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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) >> INVERTER WITH CONVERTER (for THS-HEV Model) >> Installation [10/2022 - ] >> Procedure

Installation [10/2022 - ]: Procedure

  1. INSTALL HYBRID INVERTER PROTECTOR ASSEMBLY 
    1. GTY1080283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin - -
      1. Temporarily install the hybrid inverter protector assembly to the inverter with converter assembly with the 4 bolts.
        NOTE:

        Make sure to align the guide of the hybrid inverter protector assembly with the pin.

      2. Fully tighten the bolt (A).

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

      3. Fully tighten the 3 bolts to install the hybrid inverter protector assembly to the inverter with converter assembly.

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

  2. INSTALL WIRE HARNESS CLAMP BRACKET 

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

  3. INSTALL WIRE HARNESS CLAMP BRACKET 

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

  4. INSTALL WIRE HARNESS CLAMP BRACKET 

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

  5. INSTALL NO. 2 INVERTER BRACKET 
    NOTE:

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

    GTY1066013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. *a: Bottom of Inverter with Converter Assembly
    2. *b: Support
    1. GTY1077769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Set the inverter with converter assembly on wooden blocks.
      2. Temporarily install the No. 2 inverter bracket to the inverter with converter assembly with the 2 bolts.
      3. Fully tighten the 2 bolts in the order shown in the illustration.

        Torque: 15 N.m (153 kgf/cm, 11 ft.lbf) 

  6. INSTALL NO. 1 INVERTER BRACKET 
    1. GTY1078038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Temporarily install the No. 1 inverter bracket to the inverter with converter assembly with the 2 bolts.
      2. Fully tighten the 2 bolts in the order shown in the illustration.

        Torque: 15 N.m (153 kgf/cm, 11 ft.lbf) 

  7. INSTALL INVERTER WITH CONVERTER ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.
    1. GTY1077888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Temporarily install the inverter with converter assembly with the 5 bolts and 2 nuts.
        NOTE:
        • 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.
          GTY1078304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
          *a Correct
          *b Incorrect

        HINT: 

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

      2. Fully tighten the bolt (A).

        Torque: 55 N.m (561 kgf/cm, 41 ft.lbf) 

      3. Fully tighten the 3 bolts (B).

        Torque: 55 N.m (561 kgf/cm, 41 ft.lbf) 

      4. Fully tighten the bolt (C).

        Torque: 55 N.m (561 kgf/cm, 41 ft.lbf) 

      5. Fully tighten the 2 nuts (D).

        Torque: 55 N.m (561 kgf/cm, 41 ft.lbf) 

  8. INSTALL WIRE HARNESS CLAMP BRACKET 

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

  9. CONNECT MOTOR CABLE 
    WARNING:

    Be sure to wear insulated gloves.

    NOTE:

    Do not allow any foreign matter or water to enter the inverter with converter assembly.
    1. GTY1131215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal *b 10 mm Union Nut Wrench Fulcrum Length
      *c Torque Wrench Fulcrum Length - -
      1. Temporarily connect the motor cable to the inverter with converter assembly with the 4 bolts.
        NOTE:
        • 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.
      2. 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) 

      3. Using a 10 mm union nut wrench, fully tighten the bolt (A) to connect the motor cable to the inverter with converter assembly.

        Specified tightening torque 

        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.

          Refer to PRECAUTION [10/2022 - ]

        • When using a 10 mm 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)

    2. GTY1078852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Temporarily install the 6 bolts.
        NOTE:
        • 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.
      2. Using an insulated tool, fully tighten the 6 bolts.

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

        NOTE:
        • 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.
  10. INSTALL UPPER INVERTER COVER SUB-ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

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

    NOTE:
    • 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.
      GTY1052470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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.
      GTY1077753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a No Gap
  11. CONNECT NO. 4 INVERTER COOLING HOSE 
    1. GTY1078437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Alignment Mark *b Rib
      *c 2 to 7 mm (0.0787 to 0.276 in.) *d Up
      *e LH Side - -
      1. Connect the No. 4 inverter cooling hose to the inverter with converter assembly and slide the clip to secure it.
        NOTE:
        • 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.

        HINT: 

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

  12. CONNECT NO. 1 INVERTER COOLING HOSE 
    1. GTY1079584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Alignment Mark *b Rib
      *c 2 to 7 mm (0.0787 to 0.276 in.) *d Up
      *e LH Side - -
      1. Connect the No. 1 inverter cooling hose to the inverter with converter assembly and slide the clip to secure it.
        NOTE:
        • 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.

        HINT: 

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

  13. CONNECT ENGINE WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    NOTE:
    • Do not allow any foreign matter or water to enter the inverter with converter assembly.
    • To prevent the threads from being damaged, temporarily tighten the nut by hand.
    1. GTY1078866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Engage the 2 clamps to connect the engine wire to the inverter with converter assembly.
      2. Temporarily install the nut.
        NOTE:

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

      3. Fully tighten the nut.

        Torque: 10 N.m (102 kgf/cm, 

    2. GTY1078816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. GTY1077925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N.m (102 kgf/cm, 

    4. GTY1077680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Generator Temperature Sensor Connector *b Resolver (Transmission Fluid Temperature Sensor) Connector
      1. Engage the clamp.
      2. Confirm that no foreign matter or water has entered the connector of the generator temperature sensor and resolver (transmission fluid temperature sensor) and connect the 3 connectors.
    5. GTY1078817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    6. GTY1078973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Connect the inverter with converter assembly connector and move the lock lever as shown in the illustration.
        NOTE:
        • Do not touch the waterproof seal or terminals of the connector.
        • To prevent damage due to static electricity, do not touch the terminals of the disconnected connector.
        • Do not damage the terminals, connector housing or inverter with converter assembly when connecting the connector.
  14. INSTALL WIRE HARNESS CLAMP BRACKET 

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

  15. CONNECT HV AIR CONDITIONING WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    NOTE:
    • 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.

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

  16. CONNECT FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    NOTE:
    • 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, interlock connector or inverter with converter assembly when connecting the connector.
    • Make sure that the connector is fully engaged.
    • Although the connector may feel loose, this is not due to a malfunction.

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

  17. CONNECT ENGINE ROOM MAIN WIRE 
    WARNING:

    Be sure to wear insulated gloves.

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

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

  18. INSTALL NO. 2 INVERTER PROTECTOR 

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

  19. INSTALL ECM 

    Refer to PROCEDURE - Step 3 [10/2022 - 08/2023] , or refer to PROCEDURE - Step 3 [08/2023 - ]

  20. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE 
    Refer to PROCEDURE - Step 5 [10/2022 - 08/2023] , or refer to PROCEDURE - Step 5 [08/2023 - ]
  21. CONNECT NO. 2 VENTILATION HOSE 
    Refer to PROCEDURE - Step 6 [10/2022 - 08/2023] , or refer to PROCEDURE - Step 6 [08/2023 - ]
  22. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 46 [10/2022 - 10/2024] , or refer to PROCEDURE - Step 41 [10/2024 - ]
  23. INSTALL SERVICE PLUG GRIP 

    Refer to PROCEDURE - Step 1

  24. ADD COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 2

  25. INSPECT FOR COOLANT LEAK (for Inverter) 

    See step  1

  26. PERFORM INITIALIZATION 

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

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