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 bolt and connector cover assembly.

      Note


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

      • Do not allow any foreign objects or water to enter the inverter with converter assembly.

    2. 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.

    3. Temporarily install the connector cover assembly with the bolt to prevent any foreign objects or water from entering the inverter with converter assembly.

  2. 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.

    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 cover.

  3. INSTALL NO. 4 INVERTER BRACKET


    1. Install the No. 4 inverter bracket with the 2 bolts.

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

    2. for RHD:

      Install the wire harness bracket with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  4. INSTALL INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Wear insulated gloves.


    1. Temporarily install the No. 6 inverter bracket and inverter with converter assembly with the 6 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. Remove the bolt and connector cover assembly.

      Note


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

      • Do not allow any foreign objects or water to enter the inverter with converter assembly.

    3. Connect the No. 4 floor wire to the inverter with converter assembly.

      Note


      • Do not damage the terminals, connector housings or inverter with converter assembly when connecting them.

      • Do not touch the connector waterproofing rubber or terminals.

      • Do not allow any foreign objects or water to enter the inverter with converter assembly.

      • Make sure that the connectors are fully engaged.

      • Make sure that the connector does not come out when its body is pulled.

    4. Secure the No. 4 floor wire to the inverter with converter assembly with the bolt.

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

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

      Note


      • Do not damage the terminals, connector housings or inverter with converter assembly when connecting them.

      • Do not touch the connector waterproofing rubber or terminals.

      • Do not allow any foreign objects or water to enter the inverter with converter assembly.

      • Make sure that the connectors are fully engaged.

      • Make sure that the connector does not come out when its body is pulled.

    6. Tighten the 6 bolts in the order shown in the illustration.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      A000SY1E02
      Text in Illustration
      *A for LHD *B for RHD
    7. A000S9IE02
      Text in Illustration
      *A for LHD
      *B for RHD

      Connect the connector and lock the connector with the lock lever.

      Note


      • Do not allow any foreign objects or water to enter the inverter with converter assembly.

      • Make sure that the connectors are fully engaged.

  5. INSTALL WIRE HARNESS CLAMP BRACKET A (for LHD)


    1. Install the wire harness clamp bracket A with the 2 nuts.

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

  6. CONNECT INVERTER BUS-BAR PLATE SUB-ASSEMBLY


    1. for LHD:


      1. Install the wire harness bracket with the bolt.

        Torque:
        8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

      2. Temporarily install the inverter bus-bar plate sub-assembly with the 3 nuts.

      3. A000T0EE02

        Tighten the 2 nuts labeled A in the illustration.

        Torque:
        6.9 N*m  { 70 kgf*cm, 61 in.*lbf }

      4. Tighten the nut labeled B in the illustration.

        Torque:
        11 N*m  { 107 kgf*cm, 8 ft.*lbf }

      5. Attach the harness cover.

    2. for RHD:


      1. Attach the 2 claws and install the nut.

        Torque:
        11 N*m  { 107 kgf*cm, 8 ft.*lbf }

      2. Install the relay block cover.

      3. Connect the connector and attach the clamp.

  7. CONNECT NO. 2 INVERTER COOLING INLET HOSE (for RHD)


    1. A000T0DE01
      Text in Illustration
      *a Upper
      *b LH Side
      *c 30°

      Connect the No. 2 inverter cooling inlet hose to the inverter with converter assembly, and slide the clamp secure the hose.

      Note

      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.

      Tech Tips

      Make sure the direction of the hose clamp is as shown in the illustration.

  8. CONNECT NO. 1 INVERTER COOLING INLET HOSE (for LHD)


    1. A000OD0E01
      Text in Illustration
      *a Upper
      *b RH Side
      *c 30°

      Connect the No. 1 inverter cooling inlet hose to the inverter with converter assembly, and slide the clamp secure the hose.

      Note

      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.

      Tech Tips

      Make sure the direction of the hose clamp is as shown in the illustration.

  9. INSTALL INVERTER RESERVOIR TANK ASSEMBLY (for RHD)


    1. A000MY9

      Connect the No. 2 inverter cooling outlet 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.

      • 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.

    2. Connect the inverter reservoir tank assembly to the No. 4 inverter cooling hose and install the 2 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  10. INSTALL NO. 1 INVERTER COOLING OUTLET HOSE (for LHD)


    1. A000N8GE01
      Text in Illustration
      *a Upper
      *b RH Side
      *c 20°
      *d 29°

      Install the No. 1 inverter cooling outlet hose to the inverter with converter assembly and lock the hose with the retainer, and slide the clamp secure the hose.

      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.

  11. INSTALL CONNECTOR COVER ASSEMBLY

    CAUTION:

    Wear insulated gloves.

    Note


    • Make sure that the interlock is fully engaged.

    • Do not allow any foreign objects or water to enter the inverter with converter assembly.


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

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

  12. CONNECT MOTOR CABLE

    CAUTION:

    Wear insulated gloves.

    Note


    • Do not damage the terminals, connector housings or inverter with converter assembly when connecting them.

    • Do not touch the connector waterproofing rubber or terminals.

    • Do not allow any foreign objects or water to enter the inverter with converter assembly.


    1. Temporarily install the motor cable with the 5 bolts.

    2. A000SLFE02
      Text in Illustration
      *A for LHD
      *B for RHD

      Using an insulated tool, tighten the 3 bolts labeled A in the illustration.

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

      Note


      • The connector should be connected securely.

      • The bolts should be tightened securely.

      • Tighten the bolts in the order shown in the illustration.

    3. Using an insulated tool, tighten the 2 bolts labeled B in the illustration.

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

      Note


      • The connector should be connected securely.

      • The bolts should be tightened securely.

  13. CONNECT GENERATOR CABLE

    CAUTION:

    Wear insulated gloves.

    Note


    • Do not damage the terminals, connector housings or inverter with converter assembly when connecting them.

    • Do not touch the connector waterproofing rubber or terminals.

    • Do not allow any foreign objects or water to enter the inverter with converter assembly.


    1. Temporarily install the generator cable with the 5 bolts.

    2. A000SVNE02
      Text in Illustration
      *A for LHD
      *B for RHD

      Using an insulated tool, tighten the 3 bolts labeled A in the illustration.

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

      Note


      • The connector should be connected securely.

      • The bolts should be tightened securely.

      • Tighten the bolts in the order shown in the illustration.

    3. Using an insulated tool, tighten the 2 bolts labeled B in the illustration.

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

      Note


      • The connector should be connected securely.

      • The bolts should be tightened securely.

  14. INSTALL INVERTER TERMINAL COVER

    CAUTION:

    Wear insulated gloves.


    1. for Type A:


      1. Using an insulated tool, install the inverter terminal cover with the 2 bolts.

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

        Note


        • Do not touch the inverter terminal cover waterproofing rubber.

        • Visually confirm that the inverter terminal cover waterproofing rubber is securely installed before installing the inverter terminal cover.

        • Press down on the inverter terminal cover with both hands to securely connect the interlock.

    2. for Type B:


      1. Using an insulated tool, install the inverter terminal cover with the 3 bolts.

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

        Note


        • Do not touch the inverter terminal cover waterproofing rubber.

        • Visually confirm that the inverter terminal cover waterproofing rubber is securely installed before installing the inverter terminal cover.

        • Press down on the inverter terminal cover with both hands to securely connect the interlock.

  15. INSTALL INVERTER MOTOR CABLE BRACKET ASSEMBLY


    1. 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 2 clamps to the inverter motor cable bracket assembly.

  16. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE (for LHD)

    Click here

  17. INSTALL SERVICE PLUG GRIP

    Click here

  18. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

  19. ADD COOLANT (for Inverter)

    Click here

  20. INSPECT FOR COOLANT LEAK (for Inverter)

    Click here

  21. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here

  22. INSTALL INVERTER COVER


    1. Attach the 2 inverter cover claws to the inverter with converter. Then attach the inverter cover with the clip.

  23. INSTALL NO. 2 ENGINE UNDER COVER

    Click here

  24. INSTALL FRONT SUSPENSION MEMBER BRACE

    Click here

  25. INSTALL ENGINE UNDER COVER

    Click here

  26. INSTALL NO. 1 AIR CLEANER INLET

    Click here

  27. INSTALL COOL AIR INTAKE DUCT SEAL

    Click here

  28. INSTALL ENGINE ROOM SIDE COVER

    Click here

  29. INSTALL LUGGAGE COMPARTMENT TRIM COVER LH

    Click here

  30. INSTALL LUGGAGE COMPARTMENT FLOOR MAT

    Click here