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Home >> Lexus >> 2024 >> RX 500h >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Testing and Diagnosis >> Hybrid Battery Control System - Service Information (1 Of 4) >> ELECTRIC VEHICLE CONVERTER (for T24A-FTS) >> Installation [10/2022 - ] >> Procedure

Installation [10/2022 - ]: Procedure

  1. INSTALL O-RING 
    HINT: 
    Although the O-ring is reusable, replace it if it is damaged.
  2. INSTALL CONVERTER COVER 
  3. INSTALL EV CONVERTER ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    NOTE:
    • Do not allow any foreign matter or water to enter the EV converter assembly.
    • Do not touch the waterproof seal or terminals of the air.
    • When connecting the air conditioner wire, do not damage the terminal part of the air conditioner wire, the connector housing and the EV converter assembly.
    1. GTY1129920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction (1) Install in this Direction (2)
      1. Connect the air conditioning wire with the 2 bolt to the EV converter assembly.

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

      2. Install the EV converter assembly in the direction shown in the illustration.
        NOTE:
        • When installing, install so that the PN terminals and lower portion of the EV converter assembly do not make contact.
          GTY1132712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
          *1 EV Converter Assembly
          *2 Hybrid Motor Control Inverter assembly
          *3 O-Ring
          *4 PN Terminals
        • After installing the EV converter assembly, do not move the EV converter assembly in the rotation direction prior to installing bolts A and B.
        • When installing the EV converter assembly to the vehicle, be careful not to damage surrounding parts.
        • To prevent damage, do not hold the coolant pipes, brackets and connectors when lifting up the EV converter assembly.
        • To prevent damage caused by static electricity, do not touch the terminals of connectors on the EV converter assembly side.
        • When handling the EV converter assembly, do not hold it from the positions marked in the illustration.
          GTY1132170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Install the bolt.

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      4. Engage the clamp.
      5. Install the 4 bolts.

        Torque: 20 N.m (204 kgf/cm, 15 ft.lbf) 

        NOTE:

        Tighten the bolts in the order of A, B, C, D.

    2. GTY1130240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a PN Terminals - -
      1. Using an insulated tool, tighten the 2 bolts.

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

        NOTE:

        Do not excessively tighten the PN terminals.

  4. INSTALL INVERTER COVER GASKET 
    HINT: 
    Although the inverter cover gasket is reusable, replace it if it is damaged.
  5. INSTALL INVERTER TERMINAL COVER 
    WARNING:

    Be sure to wear insulated gloves.
    1. GTY1132105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Guide Pin - -
      1. Attach the 2 guide pins and install the inverter terminal cover with 2 bolts.

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

        NOTE:
        • Do not touch the inverter cover gasket if not replacing it.
        • Do not allow any foreign matter or water to enter the EV converter assembly.
  6. CONNECT FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves.
    1. GTY1131718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal - -
      1. Connect the floor under wire with the 2 bolts.

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

        NOTE:
        • Do not allow any foreign matter or water to enter the EV converter assembly.
        • Do not touch the waterproof seal or terminals of the air.
        • When connecting the floor under wire, do not damage the terminal part of the floor under wire, the connector housing and the EV converter assembly.
    2. GTY1205006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an insulated tool, install the 4 bolts.

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

        NOTE:

        Tighten the bolts in the order of A, B, C, D.

  7. INSTALL INVERTER TERMINAL GASKET 
    HINT: 
    Although the inverter terminal gasket is reusable, replace it if it is damaged.
  8. INSTALL UPPER INVERTER COVER SUB-ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.
    1. GTY1133242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Guide Pin - -
      1. Attach the 2 guide pins and install the upper inverter cover sub-assembly with 3 bolts.

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

        NOTE:
        • Do not touch the inverter terminal gasket if not replacing it.
        • Do not allow any foreign matter or water to enter the EV converter assembly.
  9. INSTALL BATTERY COVER LOCK STRIKER 
    WARNING:

    Be sure to wear insulated gloves.
    1. GTY1130200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Battery Cover Lock Striker - -
      *a Button *b Push
      1. Install the battery cover lock striker, then push the button to lock it.
  10. INSTALL BATTERY COVER LOCK STRIKER 
    WARNING:

    Be sure to wear insulated gloves.
    1. GTY1131816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Battery Cover Lock Striker - -
      *a Button *b Push
      1. Install the battery cover lock striker, then push the button to lock it.
  11. INSTALL NO. 1 ENGINE AND INVERTER STIFFENER 

    Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

  12. CONNECT NO. 1 INVERTER COOLING HOSE ASSEMBLY 
    1. GTY1129834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Alignment Mark *b Rib
      *c 2.0 to 7.0 mm (0.079 to 0.275 in.) *d Upper
      *e LH Side - -
      1. Connect the No. 1 inverter cooling hose assembly to the EV 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.
        • Do not apply excessive force to the No. 1 inverter cooling hose assembly.
        • Make sure to align the alignment mark of the hose with the rib of the EV converter assembly.

        HINT: 

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

  13. CONNECT INLET NO. 1 INVERTER COOLING HOSE 
    1. GTY1133271Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Alignment Mark *b Rib
      *c 2.0 to 7.0 mm (0.079 to 0.275 in.) *d Upper
      *e RH Side - -
      1. Connect the inlet No. 1 inverter cooling hose to the EV 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.
        • Do not apply excessive force to the inlet No. 1 inverter cooling hose.
        • Make sure to align the alignment mark of the hose with the rib of the EV converter assembly.

        HINT: 

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

  14. CONNECT ENGINE WIRE 
    WARNING:

    Be sure to wear insulated gloves.
    1. GTY1129661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Nut Connector
      1. Install the engine wire with the nut.

        Torque: 13.5 N.m (138 kgf/cm, 10 ft.lbf) 

        NOTE:
        • As shown in the illustration, tighten the nut by moving the tool downward.
        • Be sure to perform this procedure manually since the threads may get damaged.
      2. Engage the 2 claws to close the engine wire terminal cap.
      3. Connect the connector.
    2. GTY1132177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

  15. INSTALL INTAKE AIR CONNECTOR BRACKET 

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

  16. INSTALL NO. 2 VENTILATION HOSE 
    1. GTY1131114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 4 to 10 mm (0.157 to 0.394 in.) *b 45° (Between clip claws)
      *c 25° (Between clip claws) *d Paint Mark
      *e Upper side of vehicle *f Left side of vehicle
      1. Connect the No. 2 ventilation hose to the cylinder head cover sub-assembly and secure it with the clip.
        NOTE:

        Position the clip claws in the range shown.

  17. CONNECT WATER HOSE WITH FUEL VAPOR FEED HOSE ASSEMBLY 
    1. GTY1129924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 2 to 7 mm (0.079 to 0.276 in.) *b Upper side of vehicle
      *c 360°(Between clip claws) *d Front side of vehicle
      *e Stopper portion *f Paint mark
      1. Connect the water hose to the water control valve and secure it with the clip.
        NOTE:

        Insert the water hose until it hits the stopper.

      2. Connect the fuel vapor feed hose to the purge valve (No. 1 vacuum switching valve).
      3. Attach the clamp.
  18. INSTALL ECM 
    Refer to PROCEDURE - Step 3
  19. INSTALL AIR CLEANER HOSE ASSEMBLY 
    1. GTY1133483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Positioning protrusion *b 9 to 17 mm (0.354 to 0.669 in.)
      *c Within 10 mm (0.394 in.) *d 4 to 10 mm (0.157 to 0.394 in.)
      *e Upper side of vehicle *f front side of vehicle
      *g 45° - -
      1. Align the compressor inlet elbow and positioning protrusion of air cleaner hose assembly, then fasten the hose clamp to secure the air cleaner hose assembly.
      2. Install the bolt.

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

      3. Attach the clamp and install the air cleaner hose assembly.
      4. Connect the connector.
      5. Connect the vacuum hose to the vacuum pump assembly.
      6. Connect the No. 1 vacuum transmitting hose assembly to the turbocharger.
      7. Connect the No. 1 vacuum transmitting hose assembly to the air cleaner hose assembly.
      8. Connect the No. 2 ventilation hose to the air cleaner hose assembly.
        NOTE:

        Position the clip claws in the range shown.

  20. INSTALL AIR CLEANER ASSEMBLY WITH NO. 1 AIR CLEANER HOSE 
    1. GTY1133631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion at Position *b 9 to 17 mm (0.3543 to 0.6693 in.)
      *c 10 mm (0.3937 in.) or less *d Grommet
      *e Pin - -
      1. Match a protrusion projection and connect No. 1 air cleaner hose and tighten it in hose clamp.
      2. 2 Grommet and pin make close fitting at the same time and attach air cleaner assembly with No. 1 air cleaner hose.
      3. Connect a wiring harness connector and clamp.
  21. INSTALL AIR CLEANER INLET ASSEMBLY 
  22. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 56
  23. INSTALL COOL AIR INTAKE DUCT SEAL 
  24. INSTALL NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 79

  25. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH 
  26. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH 
  27. INSTALL SERVICE PLUG GRIP 

    Refer to INSTALLATION [10/2022 - ]

  28. ADD COOLANT (for Intercooler) 

    Refer to PROCEDURE - Step 5

  29. INSPECT FOR COOLANT LEAK (for Intercooler) 

    Refer to PROCEDURE - Step 1

  30. PERFORM INITIALIZATION 

    Refer to WORK PROCEDURE [10/2022 - 08/2023] , or refer to WORK PROCEDURE [08/2023 - ]

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