembly RH to the inverter with converter assembly.

  24. INSTALL MOTOR CABLE COVER RH


    1. A000UUN

      Install the motor cable cover RH with the 2 clips.

  25. INSTALL COWL TOP VENTILATOR LOUVER RH


    1. A000ZM5

      Install the hood to cowl top seal with the 4 clips.

    2. Install the cowl top ventilator louver RH with the 6 clips.

  26. INSTALL FRONT UPPER FENDER PROTECTOR RH

    Tech Tips

    Use the same procedures described for the LH side Click here.

  27. INSTALL ENGINE ROOM SIDE COVER RH

    Click here

  28. INSTALL ENGINE ROOM SIDE COVER LH

    Click here

  29. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here