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Home >> Lexus >> 2024 >> RX 500h >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Testing and Diagnosis >> Hybrid Battery Control System - Service Information (2 Of 4) >> HV BATTERY (for PHEV Model) >> Installation [08/2023 - ] >> Procedure

Installation [08/2023 - ]: Procedure

  1. INSTALL VALVE TO CONNECTOR TUBE 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    NOTE:
    • Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.
    • Keep the O-ring and O-ring fitting surface free of foreign matter.
    1. GTY1079357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the HV supply battery assembly.

        Compressor Oil

        ND-OIL 11 or equivalent

      2. Install the 2 O-rings to the valve to connector tube.
      3. Install the valve to connector tube to the HV supply battery assembly with the bolt.

        Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf) 

  2. INSTALL HV SUPPLY BATTERY ASSEMBLY 
    WARNING:
    • Because the weight of the HV supply battery assembly is extremely heavy, make sure to follow the work procedures described in the appropriate service information .
    • If work is not performed according to the procedures described in the appropriate service information , there is a danger that the components could fall down.
    • Do not damage the HV supply battery assembly with the fork etc.
    • Be sure to wear insulated gloves and protective goggles.
    GTY563885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. GTY1079115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Area That Can Touch The Ground - -
      1. Using an engine lifter and 4 attachments or equivalent tools, support the HV supply battery assembly as shown in the illustration.
        NOTE:
        • Do not allow foreign matter, such as grease or oil, to adhere to the bolts of the HV supply battery assembly.
        • To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.
        • Since the HV supply battery assembly is very heavy, 2 people are needed to remove it. When removing the HV supply battery assembly, be careful not to damage the parts around it.
        • When removing/installing/moving the HV supply battery assembly, make sure not to tilt it more than 80°.
        • If the HV supply battery assembly has been struck or dropped, replace it.
        • Do not apply any load outside of the area that can touch the ground.
      2. Raise the HV supply battery assembly until there is no clearance between the HV supply battery assembly and vehicle.
        NOTE:

        Be careful not to drop the HV supply battery assembly.

    2. GTY1079685Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt (A)
      (Bolt Length: 28 mm (1.102 in.))      		 *b Bolt (B)
      (Bolt Length: 24 mm (0.945 in.))

      bolt(A) 

      Torque: 43 N.m (438 kgf/cm, 32 ft.lbf) 

      bolt(B) 

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

  3. CONNECT NO. 2 TRACTION BATTERY WIRE 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.
  4. CONNECT FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.
    1. GTY1080188Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Green-colored Lock - -
      Slide - -
      1. Connect the connector and slide the green-colored lock as shown in the illustration to lock it securely.
        NOTE:
        • Check that the waterproofing lip covers the connecter ends.
          GTY999389Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
          *a Waterproofing Lip
        • Check that there are no foreign substances attached within the connector and to the waterproofing lip.
      2. Slide the rubber cap as shown in the illustration and engage it.
    2. GTY1079714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Engage the 2 clamps.
      2. Connect the HV floor under wire to the HV supply battery assembly.
        NOTE:

        Make sure that the connectors are connected securely.

      3. Install the bolt.

        Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

      4. Close the wire harness protector as shown in the illustration and install the bolt.

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

      5. Connect the HV floor under wire to the HV supply battery assembly.
        NOTE:

        Make sure that the connectors are connected securely.

      6. Install the bolt.

        Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

  5. CONNECT NO. 9 DISCHARGE TUBE 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.
    1. GTY1079566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the No. 9 discharge tube.

        Compressor Oil

        ND-OIL 11 or equivalent

        NOTE:

        Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.

      2. Install the O-ring to the No. 9 discharge tube.
        NOTE:

        Keep the O-ring and O-ring fitting surface free of foreign matter.

      3. Install the No. 9 discharge tube to the HV supply battery assembly with the bolt.

        Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf) 

  6. CONNECT NO. 3 LIQUID TUBE 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.
    1. GTY1079793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the No. 3 liquid tube.

        Compressor Oil

        ND-OIL 11 or equivalent

        NOTE:

        Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.

      2. Install the O-ring to the No. 3 liquid tube.
        NOTE:

        Keep the O-ring and O-ring fitting surface free of foreign matter.

      3. Install the No. 3 liquid tube to the HV supply battery assembly with the bolt.

        Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf) 

  7. INSTALL FRONT LOWER NO. 1 FLOOR HEAT INSULATOR 

    Torque: 4.9 N.m (50 kgf/cm, 43 in.lbf) 

  8. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR 
    1. GTY1079420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Temporarily install the front No. 2 floor heat insulator with the clip and 3 nuts.
      2. Fully tighten the nut.

        Torque: 4.9 N.m (50 kgf/cm, 43 in.lbf) 

  9. INSTALL FRONT EXHAUST PIPE ASSEMBLY 

    Refer to INSTALLATION [08/2023 - ]

  10. INSTALL ENGINE UNDER COVER HEAT INSULATOR 
    1. GTY1079965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 23 Traction Battery Bracket - -
      *a Button *b Push
      1. Install the engine under cover heat insulator with the 2 bolts and 2 nuts.

        Torque: 18 N.m (184 kgf/cm, 13 ft.lbf) 

      2. Install the No. 23 traction battery bracket, then push the button to lock it.
  11. INSTALL FRONT FLOOR COVER RH 

    Refer to PROCEDURE - Step 30

  12. INSTALL NO. 2 FLOOR UNDER COVER 
    1. GTY1079952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 31

  14. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY 

    Refer to PROCEDURE - Step 67

  15. INSTALL SERVICE PLUG GRIP 

    Refer to INSTALLATION [08/2023 - ]

  16. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 3

  17. WARM UP COMPRESSOR 

    Refer to PROCEDURE - Step 4

  18. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 6

  19. PERFORM INITIALIZATION 

    Refer to WORK PROCEDURE [08/2023 - ]

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