Toyota Corolla Cross: Installation

INSTALLATION

CAUTION / NOTICE / HINT

Procedure		Part Name Code
1	SET INVERTER WITH CONVERTER ASSEMBLY	G92A0		-	-
2	MOTOR CABLE	G1148		-	-
3	UPPER INVERTER COVER	G9221		-	-
4	INSTALL INVERTER WITH CONVERTER ASSEMBLY	G92A0		-	-

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)

N*m (kgf*cm, ft.*lbf): Specified torque

Procedure		Part Name Code
5	NO. 7 ENGINE, WIRE	82127D	-	-	-
6	INLET NO. 1 INVERTER COOLING HOSE	G922AA		-	-
7	OUTLET NO. 1 INVERTER COOLING HOSE	G922C		-	-
8	ENGINE WIRE	82121		-	-
9	ENGINE ROOM MAIN WIRE	82111		-	-

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)

N*m (kgf*cm, ft.*lbf): Specified torque

Procedure		Part Name Code
10	TRANSMISSION CONTROL CABLE ASSEMBLY	33820B	-	-	-
11	VACUUM SWITCHING VALVE ASSEMBLY	17650	-	-	-
12	NO.3 ENGINE WIRE	82123	-	-	-
13	NO.2 RELAY BLOCK COVER	82662B	-	-	-
14	HV AIR CONDITIONING WIRE	821H2		-	-
15	ECM	89661	-	-	-
16	NO. 1 AIR CLEANER HOSE	17881	-	-	-
17	AIR CLEANER CASE SUB-ASSEMBLY	17701	-	-	-
18	AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY	17801	-	-	-
19	AIR CLEANER CAP SUB-ASSEMBLY	17705	-	-	-

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)

N*m (kgf*cm, ft.*lbf): Specified torque

Procedure		Part Name Code
20	FLOOR UNDER WIRE	821H1		-	-

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)

N*m (kgf*cm, ft.*lbf): Specified torque

Procedure		Part Name Code
21	SERVICE PLUG GRIP	G3834	-	-	-
22	COOLANT (for Inverter)	-	-		-
23	FOR COOLANT LEAK	-		-	-
24	ECU CONFIGURATION	-	-	-
25	RESOLVER LEARNING	-	-	-

PROCEDURE

1. SET INVERTER WITH CONVERTER ASSEMBLY

CAUTION: Be sure to wear insulated gloves. 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.

2. CONNECT MOTOR CABLE

CAUTION: Wear insulated gloves. NOTICE: Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.

(1) Temporarily install the motor cable to the inverter with converter assembly with the 4 bolts,

NOTICE:

• Do not touch the waterproof seal or terminals of the motor cable.
• Do not damage the terminals, connector housing or inverter with converter assembly during connection.
• Be careful to avoid cutting or pinching the waterproof seal during installation.

(2) Fully tighten the 3 bolts in the order shown in the illustration.

Torque:

8.0 N·m {82 kgf·cm}

(3) Using a 10 mm union nut wrench, fully tighten the bolt(A).

Torque:

Specified Tightening Torque :

8.0 N·m {82 kgf·cm, 71 in·lbf}

HINT:

• Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

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• When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 7.0 N*m (71 kgf*cm, 62 in.*lbf)

(4) Temporarily install the terminals of the motor cable with the bolts, and using an insulated tool, fully tighten the bolts.

Torque:

8.0 N·m {82 kgf·cm}

NOTICE:

• To prevent the threads from being damaged, temporarily tighten the 6 bolts by hand.
• Be sure to use a torque wrench to tighten the bolts.

3. INSTALL UPPER INVERTER COVER

CAUTION: Wear insulated gloves.

(1) To prevent the inverter with converter assembly from falling, temporarily install the bolt in the location shown in the illustration.

(2) Shift the position of the inverter with converter assembly and temporarily set it on top of the stud bolts as shown in the illustration.

NOTICE:

When lifting, make sure not to apply force to the motor cable.

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

Torque:

8.0 N·m {82 kgf·cm}

NOTICE:

• Visually confirm that the inverter cover waterproof seal is securely installed before installing the upper inverter cover.
• Do not touch the waterproof seal of the upper inverter cover.
• Make sure that the interlock is fully engaged.
• Do not damage the terminals, interlock connector or hybrid motor control inverter assembly during installation.
• Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
• Do not remove or excessively tighten the screw of the upper inverter cover.

  *1	Inverter Cover
  *a	Screw

• Although the upper inverter cover may feel loose, this is not due to a malfunction.
• Push in the upper inverter cover until it contacts the hybrid motor control inverter assembly.

  *a

  No Gap

(1) Shift the position of the inverter with converter assembly and temporarily set it on the hybrid vehicle transaxle assembly as shown in the illustration.

NOTICE:

When lifting, make sure not to apply force to the motor cable.

(2) Connect the inverter cover to the hybrid vehicle transaxle assembly with the bolt.

Torque:

8.0 N·m {82 kgf·cm}

4. INSTALL HYBRID MOTOR CONTROL INVERTER ASSEMBLY

CAUTION: Wear insulated gloves.

(1) Temporarily install the inverter with converter assembly with the bolts and the nuts, and then fully tighten the bolts and nuts in the order shown in the illustration.

Torque:

55 N·m {561 kgf·cm}

NOTICE:

• When installing the inverter with converter assembly, be careful not to damage the parts around it.
• 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.

5. INSTALL NO. 7 ENGINE WIRE

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

6. CONNECT INLET NO. 1 INVERTER COOLING HOSE

(1) Connect the inlet No. 1 inverter cooling hose to the hybrid motor control inverter assembly and slide the clip to secure it.

NOTICE:

To prevent foreign matter from entering the hybrid motor control inverter assembly and inverter cooling system, do not remove the pieces of cloth from the pipe and disconnected hose until installation.

7. CONNECT OUTLET NO. 1 INVERTER COOLING HOSE

(1) Connect the outlet No. 1 inverter cooling hose to the hybrid motor control inverter assembly and slide the clip to secure it.

NOTICE:

To prevent foreign matter from entering the hybrid motor control inverter assembly and inverter cooling system, do not remove the pieces of cloth from the pipe and disconnected hose until installation.

8. INSTALL ENGINE WIRE

CAUTION: Wear insulated gloves. NOTICE: To prevent the threads from being damaged, temporarily tighten the nut by hand. Do not touch the waterproof seal or terminals of the connectors. To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors. Do not damage the terminals, connector housing or hybrid motor control inverter assembly when connecting the connectors.

Torque:

10 N·m {102 kgf·cm, 89 in·lbf}

9. INSTALL ENGINE ROOM MAIN WIRE

10. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY

Torque:

Nut :

6.0 N·m {61 kgf·cm, 53 in·lbf}

Bolt :

12 N·m {122 kgf·cm, 9 ft·lbf}

11. INSTALL PURGE VALVE (PURGE VSV)

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

12. INSTALL NO. 3 ENGINE WIRE

Torque:

8.35 N·m {85 kgf·cm, 74 in·lbf}

13. INSTALL NO. 2 RELAY BLOCK COVER

14. CONNECT HV AIR CONDITIONING WIRE

CAUTION: Wear insulated gloves. NOTICE: Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly. Do not touch the waterproof seal or terminals of the connector. Do not damage the terminals, connector housing or hybrid motor control inverter assembly when connecting the connector.

*a	Green-colored Lock	-	-
	Slide	-	-

(1) Connect the connector and slide the green-colored lock as shown in the illustration to securely lock it.

(2) Engage the 2 clamps.

15. INSTALL ECM

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16. INSTALL NO. 1 AIR CLEANER HOSE

Torque:

2.0 N·m {20 kgf·cm, 18 in·lbf}

17. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

Torque:

4.0 N·m {41 kgf·cm, 35 in·lbf}

18. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

19. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

20. CONNECT FLOOR UNDER WIRE

CAUTION: Wear insulated gloves. NOTICE: Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly. Do not touch the waterproof seal or terminals of the connector. Do not damage the terminals, connector housing or hybrid motor control inverter assembly when connecting the connector.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

21. INSTALL SERVICE PLUG GRIP

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22. ADD COOLANT (for Inverter)

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23. INSPECT FOR COOLANT LEAK (for Inverter)

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24. PEFOME ECU CONFIGURATION

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25. PERFORM RESOLVER LEARNING

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