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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 10 (Hybrid Battery Control System - Service Information (1 Of 2)) >> Inverter With Converter >> Installation [11/2023 - ] >> Procedure

Installation [11/2023 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL HYBRID INVERTER PROTECTOR ASSEMBLY 
    1. Temporarily install the hybrid inverter protector assembly to the inverter with converter assembly with the 4 bolts.
      NOTE:

      Make sure to align the guide of the hybrid inverter protector assembly with the pin.

      GTY1000713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin
    2. Fully tighten the bolt (A).

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

    3. Fully tighten the 3 bolts to install the hybrid inverter protector assembly to the inverter with converter assembly.

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

  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) 

    2. 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) 

    3. 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 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.

    GTY912955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Bottom of Inverter with Converter Assembly
    *b Support
    1. Set the inverter with converter assembly on wooden blocks.
      GTY924661Courtesy 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.
      GTY907972Courtesy 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.
        GTY876546Courtesy 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).
      GTY894035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    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. 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) 

  7. 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.

    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 connector.
      • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
    2. Fully tighten the bolt (A).
      GTY883438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
      *b 10 mm Union Nut Wrench Fulcrum Length
      *c Torque Wrench Fulcrum Length

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

    3. Fully tighten the 2 bolts in the order shown in the illustration.

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

    4. Using a 10 mm union nut wrench, fully tighten the bolt (B) to connect the motor cable to the inverter with converter assembly.

      Specified tightening torque 

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

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
      • When using a 10 mm union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

        7.0 N.m (71 kgf/cm, 62 in.lbf)

    5. Temporarily install the 6 bolts.
      NOTE:
      • To prevent the threads from being damaged, temporarily tighten the 6 bolts by hand.
      • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
      • Do not touch the waterproof seal or terminals of the connector.
      GTY880269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. 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 connector.
      • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
      • Be sure to use a torque wrench to tighten the bolts.
  8. 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 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.
        GTY872543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a No Gap
  9. 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.
      GTY888806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Alignment Mark
      *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.

  10. 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.

      GTY940265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Alignment Mark
      *b Rib
      *c 2 to 7 mm (0.0787 to 0.276 in.)
      *d Up
      *e LH Side
  11. 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 connect 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) 

  12. 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 to 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.

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

      GTY880205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the engine wire to the inverter with converter assembly with the bolt.

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

      GTY880208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 2 clamps (B).
      GTY874646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Connect the engine wire to the inverter with converter assembly with the bolt.

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

    12. Engage the 3 clamps (A) to connect the No. 1 fuel vapor feed hose.
    13. Connect the inverter with converter assembly connector and move the lock lever to lock them.
      GTY880234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not touch the waterproof seal or terminals of the connector.
      • To prevent damage due to static electricity, do not touch the terminals of the disconnected connector.
      • Do not damage the terminals, connector housing or inverter with converter assembly when connecting the connector.
  13. 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) 

  14. CONNECT HV AIR CONDITIONING WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Engage the clamp to 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.
      GTY860075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
    2. Install the 2 bolts.

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

  15. CONNECT FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Install the 2 bolts to 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.
      GTY879275Courtesy 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.

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

      GTY877739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. for AWD:
      1. Connect the HV floor under wire to the inverter with converter 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 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.
        GTY842821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Waterproof Seal
  16. 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.
      GTY935424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not touch the waterproof seal or terminals of the connector.
      • To prevent damage due to static electricity, do not touch the terminals of the disconnected connector.
      • Do not damage the terminals, connector housing or inverter with converter assembly when connecting the connector.
  17. INSTALL NO. 2 INVERTER PROTECTOR 
    1. Install the No. 2 inverter protector to the inverter with converter assembly with the 2 nuts.

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

  18. INSTALL ECM 

    Refer to INSTALLATION [11/2023 - ]

  19. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE 
    1. Install the air cleaner cap with air cleaner hose to the throttle body with motor assembly.
      NOTE:

      Align the cutout of the air cleaner hose with the protrusion of the throttle body with motor assembly.

      GTY900131Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Cutout
      *c Hose Clamp End
      *d Paint Mark
      *e 2 mm (0.0787 in.)
      *f 4 mm (0.157 in.)
      *g End of Hose Clamp Location
    2. Tighten the hose clamp in the position shown in the illustration.
      NOTE:

      Make sure that the end of the hose clamp is positioned as shown in the illustration.

    3. Connect the No. 2 ventilation hose to the cylinder head cover sub-assembly and slide the clip to secure it.

      HINT: 

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

      GTY894038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Up
      *b Front of Vehicle
      *c 45°(Claw of Clip Location)
      *d Paint Mark
    4. Engage the 2 grommets and pin to install the air cleaner assembly with air cleaner hose.
    5. Engage the wire harness clamp.
    6. Connect the mass air flow meter sub-assembly connector.
  20. INSTALL INLET AIR CLEANER ASSEMBLY 
    1. Temporarily install the inlet air cleaner assembly with the 2 bolts.
      GTY932912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Fully tighten the 2 bolts in the order shown in the illustration.

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

  21. INSTALL COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 4

  22. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 64

  23. INSTALL SERVICE PLUG GRIP 

    Refer to INSTALLATION [11/2023 - ]

  24. ADD COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 2

  25. INSPECT FOR COOLANT LEAK (for Inverter) 

    See step  1

  26. PERFORM INITIALIZATION 

    Refer to WORK PROCEDURE [11/2023 - ]

  27. INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL 

    HINT: 

    When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

    Refer to AUTOMATIC LEARNING CHART [11/2023 - ]

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