INVERTER WITH CONVERTER INSTALLATION

CAUTION / NOTICE / HINT

Note

When replacing with a new inverter with converter assembly, securely lock the retainer of the inverter cooling hose since it is not locked.

Tech Tips

Remove the tape that was attached to the hose at removal in accordance with the installation procedure.

PROCEDURE


  1. INSTALL NO. 3 ENGINE ROOM WIRE


    1. Install the No. 3 engine room wire with the nut.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      Note

      Temporarily install the nut by hand, then tighten using a tool.

    2. Close the terminal cap.

  2. INSTALL NO. 2 INVERTER RESERVE TANK BRACKET


    1. Install the No. 2 inveter reserve tank bracket to the inverter with converter assembly with the 2 bolts.

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

  3. INSTALL HYBRID INVERTER PROTECTOR ASSEMBLY (for AWD)


    1. Install the hybrid inverter protector assembly to the inverter with converter assembly with the 2 bolts.

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

  4. INSTALL WIRE HARNESS CLAMP BRACKET (for AWD)


    1. Install the wire harness clamp bracket to the inverter with converter assembly with the bolt.

      Torque:
      7.7 N*m  { 79 kgf*cm, 68 in.*lbf }

  5. INSTALL NO. 3 INVERTER BRACKET


    1. B002K0MC02
      *a Stopper

      Temporarily install the No. 3 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:
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

  6. INSTALL NO. 2 INVERTER BRACKET


    1. B002KBBC04
      *A for AWD
      *B for 2WD
      *a Stopper

      Temporarily install the No. 2 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:
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

  7. INSTALL NO. 4 INVERTER BRACKET


    1. B002IOPC02
      *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:
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

  8. INSTALL AIR CLEANER BRACKET (for AWD)


    1. Install the air cleaner bracket to the inverter with converter assembly with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  9. INSTALL NO. 1 AIR CLEANER BRACKET


    1. for AWD:

      Install the No. 1 air cleaner bracket to the inverter with converter assembly with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    2. for 2WD:

      Install the No. 1 air cleaner bracket to the inverter with converter assembly with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  10. INSTALL HIGH VOLTAGE FUSE

    CAUTION:

    Be sure to wear insulated gloves.

    Tech Tips

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


    1. B002JFXC02
      *A for AWD
      *B for 2WD

      Remove the bolt and connector cover assembly.

      Note


      • 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.

  11. INSTALL INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.

    Note


    • Since the inverter with converter assembly is very heavy, 2 people are needed to install it on the vehicle. Take care not to damage surrounding parts.

    • To prevent damage, do not hold the connectors when lifting up the inverter with converter assembly.

    • To prevent damage caused by static electricity, do not touch the terminals at the openings of disconnected connectors.


    1. Temporarily install the No. 6 inverter bracket with the 2 bolts.

    2. Temporarily install the inverter with converter assembly with the 2 nuts and bolt.

      B002KFRC04
      *A for AWD *B for 2WD
      *1 No. 6 Inverter Bracket - -
      *a The stud bolt must firmly contact the inverter bracket stay. *b Bolt A
      *c Bolt B - -
      B002HVY Bolt B002I10 Nut

    3. Tighten the 2 nuts and 3 bolts in the order shown in the illustration.

      Torque:
      Bolt A
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      Bolt B
      10.5 N*m  { 107 kgf*cm, 8 ft.*lbf }
      Nut
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  12. CONNECT NO. 2 INVERTER COOLING HOSE ASSEMBLY


    1. Connect the No. 2 inverter cooling hose assembly, and slide the retainer as shown in the illustration to secure.

      Note


      • Push in the retainer until it clicks in place.

      • Pull the hose to check that it is securely connected.

      • If there is foreign matter on the retainer, clean it with water and finger scouring.

      • Until immediately before connecting the water hose, plug the pipe with vinyl tape, etc. to prevent foreign matter from entering the cooling path.

      B002HMKC02
      *A for AWD *B for 2WD
      *a Retainer - -

  13. CONNECT NO. 3 ENGINE ROOM WIRE


    1. B002I27

      Attach the 2 claws, and connect the No. 3 engine room wire to the junction block.

    2. Connect the No. 3 engine room wire with the nut.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    3. Install the relay block cover.

  14. CONNECT LOW VOLTAGE CONNECTOR


    1. B002HF2

      Connect the 3 low voltage connectors, and lock the connectors with the lock lever.

      Note


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

      • The connectors should be connected securely.

      • The connectors must be securely locked.

  15. INSTALL INVERTER PROTECTOR (w/ Bracket)


    1. B002H11C01
      *a Stopper

      Install the inverter protector with the bolt.

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

      Tech Tips

      When installing, align with the stopper.

  16. REMOVE CONNECTOR COVER ASSEMBLY

    Click here

  17. CONNECT NO. 2 FRAME WIRE

    CAUTION:

    Be sure to wear insulated gloves.

    Note


    • When connecting the No. 2 frame wire, do not damage the terminals, connector housing and inverter with converter assembly.

    • Do not touch the connector rubber seal and terminal.

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

    • The connectors should be connected securely.

    • The connectors must be securely locked.


    1. B002K50C03
      *A for AWD
      *B for 2WD

      Connect the No. 2 frame wire to the inverter with converter assembly with the clamp.

    2. Secure the No. 2 frame wire to the inverter with converter assembly with the bolt.

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

  18. CONNECT ENGINE WIRE

    CAUTION:

    Be sure to wear insulated gloves.

    Note


    • When connecting the engine wire, do not damage the terminals, connector housing and inverter with converter assembly.

    • Do not touch the connector rubber seal and terminal.

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

    • The connectors should be connected securely.

    • The connectors must be securely locked.


    1. B002IQ5C03
      *A for AWD
      *B for 2WD

      Connect the engine wire to the inverter with converter assembly.

  19. INSTALL CONNECTOR COVER ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


    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 }

      Note

      Make sure that the interlock is fully engaged.

  20. INSTALL NO. 1 INVERTER RESERVE TANK BRACKET (for 2WD)


    1. Install the No. 1 inveter reserve tank bracket to the inverter with converter assembly with the 2 bolts.

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

  21. INSTALL NO. 2 FRAME WIRE

    CAUTION:

    Be sure to wear insulated gloves.

    Note


    • When connecting the No. 2 frame wire, do not damage the terminals, connector housing and inverter with converter assembly.

    • Do not touch the connector rubber seal and terminal.

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


    1. B002IZQ

      for AWD:

      Connect the No. 2 frame wire (rear motor high-voltage cable side) to the air cleaner bracket, and secure with the clamp.

    2. B002JPZC03
      *A for AWD
      *B for 2WD

      Secure the No. 2 frame wire.

    3. Attach the 2 clamps.

    4. for AWD:

      Using an insulated tool, secure the No. 2 frame wire to the inverter with converter assembly with the 3 bolts.

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

      Note


      • Make sure that the terminal is installed securely.

      • Make sure that the bolts are fully tightened.

  22. INSTALL UPPER INVERTER COVER (for AWD)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Using an insulated tool, install the upper inverter cover (rear motor high-voltage cable side) with the 2 bolts.

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

      Note


      • Do not touch the rubber seal of the upper inverter cover.

      • Confirm that the rubber seal of the upper inverter cover is securely installed, then install the cover.

      • Make sure that the interlock is fully engaged.

  23. CONNECT MOTOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.

    Note


    • When connecting the motor cable, do not damage the terminals, connector housing and inverter with converter assembly.

    • Do not touch the connector rubber seal and terminal.

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


    1. B002I5NC02
      *A for AWD
      *B for 2WD

      Connect the motor cable to the inverter with converter assembly, and secure with the clamp.

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

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

      Note


      • Make sure that the terminal is installed securely.

      • Make sure that the bolts are fully tightened.

  24. INSTALL UPPER INVERTER COVER

    CAUTION:

    Be sure to wear insulated gloves.


    1. Using an insulated tool, install the upper inverter cover (motor cable side) with the 2 bolts.

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

      Note


      • Do not touch the rubber seal of the upper inverter cover.

      • Confirm that the rubber seal of the upper inverter cover is securely installed, then install the cover.

      • Make sure that the interlock is fully engaged.

  25. CONNECT GENERATOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.

    Note


    • When connecting the motor cable, do not damage the terminals, connector housing and inverter with converter assembly.

    • Do not touch the connector rubber seal and terminal.

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


    1. B002JR2C02
      *A for AWD
      *B for 2WD

      Connect the generator cable to the inverter with converter assembly, and secure with the clamp.

    2. B002JUBC02
      *A for AWD
      *B for 2WD

      Using an insulated tool, secure the generator cable to the inverter with converter assembly with the 3 bolts.

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

      Note


      • Make sure that the terminal is installed securely.

      • Make sure that the bolts are fully tightened.

  26. INSTALL UPPER INVERTER COVER

    CAUTION:

    Be sure to wear insulated gloves.


    1. Using an insulated tool, install the upper inverter cover (generator cable side) with the 2 bolts.

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

      Note


      • Do not touch the rubber seal of the upper inverter cover.

      • Confirm that the rubber seal of the upper inverter cover is securely installed, then install the cover.

      • Make sure that the interlock is fully engaged.

  27. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  28. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  29. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  30. INSTALL RADIATOR SUPPORT OPENING COVER

    Click here

  31. INSTALL INVERTER RESERVE TANK ASSEMBLY


    1. B002JN9C02
      *a Quick Connector
      *b Top
      *c Right Side of the Vehicle
      *d 180°
      *e Retainer

      Connect the No. 1 inverter cooling hose assembly, and slide the retainer as shown in the illustration to secure.

      Note


      • Push in the retainer until it clicks in place.

      • Pull the No. 1 inverter cooling hose assembly to check that it is securely connected.

      • If there is foreign matter on the retainer, clean it with water and finger scouring.

      • Until immediately before connecting the water hose, secure the cover with a plastic bag and tape, etc. to prevent foreign matter from entering the cooling path.

      Tech Tips

      When installing the quick connector, first turn it to the left, then return it to the right, and lock the retainer at the position where the retainer is facing up.

    2. Connect the inverter water hose to the inveter reserve tank sub-assembly, and secure with the hose clamp.

      Tech Tips

      Align the hose clamp at the position shown in the illustration.

    3. Install the inveter reserve tank sub-assembly with the 2 bolts.

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

  32. CONNECT WIRE HARNESS


    1. Secure the 4 wire harness clamps to the inveter reserve tank sub-assembly and inverter with converter assembly.

  33. INSTALL SERVICE PLUG GRIP

    Click here

  34. ADD COOLANT (for Inverter Coolant)

    Click here

  35. INSPECT FOR COOLANT LEAK (for Inverter Coolant)

    Click here