Installation [10/2018 - ]: Procedure

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2024 Lexus UX 250h, 2023 Lexus UX 250h, 2022 Lexus UX 250h, 2021 Lexus UX 250h, and 2020 Lexus UX 250h. However, it is still accessible from the selected car via links, so may be relevant.

HOW TO PREVENT STATIC ELECTRICITY

SST: 09890-47010

NOTE:

Static electricity should be eliminated when removing/installing the inverter with converter assembly.
Do not touch the electronic components of a circuit board.
Keep clothes away from electronic components.
Place the inverter with converter assembly and any removed electronic components on SST (antistatic mat).

Wear an antistatic wrist strap.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Connect the ground clip of the antistatic mat securely to a ground point provided in the workshop or on a workbench (anchor bolt).
HINT:

If the ground clip cable is too short, use an extension cable.
Connect the ground clip of the antistatic wrist strap securely to the specified point of the antistatic mat.
When handling internal components of the inverter with converter assembly, use only antistatic gloves or bare hands to prevent damage from static electricity or the entry of foreign matter.

INSTALL HV CONVERTER KIT

WARNING:

As there is a coolant passage underneath the HV converter kit, be careful not to spill any coolant (for inverter) into the filter condenser or the holes around the edge of the inverter with converter assembly.
If any coolant (for inverter) spills into the filter condenser or the holes around the edge of the inverter with converter assembly, do not reuse the inverter with converter assembly.
If any coolant (for inverter) spills onto any area other than the specified areas, remove it with a clean piece of cloth.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Do Not Allow Coolant (for Inverter) to Enter

NOTE:

Be careful not to touch any part of the HV converter kit other than the specified areas.
Do not allow any moisture to come into contact with the circuit board.

Install a new O-ring to the inverter with converter assembly and then press it at the 7 areas shown in the illustration to ensure it is installed securely.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Press Area

NOTE:

Make sure that the O-ring is free of foreign matter.

HINT:

The O-ring is symmetrical.

While holding the corners of the new HV converter kit, align it with the guide pins of the inverter with converter assembly and temporarily install it.

NOTE:

Make sure that the sealing surfaces and contact surfaces are free of foreign matter.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Guide Pins

Hold Here

Connect the HV converter kit connector.

NOTE:

Make sure that the inside of the connector is free of foreign matter.
Make sure that the connectors are connected securely.
Make sure that the wire harness of the connector is engaged to the filter condenser.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Temporarily install the new 8 bolts evenly in several steps in the order shown in the illustration, and then tighten them to the specified torque.

Fig 1: Inverter With Converter Assembly 8 Bolts Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
Temporarily install the new 3 bolts evenly in several steps in the order shown in the illustration, and then tighten them to the specified torque.

Fig 2: Inverter With Converter Assembly 3 Bolts Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)

Check the torque of the 11 bolts in the order shown in the illustration.

Fig 3: Inverter With Converter Assembly 11 Bolts Tightening Sequence

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

	Bolt (A)
	Bolt (B)

Bolt (A)

Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)

Bolt (B)

Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)

CHECK FOR AIR LEAK

Remove the cap from the black colored coolant pipe.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a vacuum pump, apply a vacuum of 50 kPa (375 mmHg) and check vacuum can be maintained.

Standard

The vacuum pressure does not decrease for at least 30 seconds.

NOTE:

If the vacuum pressure decreases, check for a leak between the vacuum pump and coolant pipe. If a leak is not found, remove the HV converter kit and check the installation condition of the O-ring.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL CONVERTER COVER

NOTE:

Do not touch the circuit board.
Do not allow any foreign matter or water to enter the inverter with converter assembly.
Do not touch or allow grease or oil to contact the sealing surfaces of the inverter with converter assembly.

Clean the seal packing removal cover.

Set the seal packing removal cover on the inverter with converter assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Apply seal packing (diameter: 3.0 mm (0.118 in.)) in a continuous line to the locations shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Seal Packing
*a	3.0 mm (0.118 in.)
*b	3.0 mm (0.118 in.)
*c	Approximately 20 mm
*d	View A

Seal Packing

Toyota Genuine Seal Packing 1207F

NOTE:

Install the converter cover within 3 minutes of applying seal packing.
Tighten the bolts within 15 minutes of applying seal packing.

Remove the seal packing removal cover.
NOTE:
Slowly remove the seal packing removal cover without touching the seal packing surface.

Align a new converter cover with the guide pins of the inverter with converter assembly and temporarily install it.

NOTE:

Make sure that the converter cover is free of foreign matter.
Make sure to align the HV converter kit with the guide pins correctly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Guide Pin

Temporarily install the new 8 bolts evenly in several steps in the order shown in the illustration, and then tighten them to the specified torque.

Fig 4: Converter Cover Bolt Tightening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 7.3 N*m (74 kgf*cm, 65 in.*lbf)
Check the torque of the 8 bolts in the order shown in the illustration.
Torque: 7.3 N*m (74 kgf*cm, 65 in.*lbf)

NOTE:
Make sure that the bolts are securely contacting the converter cover.

INSTALL WIRE HARNESS CLAMP BRACKET
See step 2
INSTALL TRANSMISSION CONTROL CABLE SUPPORT
See step 3
INSTALL NO. 2 INVERTER BRACKET
See step 4
INSTALL NO. 1 INVERTER BRACKET
See step 5
INSTALL INVERTER WITH CONVERTER ASSEMBLY
Refer to INSTALLATION [10/2018 - ]

INSPECT FOR COOLANT LEAK (for Inverter)

WARNING:

To avoid the danger of being burned, do not remove the reserve tank cap while the coolant (for inverter) is still hot. Pressurized, hot coolant (for inverter) and steam may be released and cause serious burns.

Remove the reserve tank cap from the inverter reserve tank assembly.
Add coolant to the FULL line of the inverter reserve tank assembly.

Install a radiator cap tester to the inverter reserve tank assembly.

Pump the radiator cap tester to 122 kPa (1.2 kgf/ cm² , 18 psi), and then check that the pressure does not drop.
HINT:

If the pressure drops, check the hoses, radiator assembly, inverter water pump assembly, hybrid vehicle transaxle assembly, and inverter with converter assembly for leaks.
Reinstall the reserve tank cap to the inverter reserve tank assembly.

OPERATION CHECK

HINT:

After the repair, perform the operation checks as follows. Then check for DTCs again.

Operation check 1
1. Connect the GTS to the DLC3.
2. Turn the power switch on (IG), turn the GTS on and clear the DTCs.
3. Turn the power switch on (READY).
4. Warm up the engine with the shift lever in P and the A/C turned off until the engine stops.
  HINT:
  
  The engine will stop automatically when it is warmed up.
5. Depress the accelerator pedal with the shift lever in P to start the engine.
6. As soon as the engine starts, release the accelerator pedal and wait until the engine stops.
7. Move the shift lever to D and creep the vehicle forward 5 m (16.4 ft.) with the engine stopped and without depressing the accelerator pedal.
  NOTE:
  Confirm the safety of the surrounding area before moving the vehicle.
8. Move the shift lever to R and creep the vehicle backward 5 m (16.4 ft.) with the engine stopped and without depressing the accelerator pedal.
  NOTE:
  Confirm the safety of the surrounding area before moving the vehicle.

Operation check 2

HINT:

The current at the AMD terminal cannot be measured directly because of space limitations. Measure the current flowing at the auxiliary battery instead.

Connect the AC/DC 400 A probe of the tester to the positive (+) auxiliary battery cable.

*a	Probe Direction
*b	Current Flowing to Auxiliary Battery

NOTE:

Check the AC/DC 400 A probe is installed in the right direction (positive (+) and negative (-)).

Turn the power switch on (READY) and leave the vehicle as it is until the electric current flowing to the auxiliary battery becomes 10 A or less.

Change the orientation of the AC/DC 400 A probe.

*a	Probe Direction
*b	Current Flowing from Auxiliary Battery

NOTE:

Check the AC/DC 400 A probe is installed in the right direction (positive (+) and negative (-)).

Measure the current flowing from the auxiliary battery with the power switch on (READY), the headlight position switch and blower motor switch in the HI position, and the rear window defogger turned on.

Standard Current

Item	Condition	Specified Condition
Current flowing from auxiliary battery	Power switch on (READY) (Headlight position switch and blower motor switch in HI position, and rear window defogger on)	0 A or less (No current from auxiliary battery)

Check for DTCs.
Refer to DTC CHECK / CLEAR [10/2018 - ]
Turn the power switch off.