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Home >> Toyota >> 2019 >> RAV4 XLE, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 10 (Hybrid Battery Control System - Service Information (1 Of 7)) >> INVERTER WITH CONVERTER (for 2WD) >> Installation [11/2018 - 08/2020] >> Procedure

Installation [11/2018 - 08/2020]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install the wire harness clamp bracket to the inverter with converter assembly with the bolt.

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

    2. Install the wire harness clamp bracket to the inverter with converter assembly with the bolt.

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

    3. Install the 2 wire harness clamp brackets to the inverter with converter assembly with the 2 bolts.

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

  2. 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.

    GTY764594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Bottom of Inverter with Converter Assembly
    *b Support
    1. Set the inverter with converter assembly on wooden blocks.
      Fig 1: No. 2 Inverter Bracket Bolts Tightening Sequence
      GTY860451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
    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) 

  3. INSTALL NO. 1 INVERTER BRACKET 
    1. Temporarily install the No. 1 inverter bracket to the inverter with converter assembly with the 2 bolts.
      Fig 2: No. 1 Inverter Bracket Bolts Tightening Sequence
      GTY856782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
    2. Fully tighten the 2 bolts in the order shown in the illustration.

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

  4. INSTALL INVERTER WITH CONVERTER ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    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.
        GTY912827Courtesy 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) 

      GTY857784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

  5. 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.
    • Adhere to the following installation procedure. Otherwise, the connector and the inverter with converter assembly may be damaged.
    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 motor cable.
      • Do not damage the terminals, connector housing or inverter with converter assembly during connection.
    2. Fully tighten the bolt (A).
      Fig 3: Motor Cable To Inverter With Converter Assembly Bolts Tightening Sequence
      GTY848030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal

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

    3. 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) 

    4. Temporarily install the 6 bolts.
      NOTE:
      • To prevent the threads from being damaged, temporarily tighten the 6 bolts by hand.
      • Do not touch the waterproof seal or terminals of the motor cable.
      • Do not damage the terminals, connector housing or inverter with converter assembly during connection.
      GTY903509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. 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 motor cable.
      • 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.
  6. INSTALL INVERTER COVER 
    WARNING:

    Be sure to wear insulated gloves.

    1. Install the inverter cover to the inverter with converter assembly with the 2 bolts.

      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.
        GTY596586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Inverter Cover
        *a Do not remove or excessively tighten the 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.
        GTY753047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a No Gap
  7. CONNECT NO. 4 INVERTER COOLING HOSE 
    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.
      GTY915539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Alignment Mark (Yellow)
      *b Rib
      *c 2 to 7 mm (0.0787 to 0.276 in.)
      *d Up
      *e LH Side

      HINT: 

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

  8. CONNECT NO. 1 INVERTER COOLING HOSE 
    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.

      GTY922250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Alignment Mark (White)
      *b Rib
      *c 2 to 7 mm (0.0787 to 0.276 in.)
      *d Up
      *e LH Side
  9. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Connect the transmission control cable assembly to the inverter with converter assembly with the 3 bolts.

      Torque: 12 N.m (122 kgf/cm, 9 ft.lbf) 

    2. Turn the control shaft lever clockwise until it stops, then turn it counterclockwise 2 notches.
      GTY741264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Engage the 2 claws to install a new clip to the transmission control cable assembly.
    4. Using a screwdriver, engage the 4 claws and install the transmission control cable assembly to the No. 1 transmission control cable bracket.
      GTY746243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Transmission Control Cable Assembly
      *2 No. 1 Transmission Control Cable Bracket
      *a Claw (A)
      *b Claw (B)
      NOTE:
      • Make sure that the claws (A) of the clip are securely engaged in the grooves of the bracket.
      • Make sure that the transmission control cable assembly is securely installed inside of the claws (B) of the clip.
    5. Connect the transmission control cable assembly to the control shaft lever with the nut.

      Torque: 12 N.m (122 kgf/cm, 9 ft.lbf) 

  10. 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.

    1. Engage the 2 clamps and connect the engine wire to the inverter with converter assembly.
      GTY903492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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, 7 ft.lbf) 

    4. Engage the 2 claws to close the engine wire terminal cover.
    5. Connect the engine wire to the inverter with converter assembly with the bolt.
      GTY903494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    6. Connect the engine wire to the inverter with converter assembly with the bolt.
      GTY940572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    7. Engage the 2 clamps.
    8. Engage the clamp.
    9. Confirm that no foreign matter or water has entered the connector of the generator temperature sensor, resolver (transmission fluid temperature sensor) and shift lever position sensor and connect the 3 connectors.
    10. Engage the clamp (B).
      GTY942030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Connect the engine wire to the intake manifold with the bolt.

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

    12. Engage the 2 clamps (A) and connect the No. 1 fuel vapor feed hose and No. 2 fuel vapor feed hose.
    13. Connect the EGR valve connector.
    14. Engage the 2 clamps (B).
      GTY896450Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    15. Connect the engine wire to the inverter with converter assembly with the bolt.

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

    16. Engage the 2 clamps (A) and connect the No. 1 fuel vapor feed hose.
    17. Connect the inverter with converter assembly connector and move the lock lever to lock them.
      GTY919443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not touch the waterproof seal or terminals of the connectors.
      • To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.
      • Do not damage the terminals, connector housing or inverter with converter assembly when connecting the connectors.
  11. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install the wire harness clamp bracket to the inverter with converter assembly with the nut.

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

  12. CONNECT HV AIR CONDITIONING WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Engage the clamp and connect the HV air conditioning wire to the inverter with converter assembly.
      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.
      GTY936945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
    2. Install the 2 bolts.

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

  13. CONNECT HV FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Engage the 2 clamps and connect the HV floor under wire to the inverter with converter assembly.
      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.
      GTY839109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
    2. Install the 2 bolts.

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

  14. CONNECT ENGINE ROOM MAIN WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Engage the clamp to connect the engine room main wire to the inverter with converter assembly.
    2. Install the bolt.

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

    3. Connect the inverter with converter assembly connector and move the lock lever to lock them.
      GTY940656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not touch the waterproof seal or terminals of the connectors.
      • To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.
      • Do not damage the terminals, connector housing or inverter with converter assembly when connecting the connectors.
  15. INSTALL ECM 

    Refer to INSTALLATION [11/2018 - 02/2019] , or refer to INSTALLATION [02/2019 - 08/2020]

  16. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 2 [11/2018 - 02/2019] , or refer to PROCEDURE - Step 2 [02/2019 - 08/2020]

  17. INSTALL INLET AIR CLEANER ASSEMBLY 

    Refer to PROCEDURE - Step 3 [11/2018 - 02/2019] , or refer to PROCEDURE - Step 3 [02/2019 - 08/2020]

  18. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 58 [11/2018 - 02/2019] , or refer to PROCEDURE - Step 58 [02/2019 - 08/2020]

  19. INSTALL SERVICE PLUG GRIP 

    Refer to INSTALLATION [11/2018 - ]

  20. ADD COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 2

  21. INSPECT FOR COOLANT LEAK (for Inverter) 

    See step  1

  22. INSPECT SHIFT LEVER POSITION 

    Refer to PROCEDURE - Step 2 [11/2018 - 02/2019] , or refer to PROCEDURE - Step 2 [02/2019 - ]

  23. ADJUST SHIFT LEVER POSITION 

    Refer to ADJUSTMENT [11/2018 - ]

  24. PERFORM INITIALIZATION 

    Refer to INITIALIZATION [11/2018 - 02/2019] , or refer to INITIALIZATION [02/2019 - 10/2019] , or refer to INITIALIZATION [10/2019 - 06/2020] , or refer to INITIALIZATION [06/2020 - 08/2020]

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