Installation [09/2023 - ]: Procedure

HINT: 

Perform this procedure only when replacement of the No. 1 inverter busbar plate is necessary.

1. Fig 1: No. 1 Inverter Busbar Plate Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Using a T30 "TORX" socket wrench, install the No. 1 inverter busbar plate with the 3 bolts in the order shown in the illustration.

      Torque: 8.5 N.m (87 kgf/cm, 75 in.lbf) 

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Mark	*b	Rib
   *c	2 to 7 mm (0.0787 to 0.276 in.)	*d	Upper Side of Vehicle
   *e	RH Side	*f	180° (Claw of Clip Location)

   1. Install the inlet No. 1 inverter cooling hose to the hybrid motor control inverter assembly and slide the 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 mark of the inlet No. 1 inverter cooling hose with the rib of the hybrid motor control inverter assembly.
      • Make sure that the claws of the clip are within the location shown in the illustration.

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   1. Install SST in the location shown in the illustration.
      • SST: 09382-00010 
   2. Install a new inverter case gasket while passing it through SST.
      NOTE:

      When installing, do not directly touch the gasket contact surface.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. While passing the hybrid motor control inverter assembly through SST, lower it so that it does not interfere with the No. 1 inverter busbar plate, and connect it to the transaxle with motor assembly.
      NOTE:

      • Lower the hybrid motor control inverter assembly to a position where it does not interfere, so that the No. 1 inverter busbar plate is not damaged or bent.
      • Be careful not to damage the surrounding parts when installing the hybrid motor control inverter assembly to the vehicle.
      • To prevent damage, do not hold the coolant pipes, brackets and connectors when lifting up the hybrid motor control inverter assembly.
      • To prevent damage caused by static electricity, do not touch the terminals of connectors on the hybrid motor control inverter assembly side.
      • Do not remove the pieces of connector cover or tape from the pipe and disconnected hose until installation.
   2. Remove SST.
   3. Using a T30 "TORX" socket wrench, temporarily install the 12 bolts in the order shown illustration.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Rotating the lock lever

   -

   -

   1. Connect the engine wire connector.

      HINT: 

      Make sure that the connector is fully inserted before rotating the lock lever to engage the lock.

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   Rotating the lock lever

   -

   -

   1. Connect the resolver thermistor wire connector.

      HINT: 

      Make sure that the connector is fully inserted before rotating the lock lever to engage the lock.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Mark	*b	Rib
   *c	2 to 7 mm (0.0787 to 0.276 in.)	*d	Rear
   *e	RH Side	*f	120° (Claw of Clip Location)

   1. Connect the No. 4 inverter cooling hose to the hybrid motor control inverter assembly and slide the clip to secure it.
      NOTE:

      • Do not remove the pieces of cloth or plastic bags from the pipe and disconnected hose until installation.
      • Make sure to align the mark of the No. 4 inverter cooling hose with the rib of the hybrid motor control inverter assembly.
      • Do not apply excessive force to the No. 4 inverter cooling hose.
      • Make sure that the claws of the clip are within the location shown in the illustration.
   2. Engage the clamp.

See step  6

WARNING: Be sure to wear insulated gloves. NOTE: Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.

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   1. Temporarily connect the No. 1 inverter busbar plate with the 3 bolts.
      NOTE:

      • Be sure to perform this procedure manually since the threads may get damaged.
      • Do not damage the terminals or hybrid motor control inverter assembly when connecting them.
   2. Using an insulated tool and T30 "TORX" socket wrench, fully tighten the 3 bolts.

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

      NOTE:

      • Do not damage the terminals or hybrid motor control inverter assembly when connecting them.
      • Be sure to use a torque wrench for tightening.
      • Do not damage the opening of the hybrid motor control inverter assembly with the tool.
      • Do not excessively tighten the No. 1 inverter busbar plate connection area.

1. Fig 2: Upper Inverter Cover Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Guide Pin	*b	Waterproof Seal
   *c	Connector Area	-	-

   1. Engage the 2 guide pins and install the upper inverter cover.
      NOTE:

      • Do not touch the waterproof seal.
      • Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
      • Attach the guide pin so that the connector area is attached horizontally to the connector fitting surface on the mating part.

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   2. Temporarily install the 5 bolts.
   3. Using a T30 "TORX" socket wrench, install the 5 bolts in the order shown illustration.

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

1. Fig 3: Fully Tighten Hybrid Motor Control Inverter Assembly Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Using a T30 "TORX" socket wrench, fully tighten the 12 bolts in the order shown illustration.

      Torque: 9.1 N.m (93 kgf/cm, 81 in.lbf) 

      HINT: 

      Tighten 2 times in the order shown in the illustration.

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   1. Using a T30 "TORX" socket wrench, connect the breather hose with the bolt.

      Torque: 5.4 N.m (55 kgf/cm, 48 in.lbf) 

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   	Bolt (A)		Bolt (B)
   	Nut	-	-

   1. Install the engine mounting insulator sub-assembly LH with the 2 bolts (B) and nut.

      Torque: 72 N.m (734 kgf/cm, 53 ft.lbf) 

      HINT: 

      Tightening order of bolt (B) and nut: Temporarily tighten (a) → Fully tighten (b) → Fully tighten (a) → Fully tighten (c)

   2. Connect the engine mounting insulator sub-assembly LH to the transaxle assembly with motor and inverter with the 4 bolts (A).

      Torque: 42 N.m (428 kgf/cm, 31 ft.lbf) 

      HINT: 

      Tightening order of bolt (A): Fully tighten (g) → Fully tighten (e) → Fully tighten (f) → Fully tighten (d)

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Install the engine mounting stay LH with the 4 bolts.

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

      HINT: 

      Tightening order: Temporarily tighten bolt (A) → Fully tighten bolt (B) → Fully tighten bolt (C) → Fully tighten bolt (A)

NOTE: When replacing the hybrid motor control inverter assembly, perform "19.ECU CONFIGURATION" after connecting the cable to the auxiliary battery terminal.

Refer to INSTALLATION [09/2023 - ]

NOTE: The resolver learned values cannot be initialized by disconnecting the cable from the negative (-) auxiliary battery terminal or removing a fuse. If resolver learning is not performed after the part related has been replaced, the following DTCs may be stored and the symptoms may occur: DTC output P1C5D19 (Drive Motor "A" Inverter Circuit Current Above Threshold) P0C7917 (Drive Motor "A" Inverter Voltage Sensor(VH) Circuit Voltage Above Threshold) P0BFF1D (Drive Motor "A" Circuit Current Out of Range) P0C1900 (Drive Motor "A" Execution Torque Performance) Slight vibration at a vehicle speed of 5 km/h (3 mph) or less Shock or vibration during acceleration HINT:  After replacing the hybrid motor control inverter assembly, write the stored resolver compensation value. If the "read compensation value" cannot be performed, the resolver compensation value on the QR code label of the transaxle with motor assembly will need to be checked.

1. Store resolver compensation value (if the "read compensation value" can be performed)
   1. Turn the ignition switch off and wait for 2 minutes or more.
   2. Check that the air conditioning system and power outlet socket are turned off.
   3. Enter the following menus.

      Powertrain > Motor Generator > Utility 

      Tester Display
      Front Resolver Correction Value Registration

   4. Select "register compensation value", enter the compensation value read prior to replacement and then write the resolver compensation value.
   5. Clear the DTCs.
      NOTE:

      After replacing the hybrid motor control inverter assembly, DTCs are stored when turning the ignition switch to ON, so be sure to clear the DTCs.

   6. Turn the ignition switch off and wait for 10 seconds or more.
   7. Turn the ignition switch to ON and wait for 5 seconds or more, and check that no DTC is output.
2. Check resolver compensation value on QR code label (if the "read compensation value" cannot be performed)
   1. Turn the ignition switch off and wait for 2 minutes or more.
   2. Turn the ignition switch to ON, wait for 5 seconds or more, and check that no DTC is output.
   3. Enter the following menus.

      Powertrain > Motor Generator > Utility 

      Tester Display
      Front Resolver Correction Value Writing

   4. Enter the resolver compensation value on the QR code label checked prior to replacement, and then write the resolver compensation value.
   5. Clear the DTCs.
      NOTE:

      After replacing the hybrid motor control inverter assembly, DTCs are stored when turning the ignition switch to ON, so be sure to clear the DTCs.

   6. Turn the ignition switch off and wait for 10 seconds or more.
   7. Turn the ignition switch to ON and wait for 5 seconds or more, and check that no DTC is output.

Refer to WORK PROCEDURE [09/2023 - 12/2023] , or refer to WORK PROCEDURE [12/2023 - ]