Lexus ES manuals

Lexus ES: Installation

Lexus ES (XZ10) Service Manual / Engine & Hybrid System / Hybrid / Battery Control / Inverter With Converter / Installation

INSTALLATION

PROCEDURE

1. INSTALL INVERTER PROTECTOR

(a) Install the inverter protector to the inverter with converter assembly with the bolt.

Torque:

9.5 N·m {97 kgf·cm, 84 in·lbf}

NOTICE:

Make sure to align the hole of the inverter protector with the pin.

*a

Pin

2. INSTALL WIRE HARNESS CLAMP BRACKET

(a) 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}

(b) 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}

(c) 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}

3. INSTALL NO. 2 INVERTER BRACKET

NOTICE:

Make sure to support the inverter with converter assembly at the positions shown in the illustration, otherwise it may be damaged.

*a

Bottom of Inverter with Converter Assembly

*b

Support

(a) Set the inverter with converter assembly on wooden blocks.

*a

Wooden Block

(b) Temporarily install the No. 2 inverter bracket to the inverter with converter assembly with the 2 bolts.

(c) 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

(a) Temporarily install the No. 1 inverter bracket to the inverter with converter assembly with the 2 bolts.

*a

Wooden Block

(b) 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

CAUTION:

Be sure to wear insulated gloves.

(a) Temporarily install the inverter with converter assembly with the 5 bolts and 2 nuts.

NOTICE:

  • 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.

    *a

    Correct

    *b

    Incorrect

HINT:

If the bolts and nuts are not tightened appropriately, the inverter with converter assembly may make an abnormal noise.

(b) Fully tighten the bolt (A).

Torque:

55 N·m {561 kgf·cm, 41 ft·lbf}

(c) Fully tighten the 3 bolts (B).

Torque:

55 N·m {561 kgf·cm, 41 ft·lbf}

(d) Fully tighten the bolt (C).

Torque:

55 N·m {561 kgf·cm, 41 ft·lbf}

(e) Fully tighten the 2 nuts (D).

Torque:

55 N·m {561 kgf·cm, 41 ft·lbf}

6. CONNECT MOTOR CABLE

CAUTION:

Be sure to wear insulated gloves.

NOTICE:

Do not allow any foreign matter or water to enter the inverter with converter assembly.

(a) Temporarily connect the motor cable to the inverter with converter assembly with the 4 bolts.

NOTICE:

  • 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.

(b) Fully tighten the bolt (A).

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

*a

Waterproof Seal

(c) 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}

(d) Temporarily install the 6 bolts.

NOTICE:

  • 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.

(e) Using an insulated tool, fully tighten the 6 bolts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

NOTICE:

  • 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

CAUTION:

Be sure to wear insulated gloves.

(a) 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}

NOTICE:

  • 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.

    *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.

    *a

    No Gap

8. CONNECT NO. 4 INVERTER COOLING HOSE

(a) Connect the No. 4 inverter cooling hose to the inverter with converter assembly and slide the clip to secure it.

NOTICE:

  • 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.

*a

Alignment Mark (Orange)

*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

(a) Connect the No. 1 inverter cooling hose to the inverter with converter assembly and slide the clip to secure it.

NOTICE:

  • 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.

*a

Alignment Mark (Blue)

*b

Rib

*c

2 to 7 mm (0.0787 to 0.276 in.)

*d

Up

*e

LH Side

10. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) 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}

(b) Turn the control shaft lever clockwise until it stops, then turn it counterclockwise 2 notches.

(c) Engage the 2 claws to install a new clip to the transmission control cable assembly.

(d) Using a screwdriver, engage the 4 claws and install the transmission control cable assembly to the No. 1 transmission control cable bracket.

NOTICE:

  • 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.

*1

Transmission Control Cable Assembly

*2

No. 1 Transmission Control Cable Bracket

*a

Claw (A)

*b

Claw (B)

(e) 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

CAUTION:

Be sure to wear insulated gloves.

NOTICE:

Do not allow any foreign matter or water to enter the inverter with converter assembly.

(a) Engage the 2 clamps and connect the engine wire to the inverter with converter assembly.

(b) Temporarily install the nut.

NOTICE:

To prevent the threads from being damaged, temporarily tighten the nut by hand.

(c) Fully tighten the nut.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Engage the 2 claws to close the engine wire terminal cover.

(e) Connect the engine wire to the inverter with converter assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(f) Connect the engine wire to the inverter with converter assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(g) Engage the 2 clamps.

(h) Engage the clamp.

(i) 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.

(j) Engage the clamp (B).

(k) Connect the engine wire to the intake manifold with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(l) Engage the 2 clamps (A) and connect the No. 1 fuel vapor feed hose and No. 2 fuel vapor feed hose.

(m) Engage the 2 clamps (B).

(n) Connect the engine wire to the inverter with converter assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(o) Engage the 3 clamps (A) and connect the No. 1 fuel vapor feed hose.

(p) Connect the inverter with converter assembly connector and move the lock lever to lock it.

NOTICE:

  • 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

(a) 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}

13. CONNECT HV AIR CONDITIONING WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Engage the clamp and connect the HV air conditioning wire to the inverter with converter assembly.

NOTICE:

  • 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.

*a

Waterproof Seal

(b) Install the 2 bolts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

14. CONNECT FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Engage the 2 clamps and connect the HV floor under wire to the inverter with converter assembly.

NOTICE:

  • 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.

*a

Waterproof Seal

(b) Install the 2 bolts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

15. CONNECT ENGINE ROOM MAIN WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Engage the clamp to connect the engine room main wire to the inverter with converter assembly.

(b) Install the bolt.

Torque:

12.5 N·m {127 kgf·cm, 9 ft·lbf}

(c) Connect the inverter with converter assembly connector and move the lock lever to lock it.

NOTICE:

  • 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 ECM

Click here

17. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE

(a) Install the air cleaner assembly with air cleaner hose to the throttle body with motor assembly.

NOTICE:

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

*a

Protrusion

*b

Cutout

*c

Hose Clamp Tip

*d

Alignment Mark (Blue)

*e

2 mm (0.0787 in.)

*f

4 mm (0.157 in.)

*g

End of Hose Clamp Location

(b) Tighten the hose clamp in the position shown in the illustration.

NOTICE:

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

(c) 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.

*a

Top

*b

Front of Vehicle

*c

Alignment Mark (Yellow)

(d) Engage the 2 grommets and pin to install the air cleaner assembly with air cleaner hose.

(e) Engage the wire harness clamp.

(f) Connect the mass air flow meter sub-assembly connector.

18. INSTALL INLET AIR CLEANER ASSEMBLY

(a) Temporarily install the inlet air cleaner assembly with the 2 bolts.

(b) Fully tighten the 2 bolts in the order shown in the illustration.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

19. INSTALL COOL AIR INTAKE DUCT SEAL

Click here

20. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

Click here

21. INSTALL SERVICE PLUG GRIP

Click here

22. ADD COOLANT (for Inverter)

Click here

23. INSPECT FOR COOLANT LEAK (for Inverter)

Click here

24. PERFORM INITIALIZATION

Click here

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