HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER: INSTALLATION; 2020 MY Corolla Corolla HV [01/2019

Last Modified: 07-31-2024	6.11:8.1.0	Doc ID: RM100000001GCPK
Model Year Start: 2020	Model: Corolla	Prod Date Range: [01/2019 - 04/2020]
Title: HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER: INSTALLATION; 2020 MY Corolla Corolla HV [01/2019 - 04/2020]

INSTALLATION

PROCEDURE

1. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Install the wire harness clamp bracket to the inverter with converter assembly with the bolt.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(b) Install the wire harness clamp bracket to the inverter with converter assembly with the bolt.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

2. INSTALL TRANSMISSION CONTROL CABLE SUPPORT

(a) Install the transmission control cable support to the inverter with converter assembly with the bolt.

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

3. INSTALL NO. 2 INVERTER BRACKET

NOTICE:

Make sure to support the inverter with converter assembly at the positions shown in the illustration, otherwise it may be damaged.

*a	Bottom of Inverter with Converter Assembly
*b	Support

(a) Set the inverter with converter assembly on wooden blocks.

*a	Wooden Block

(b) Temporarily install the No. 2 inverter bracket to the inverter with converter assembly with the 2 bolts.

Torque:

15 N·m {153 kgf·cm, 11 ft·lbf}

4. INSTALL NO. 1 INVERTER BRACKET

(a) Temporarily install the No. 1 inverter bracket to the inverter with converter assembly with the 2 bolts.

*a	Wooden Block

(b) Fully tighten the 2 bolts in the order shown in the illustration.

Torque:

15 N·m {153 kgf·cm, 11 ft·lbf}

5. INSTALL INVERTER WITH CONVERTER ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Temporarily install the inverter with converter assembly with the 5 bolts and 2 nuts.

NOTICE:

When installing the inverter with converter assembly, be careful not to damage the parts around it.
To prevent damage, do not hold the inverter with converter assembly by the connectors, brackets or cooling pipes.
To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.

Make sure that the inverter with converter assembly is positioned so that the stud bolts are in contact with the base of the U-shaped portions of the No. 1 inverter bracket.

*a	Correct
*b	Incorrect

HINT:

If the bolts and nuts are not tightened appropriately, the inverter with converter assembly may make an abnormal noise.

(b) Fully tighten the bolt (A).

Torque:

25 N·m {255 kgf·cm, 18 ft·lbf}

Torque:

25 N·m {255 kgf·cm, 18 ft·lbf}

(d) Fully tighten the bolt (C).

Torque:

25 N·m {255 kgf·cm, 18 ft·lbf}

(e) Fully tighten the 2 nuts (D).

Torque:

25 N·m {255 kgf·cm, 18 ft·lbf}

6. CONNECT MOTOR CABLE

CAUTION:

Be sure to wear insulated gloves.

NOTICE:

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

(a) Temporarily connect the motor cable to the inverter with converter assembly with the 4 bolts.

NOTICE:

Do not touch the waterproof seal or terminals of the connector.
Do not damage the terminals, connector housing or inverter with converter assembly during connection.

(b) Fully tighten the bolt (A).

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

*a	Waterproof Seal

(c) Fully tighten the 3 bolts in the order shown in the illustration to connect the motor cable to the inverter with converter assembly.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(d) Temporarily install the 6 bolts.

NOTICE:

To prevent the threads from being damaged, temporarily tighten the 6 bolts by hand.
Do not damage the terminals, connector housing or inverter with converter assembly during connection.
Do not touch the waterproof seal or terminals of the connector.

(e) Using an insulated tool, fully tighten the 6 bolts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

NOTICE:

Do not touch the waterproof seal or terminals of the connector.
Do not damage the terminals, connector housing or inverter with converter assembly during connection.
Be sure to use a torque wrench to tighten the bolts.

7. INSTALL INVERTER COVER

CAUTION:

Be sure to wear insulated gloves.

(a) Install the inverter cover to the inverter with converter assembly with the 2 bolts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

NOTICE:

Visually confirm that the inverter cover waterproof seal is securely installed before installing the inverter cover.
Do not touch the waterproof seal of the inverter cover.
Make sure that the interlock is fully engaged.
Do not damage the terminals, interlock connector or inverter with converter assembly during installation.
Do not allow any foreign matter or water to enter the inverter with converter assembly.

Do not remove or excessively tighten the screw of the inverter cover.

*1	Inverter Cover
*a	Screw

Although the inverter cover may feel loose, this is not due to a malfunction.

Push in the inverter cover until it contacts the inverter with converter assembly.

No Gap

8. CONNECT INLET NO. 1 INVERTER COOLING HOSE

(a) Connect the inlet No. 1 inverter cooling hose to the inverter with converter assembly and slide the clip to secure it.

NOTICE:

To prevent foreign matter from entering the inverter with converter assembly and inverter cooling system, do not remove the pieces of cloth from the pipe and disconnected hose until installation.
Make sure to align the alignment mark of the hose with the alignment mark of the pipe of the inverter with converter assembly.

HINT:

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

*a	Alignment Mark (Light Blue)
*b	2 to 11 mm (0.0787 to 0.4331 in.)
*c	Up
*d	LH Side

9. CONNECT OUTLET NO. 1 INVERTER COOLING HOSE

(a) Connect the outlet No. 1 inverter cooling hose to the inverter with converter assembly and slide the clip to secure it.

NOTICE:

To prevent foreign matter from entering the inverter with converter assembly and inverter cooling system, do not remove the pieces of cloth from the pipe and disconnected hose until installation.
Make sure to align the alignment mark of the hose with the rib of the inverter with converter assembly.

*a	Alignment Mark (Pink)
*b	Rib
*c	2 to 11 mm (0.0787 to 0.4331 in.)

10. CONNECT NO. 3 ENGINE WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Engage the clamp and connect the No. 3 engine wire to the inverter with converter assembly.

(b) Temporarily install the nut.

NOTICE:

To prevent the threads from being damaged, temporarily tighten the nut by hand.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(d) Engage the 2 claws to close the No. 3 engine wire terminal cover.

(e) Connect the No. 3 engine wire to the inverter with converter assembly with the bolt.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

(f) Connect the No. 3 engine wire to the inverter with converter assembly with the bolt.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

11. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Install the wire harness clamp bracket to the inverter with converter assembly with the nut.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

12. CONNECT HV AIR CONDITIONING WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Engage the clamp.

(b) Connect the HV air conditioning wire to the inverter with converter assembly and install the 2 bolts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

NOTICE:

Do not allow any foreign matter or water to enter the inverter with converter assembly.
Do not touch the waterproof seal or terminals of the connector.
Do not damage the terminals, connector housing or inverter with converter assembly when connecting the connector.

13. CONNECT FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Engage the 2 clamps.

(b) Connect the HV floor under wire to the inverter with converter assembly and install the 2 bolts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

NOTICE:

Do not allow any foreign matter or water to enter the inverter with converter assembly.
Do not touch the waterproof seal or terminals of the connector.
Do not damage the terminals, connector housing or inverter with converter assembly when connecting the connector.

14. CONNECT ENGINE WIRE

CAUTION:

Be sure to wear insulated gloves.

NOTICE:

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

(a) Engage the clamp to connect the engine wire.

(b) Install the 2 bolts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

Torque:

9.5 N·m {97 kgf·cm, 84 in·lbf}

(d) Engage the 2 clamps.

(e) Connect the 2 inverter with converter assembly connectors move the lock lever as shown in the illustration.

NOTICE:

To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.
Do not damage the terminals, connector housing or inverter with converter assembly when connecting the connectors.
Do not touch the waterproof seal or terminals of the connectors.

(f) Engage the 2 claws to connect the engine wire to the No. 1 engine room relay block.

(g) Connect the 3 No. 1 engine room relay block connectors.

(h) Install the No. 1 relay block cover to the No. 1 engine room relay block.

15. CONNECT FLOOR SHIFT TRANSMISSION CONTROL SELECT CABLE

(a) Engage the clamp to connect the floor shift transmission control select cable.

16. INSTALL BATTERY CLAMP SUB-ASSEMBLY

(a) Install the battery clamp sub-assembly to the vehicle with the 3 bolts.

Torque:

15.4 N·m {157 kgf·cm, 11 ft·lbf}

17. INSTALL ECM

Click here

18. INSTALL SERVICE PLUG GRIP

Click here

19. INSTALL AUXILIARY BATTERY

Click here

20. CONNECT ENGINE WIRE

(a) Connect the battery state sensor assembly connector.

(b) Engage the 2 claws to connect the engine wire to the battery current sensor holder.

21. ADD COOLANT (for Inverter)

Click here

22. INSPECT FOR COOLANT LEAK (for Inverter)

Click here

23. PERFORM RESOLVER LEARNING

Click here