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Home >> Lexus >> 2020 >> LS 500h AWD >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Electric Motor Systems >> Hybrid Battery Control System - Service Information (1 Of 5) >> Inverter With Converter >> Installation [10/2020 - ] >> Procedure

Installation [10/2020 - ]: Procedure

  1. INSTALL HIGH VOLTAGE FUSE 
    WARNING:

    Wear insulated gloves.

    HINT: 

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

    1. Remove the connector cover assembly.

      See step  12 [10/2020 - 11/2021], or see step  12 [11/2021 - 10/2022], or see step  12 [10/2022 - 10/2023], or see step  12 [10/2023 - ]

    2. Install the high voltage fuse with the 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.

      GTY790293Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Temporarily install the connector cover assembly.

      See step  14 [10/2020 - 11/2021], or see step  14 [11/2021 - 10/2022], or see step  14 [10/2022 - 10/2023], or see step  14 [10/2023 - ]

  2. INSTALL NO. 1 INVERTER COOLING HOSE 

    HINT: 

    Perform this procedure only when replacement of the No. 1 inverter cooling hose is necessary.

    1. Install the No. 1 inverter cooling hose to the inverter with converter assembly and slide the 2 hose clips to secure it.
      NOTE:

      Do not remove the pieces of cloth or plastic bags from the pipes until installation.

      HINT: 

      Make sure that the 2 hose clips are positioned as shown in the illustration.

      GTY814708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Alignment Mark
  3. 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.
      NOTE:

      If the inverter bus-bar plate sub-assembly is dropped or deformed, replace it with a new one.

      GTY788452Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Stopper

      HINT: 

      When installing, align with the stopper.

    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 terminal cover.
  4. INSTALL NO. 4 INVERTER BRACKET 
    1. Temporarily install the No. 4 inverter bracket to the inverter with converter assembly with the 2 bolts.
      GTY791873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Stopper

      HINT: 

      When installing, align with the stopper.

    2. Tighten the 2 bolts in the sequence shown in the illustration.

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

  5. INSTALL INVERTER WITH CONVERTER ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. Temporarily install the No. 6 inverter bracket with the 2 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.
      GTY795303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the inverter with converter assembly with the 4 bolts.
    3. Tighten the 6 bolts in the order shown in the illustration.

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

    4. Attach the clamp.
    5. Open the inverter bus-bar plate sub-assembly cover.
      GTY814788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the inverter bus-bar plate sub-assembly with the nut.

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

    7. Connect the connector.
  6. INSTALL FLOOR UNDER WIRE 
    WARNING:

    Wear insulated gloves.

    1. Remove the connector cover assembly.

      See step  12 [10/2020 - 11/2021], or see step  12 [11/2021 - 10/2022], or see step  12 [10/2022 - 10/2023], or see step  12 [10/2023 - ]

    2. Connect the HV floor under wire.
      NOTE:
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Do not touch the connector waterproofing rubber or terminals.
      • Do not damage the connectors, connector housings or inverter with converter assembly during connection.
      • Make sure that the connector is fully engaged.
      GTY835979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Secure the HV floor under wire to the inverter with converter assembly with the bolt.

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

    4. Temporarily install the connector cover assembly.

      See step  14 [10/2020 - 11/2021], or see step  14 [11/2021 - 10/2022], or see step  14 [10/2022 - 10/2023], or see step  14 [10/2023 - ]

  7. INSTALL ENGINE ROOM MAIN WIRE 
    WARNING:

    Wear insulated gloves.

    1. Remove the connector cover assembly.

      See step  12 [10/2020 - 11/2021], or see step  12 [11/2021 - 10/2022], or see step  12 [10/2022 - 10/2023], or see step  12 [10/2023 - ]

    2. Connect the engine room main wire (air conditioning harness) to the inverter with converter assembly.
      NOTE:
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Do not touch the connector waterproofing rubber or terminals.
      • Do not damage the connectors, connector housings or inverter with converter assembly during connection.
      • Make sure that the connector is fully engaged.
      GTY814792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Temporarily install the connector cover assembly.

      See step  14 [10/2020 - 11/2021], or see step  14 [11/2021 - 10/2022], or see step  14 [10/2022 - 10/2023], or see step  14 [10/2023 - ]

    4. Temporarily install the wiring harness clamp bracket with the 2 nuts.
      GTY788304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Torque Wrench Fulcrum Length
    5. Using SST, tighten the 2 nuts.
      • SST: 09961-00950 

      Specified tightening torque 

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

      HINT: 

    6. Connect the engine room main wire (inverter with converter assembly connector) to the inverter with converter assembly and lock the connector with the lock lever as shown in the illustration.
      GTY835982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. CONNECT NO. 4 INVERTER COOLING HOSE 
    1. Connect the No. 4 inverter cooling hose to the inverter with converter assembly and slide the hose clip to secure it.
      NOTE:

      Do not remove the pieces of cloth or plastic bags from the pipe and disconnected hose until installation.

      HINT: 

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

      GTY828896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Insert
      *b Upper
      *c RH Side
      *d 120°
      *e Mark (Yellow)
      *f 2.0 to 5.0 mm (0.079 to 0.196 in.)
  9. CONNECT NO. 5 INVERTER COOLING HOSE 
    1. Connect the No. 5 inverter cooling hose to the inverter with converter assembly and lock the hose with the retainer as shown in the illustration.
      NOTE:
      • Push in 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 pipe and disconnected hose until installation.
      GTY814813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL FENDER APRON BRACE SUB-ASSEMBLY RH 
    1. Install the fender apron brace sub-assembly RH with the 2 bolts.

      Torque: 49 N.m (500 kgf/cm, 36 ft.lbf) 

      GTY814814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach the clamp.
  11. 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) 

      GTY814810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach the 3 clamps.
  12. CONNECT MOTOR CABLE 
    WARNING:

    Wear insulated gloves.

    1. Temporarily install the motor cable to the inverter with converter assembly with the 5 bolts.
      NOTE:
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Do not touch the connector waterproofing rubber or terminals.
      • Do not damage the terminals, connector housings or inverter with converter assembly when connecting them.
      GTY830079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an insulated tool, tighten the 3 bolts (A) in the order shown in the illustration.

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

    3. Using an insulated tool, tighten the 2 bolts (B).

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

  13. CONNECT GENERATOR CABLE 
    WARNING:

    Wear insulated gloves.

    1. Temporarily install the generator cable to the inverter with converter assembly with the 5 bolts.
      NOTE:
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Do not touch the connector waterproofing rubber or terminals.
      • Do not damage the terminals, connector housings or inverter with converter assembly when connecting them.
      GTY828579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an insulated tool, tighten the 3 bolts (A) in the order shown in the illustration.

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

    3. Using an insulated tool, tighten the 2 bolts (B).

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

  14. INSTALL INVERTER TERMINAL COVER 
    WARNING:

    Wear insulated gloves.

    1. Temporarily install the inverter terminal cover to the inverter with converter assembly.
      NOTE:
      • Do not touch the inverter terminal cover waterproofing rubber.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Make sure that the interlock is fully engaged.
      GTY811303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Press the inverter terminal cover by hand until it is firmly attached to the inverter with converter assembly.
    3. Tighten the 3 bolts to the inverter terminal cover.

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

      NOTE:

      Tighten the 3 bolts in the sequence shown in the illustration.

  15. INSTALL CONNECTOR COVER ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. Install the connector cover assembly to the inverter with converter assembly with the 2 bolts.

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

      NOTE:
      • Visually confirm that the connector cover assembly waterproofing rubber is securely installed before installing the connector cover assembly.
      • Do not touch the connector cover assembly waterproofing rubber.
      • Make sure that the interlock is fully engaged.
      GTY814815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 

    Refer to INSTALLATION [10/2020 - ]

  17. INSTALL INVERTER COVER ASSEMBLY RH 
    1. Engage the 2 claws and install the inverter cover assembly LH.
      GTY815204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the clip.
  18. INSTALL LOWER RADIATOR AIR DEFLECTOR 

    Refer to PROCEDURE - Step 43 [10/2017 - 10/2023] , or refer to PROCEDURE - Step 31 [10/2023 - ]

  19. INSTALL RADIATOR COVER PLATE 

    Refer to PROCEDURE - Step 45 [10/2017 - 10/2023] , or refer to PROCEDURE - Step 33 [10/2023 - ]

  20. INSTALL UPPER RADIATOR SUPPORT SEAL 

    Refer to PROCEDURE - Step 44 [10/2017 - 10/2023] , or refer to PROCEDURE - Step 32 [10/2023 - ]

  21. INSTALL SERVICE PLUG GRIP 

    Refer to INSTALLATION [10/2020 - ]

  22. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to PROCEDURE - Step 2 [10/2020 - 10/2023] , or refer to PROCEDURE - Step 2 [10/2023 - ]

  23. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 13 [10/2020 - 11/2021] , or refer to PROCEDURE - Step 13 [11/2021 - 10/2023] , or refer to PROCEDURE - Step 13 [10/2023 - ]

  24. ADD COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 7 [10/2017 - 10/2023] , or refer to PROCEDURE - Step 7 [10/2023 - ]

  25. INSPECT FOR COOLANT LEAK (for Inverter) 

    See step  1

  26. PERFORM RESOLVER LEARNING 

    Refer to UTILITY [10/2017 - ]

  27. INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL 

    Refer to WORK PROCEDURE [10/2020 - 11/2021] , or refer to WORK PROCEDURE [11/2021 - 10/2022] , or refer to WORK PROCEDURE [10/2022 - ]

    HINT: 

    When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

    Refer to AUTOMATIC LEARNING CHART [10/2020 - 11/2021] , or refer to AUTOMATIC LEARNING CHART [11/2021 - 10/2023] , or refer to AUTOMATIC LEARNING CHART [10/2023 - ]

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