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Home >> Toyota >> 2020 >> RAV4 XLE, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 10 (Hybrid Battery Control System - Service Information (1 Of 7)) >> INVERTER WITH CONVERTER (for AWD) >> Installation [02/2019 - 06/2020] >> Procedure

Installation [02/2019 - 06/2020]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL HYBRID INVERTER PROTECTOR ASSEMBLY (w/ HYBRID INVERTER PROTECTOR ASSEMBLY) 
    1. Put locating pin guide of hybrid inverter protector assembly to the inverter with converter assembly.
      GTY902867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Locating pin
    2. Install the hybrid inverter protector assembly to the inverter with converter assembly with the 4 bolts.

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

      HINT: 

      Temporarily tighten the bolt (A) and then fully tighten the 4 bolts in the order of (A), (B), (C) and (D).

  2. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install the wire harness clamp bracket to the inverter with converter assembly with the 2 bolts.

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

      GTY859163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the wire harness clamp bracket to the inverter with converter assembly with the 2 bolts.

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

      GTY859164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the wire harness clamp bracket to the inverter with converter assembly with the 2 bolts.

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

      GTY842232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. 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) 

      GTY842231Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. w/o hybrid inverter protector assembly:
      1. Install the wire harness clamp bracket to the inverter with converter assembly with the 2 bolts.

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

        GTY842239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. 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.

    GTY884547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Bottom of Inverter with Converter Assembly
    *b Support
    1. Set the inverter with converter assembly on wooden blocks.
      GTY844374Courtesy 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) 

  4. INSTALL NO. 1 INVERTER BRACKET 
    1. Temporarily install the No. 1 inverter bracket to the inverter with converter assembly with the 2 bolts.
      GTY839628Courtesy 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) 

  5. 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.
        GTY889598Courtesy 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) 

      GTY922702Courtesy 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) 

  6. 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).
      GTY942880Courtesy 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.
      GTY927069Courtesy 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.
  7. 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
  8. 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.
      GTY895074Courtesy 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.

  9. 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.

      GTY902807Courtesy 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
  10. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Connect the transmission control cable assembly to the inverter with converter assembly with the 2 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) 

  11. 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.
      GTY842227Courtesy 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.
      GTY842213Courtesy 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.
      GTY842212Courtesy 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).
      GTY938557Courtesy 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 3 clamps (B).
      GTY886133Courtesy 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 clamp (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.
      GTY842245Courtesy 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.
  12. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install the wire harness clamp bracket to the inverter with converter assembly with the nut.

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

  13. 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.
      GTY872530Courtesy 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 HV FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Install the 2 bolts and connect the HV floor under wire to the inverter with converter assembly.

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

      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.
      GTY865535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
    2. Connect the HV floor under wire to the inverter with converter assembly with the 2 nuts.
      GTY842243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Connect the HV floor under wire to the inverter with converter assembly with the 2 bolts.
      GTY936929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal

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

      NOTE:
      • Make sure that the connector is fully engaged.
      • Do not damage the terminals, interlock connector or inverter with converter assembly during installation.
      • Do not touch the waterproof seal or terminals of the connector.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      • Although the connector may feel loose, this is not due to a malfunction.
  15. 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.
      GTY842206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
      GTY927073Courtesy 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.
  16. INSTALL NO. 2 INVERTER PROTECTOR (w/ NO. 2 INVERTER PROTECTOR) 
    1. Install the No. 2 inverter protector to the inverter with converter assembly with the 2 bolts.

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

      GTY842242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL ECM 

    Refer to INSTALLATION [02/2019 - 08/2020]

  18. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 2

  19. INSTALL INLET AIR CLEANER ASSEMBLY 

    Refer to PROCEDURE - Step 3

  20. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 58

  21. INSTALL SERVICE PLUG GRIP 

    Refer to INSTALLATION [11/2018 - ]

  22. ADD COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 2

  23. INSPECT FOR COOLANT LEAK (for Inverter) 

    See step  1

  24. INSPECT SHIFT LEVER POSITION 

    Refer to ON-VEHICLE INSPECTION [02/2019 - ]

  25. ADJUST SHIFT LEVER POSITION 

    Refer to ADJUSTMENT [11/2018 - ]

  26. PERFORM INITIALIZATION 

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

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