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Home >> Toyota >> 2025 >> RAV4 Plug-In Hybrid SE >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Electric Motor Systems >> Hybrid Battery Control System (PHEV) - Service Information (1 Of 3) >> Inverter With Converter >> Installation [06/2020 - ] >> Procedure

Installation [06/2020 - ]: Procedure

  1. INSTALL HYBRID INVERTER PROTECTOR ASSEMBLY 
    1. Put locating pin guide of hybrid inverter protector assembly to the hybrid motor control inverter assembly.
      GTY994091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Locating Pin
    2. Install the hybrid inverter protector assembly to the hybrid motor control inverter 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 hybrid motor control inverter assembly with the bolt.

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

      GTY998431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the wire harness clamp bracket to the hybrid motor control inverter assembly with the 2 bolts.

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

      GTY998432Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the wire harness clamp bracket to the hybrid motor control inverter assembly with the bolt.

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

      GTY998435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 2 INVERTER BRACKET 
    NOTE:

    Make sure to support the hybrid motor control inverter assembly at the positions shown in the illustration, otherwise it may be damaged.

    GTY998052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Bottom of Hybrid Motor Control Inverter Assembly
    *b Support
    1. Set the hybrid motor control inverter assembly on wooden blocks.
      Fig 1: Hybrid Motor Control Inverter Tightening Sequence
      GTY998083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
    2. Temporarily install the No. 2 inverter bracket to the hybrid motor control inverter assembly with the 2 bolts.
    3. Fully tighten the 2 bolts in the order shown in the illustration.

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

  4. INSTALL NO. 1 INVERTER BRACKET 
    1. Temporarily install the No. 1 inverter bracket to the hybrid motor control inverter assembly with the 2 bolts.
      Fig 2: No. 1 Inverter Bracket Tightening Sequence
      GTY997913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
    2. Fully tighten the 2 bolts in the order shown in the illustration.

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

  5. INSTALL HYBRID MOTOR CONTROL INVERTER ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    1. Temporarily install the hybrid motor control inverter assembly with the 5 bolts and 2 nuts.
      NOTE:
      • When installing the hybrid motor control inverter assembly, be careful not to damage the parts around it.
      • To prevent damage, do not hold the hybrid motor control inverter 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 hybrid motor control inverter 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.
        GTY998125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Correct
        *b Incorrect

      HINT: 

      If the bolts and nuts are not tightened appropriately, the hybrid motor control inverter assembly may make an abnormal noise.

    2. Fully tighten the bolt (A).

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

      GTY997889Courtesy 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 hybrid motor control inverter assembly.
    • Adhere to the following installation procedure. Otherwise, the connector and the hybrid motor control inverter assembly may be damaged.
    1. Temporarily connect the motor cable to the hybrid motor control inverter 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 hybrid motor control inverter assembly during connection.
    2. Fully tighten the bolt (A).

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

      Fig 3: Hybrid Motor Control Inverter Assembly Tightening Sequence
      GTY997562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
    3. Fully tighten the 3 bolts in the order shown in the illustration to connect the motor cable to the hybrid motor control inverter 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 hybrid motor control inverter assembly during connection.
      GTY998545Courtesy 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 hybrid motor control inverter assembly during connection.
      • Be sure to use a torque wrench to tighten the bolts.
  7. INSTALL UPPER INVERTER COVER SUB-ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves.

    1. Install the upper inverter cover sub-assembly to the hybrid motor control inverter assembly with the 2 bolts.

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

      NOTE:
      • Visually confirm that the upper inverter cover sub-assembly waterproof seal is securely installed before installing the upper inverter cover sub-assembly.
      • Do not touch the waterproof seal of the upper inverter cover sub-assembly.
      • Make sure that the interlock is fully engaged.
      • Do not damage the terminals, interlock connector or hybrid motor control inverter assembly during installation.
      • Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
      • Do not remove or excessively tighten the screw of the upper inverter cover sub-assembly.
        GTY596586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Upper Inverter Cover Sub-assembly
        *a Do not remove or excessively tighten the screw
      • Although the upper inverter cover sub-assembly may feel loose, this is not due to a malfunction.
      • Push in the upper inverter cover sub-assembly until it contacts the hybrid motor control inverter assembly.
        GTY997763Courtesy 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 hybrid motor control inverter assembly and slide the clip to secure it.
      NOTE:
      • To prevent foreign matter from entering the hybrid motor control inverter 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 hybrid motor control inverter assembly.

      HINT: 

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

      GTY997705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Alignment Mark (Red)
      *b Rib
      *c 2 to 7 mm (0.0787 to 0.276 in.)
      *d Up
      *e LH Side
  9. CONNECT NO. 1 INVERTER COOLING HOSE 
    1. Connect the No. 1 inverter cooling hose to the hybrid motor control inverter assembly and slide the clip to secure it.
      NOTE:
      • To prevent foreign matter from entering the hybrid motor control inverter 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 hybrid motor control inverter assembly.

      HINT: 

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

      GTY998280Courtesy 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 
    NOTE:

    Before adjusting the transmission control cable assembly, check that the shift lever position sensor and shift lever are in N.

    1. Connect the transmission control cable assembly to the hybrid motor control inverter 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 hybrid motor control inverter assembly.

    1. GTY998518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Engage the 2 clamps and connect the engine wire to the hybrid motor control inverter assembly.

    2. Connect the engine wire to the hybrid motor control inverter assembly with the bolt.

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

    3. Engage the 2 clamps.
    4. Engage the clamp.
    5. Connect the shift lever position sensor connector.
    6. Connect the resolver (transmission fluid temperature sensor) connector.
    7. Connect the generator temperature sensor connector.
    8. Engage the clamp (B).
      GTY997753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Connect the engine wire to the intake manifold with the bolt.

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

    10. Engage the 2 clamps (A) and connect the No. 1 fuel vapor feed hose and No. 2 fuel vapor feed hose.
    11. Connect the EGR valve connector.
    12. Engage the clamp (B).
      GTY997196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Connect the engine wire to the hybrid motor control inverter assembly with the bolt.

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

    14. Engage the clamp (A) and connect the No. 1 fuel vapor feed hose.
    15. Connect the hybrid motor control inverter assembly connector and move the lock lever to lock them.
      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 hybrid motor control inverter assembly when connecting the connectors.
      GTY998466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. CONNECT FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Connect the HV floor under wire to the hybrid motor control inverter assembly with the 2 bolts.

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

      NOTE:
      • Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
      • Do not touch the waterproof seal or terminals of the connector.
      • Do not damage the terminals, connector housing or hybrid motor control inverter assembly when connecting the connector.
      GTY998000Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
    2. Connect the HV floor under wire to the hybrid motor control inverter assembly with the 2 bolts.

      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 hybrid motor control inverter 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 hybrid motor control inverter assembly.
      • Although the connector may feel loose, this is not due to a malfunction.
      GTY997439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
    3. Engage the clamp.
      GTY997274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    4. Install the wire harness clamp bracket to the hybrid motor control inverter assembly with the 2 bolts and nut.

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

    5. Install the wire harness clamp bracket to the hybrid motor control inverter assembly with the bolt and nut.

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

      GTY997542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    6. Install the wire harness clamp bracket to the hybrid motor control inverter assembly with the 2 bolts.
      GTY997681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    7. Install the 2 nuts.
      GTY997682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  13. 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 hybrid motor control inverter assembly.
      GTY997696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bolt.

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

    3. Connect the hybrid motor control inverter assembly connector and move the lock lever to lock them.
      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 hybrid motor control inverter assembly when connecting the connectors.
      GTY998463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL NO. 2 INVERTER PROTECTOR 
    1. Install the No. 2 inverter protector to the hybrid motor control inverter assembly with the 2 bolts.
      GTY997671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  15. INSTALL ECM 

    Refer to INSTALLATION [06/2020 - ]

  16. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 2

  17. INSTALL INLET AIR CLEANER ASSEMBLY 

    Refer to PROCEDURE - Step 3

  18. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 60

  19. INSTALL SERVICE PLUG GRIP 

    Refer to INSTALLATION [06/2020 - 10/2022] , or refer to INSTALLATION [10/2022 - ]

  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

  23. ADJUST SHIFT LEVER POSITION 

    Refer to ADJUSTMENT [06/2020 - ]

  24. PERFORM INITIALIZATION 

    Refer to WORK PROCEDURE [06/2020 - 12/2021] , or refer to WORK PROCEDURE [12/2021 - 10/2022] , or refer to WORK PROCEDURE [10/2022 - ]

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