Diesel Data: Automotive Repair
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Frame Wire






















FRAME WIRE
REPLACEMENT

NOTICE:
^ When working on the high voltage systems, always wear insulating gloves.
^ After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU.
^ Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle.
^ After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes.

1. PRECAUTION
2. REMOVE FRONT WHEELS
3. REMOVE REAR FLOOR BOARD NO.2
4. REMOVE DECK FLOOR BOX REAR
5. REMOVE REAR FLOOR BOARD NO.3
6. DISCONNECT BATTERY NEGATIVE TERMINAL
7. REMOVE SERVICE PLUG GRIP
8. REMOVE DECK TRIM COVER REAR
9. REMOVE TONNEAU COVER ASSY
10. REMOVE REAR SEAT CUSHION ASSY
11. REMOVE REAR FLOOR BOARD NO.1
12. REMOVE REAR SIDE SEAT BACK FRAME LH
13. REMOVE REAR FLOOR BOARD NO.4
14. REMOVE DECK FLOOR BOX LH
15. REMOVE DECK TRIM SIDE PANEL ASSY LH
16. REMOVE BATTERY CARRIER BRACKET





17. REMOVE REAR DOOR SCUFF PLATE LH
a. Remove the clip and 4 joints shown in the illustration, then remove the rear door scuff plate.
18. REMOVE FLOOR SIDE PANEL LH





a. Remove the clip, then roll back the carpet.





b. Remove the clip from the floor side panel.
c. Remove the 3 bolts and floor side panel.
19. REMOVE BATTERY CARRIER PANEL NO.6

NOTICE: Wear insulating gloves.

20. REMOVE JUNCTION TERMINAL

NOTICE: Wear insulating gloves.

21. REMOVE FRAME WIRE (RR POSITION)

NOTICE: Wear insulating gloves.





a. Remove the 2 nuts, then remove the frame wire from the system main relay No. 2 and No. 3.

NOTICE: Insulate the removed terminals with insulating tape.





b. Remove the clamps, then remove the frame wire from the rear floor.





c. Remove the 2 clamps, then disconnect the frame wire from the center floor panel.
d. Disconnect the connector.
e. Disconnect the grommet.
22. REMOVE FRONT WIPER ARM HEAD CAP
23. REMOVE FR WIPER ARM LH
24. REMOVE FR WIPER ARM RH
25. REMOVE HOOD TO COWL TOP SEAL
26. REMOVE COWL TOP VENTILATOR LOUVER LH
27. REMOVE COWL TOP VENTILATOR LOUVER RH
28. REMOVE WINDSHIELD WIPER LINK ASSY
29. REMOVE COWL TOP PANEL SUB-ASSY OUTER FRONT
30. SEPARATE FRAME WIRE (FR POSITION)

NOTICE: Wear insulating gloves.





a. Flip open the cover of the jump start terminal on the engine room relay block.





b. Remove the side cover by sliding it upward.
c. Remove the nut, then disconnect the frame wire from the engine room relay block.
d. Disconnect the clamp, then disconnect the frame wire from the side member.





e. Remove the 2 frame wire connectors shown in the illustration from the with converter inverter assembly.
f. Disconnect the clamp, then disconnect the frame wire from the dash panel bracket.
31. REMOVE COLUMN HOLE COVER SILENCER SHEET
32. SEPARATE STEERING INTERMEDIATE SHAFT
33. REMOVE ENGINE UNDER COVER RH
34. REMOVE ENGINE UNDER COVER LH





35. REMOVE FRONT FLOOR COVER LH
a. Remove the 6 clips and front floor cover LH.





36. REMOVE FRONT FLOOR COVER CENTER LH
a. Remove the 5 clips and front floor cover center LH.





37. REMOVE WIRING HARNESS PROTECTOR NO.1

NOTICE: Wear insulating gloves.

a. Remove the 2 nuts, bolt and wiring harness protector No. 1.

38. SEPARATE FRONT SUSPENSION CROSSMEMBER SUB-ASSY





a. Support the front suspension cross member using a jack.





b. Remove the 4 bolts shown in the illustration from the front suspension crossmember.
39. REMOVE FRAME WIRE

NOTICE: Wear insulating gloves.





a. Remove the 2 bolts shown in the illustration.
b. Disconnect the 2 clamps.
c. Lower the jack a little and remove both nuts A.

NOTICE:
^ Lower the jack slowly to avoid interfering with objects loaded on the front suspension crossmember.
^ Do not remove the jack.

d. Remove both nuts B.





e. Disconnect the fit in clamp, then remove the frame wire.
40. INSTALL FRAME WIRE

NOTICE: Wear insulating gloves.

a. Temporarily fasten the frame wire to the vehicle.
b. Connect the fit in clamp to the stud in the floor panel, then install the frame wire with both nuts A.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)





c. Install both nuts B shown in the illustration.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)





d. As shown in the illustration, point the arrow on the grommet in the front direction, then install the grommet.
e. Install the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
f. Install the 2 clamps.





41. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSY
a. Install the front suspension crossmember with the 4 bolts.
Torque:
113 Nm (1,152 kgf-cm, 83 ft. lbs.) for bolt A
157 Nm (1,601 kgf-cm, 116 ft. lbs.) for bolt B
b. Remove the jack.





42. INSTALL WIRING HARNESS PROTECTOR NO.1

NOTICE: Wear insulating gloves.

a. Install the wiring harness protector No. 1 with the 2 bolts and nut.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
43. INSTALL FRONT FLOOR COVER CENTER LH
44. INSTALL FRONT FLOOR COVER LH
45. INSTALL ENGINE UNDER COVER RH
46. INSTALL ENGINE UNDER COVER LH
47. INSTALL STEERING INTERMEDIATE SHAFT
48. INSTALL COLUMN HOLE COVER SILENCER SHEET
49. INSTALL FRAME WIRE (FR POSITION)

NOTICE: Wear insulating gloves.





a. Connect the 2 connectors shown in the illustration to the with converter inverter assembly.
b. Connect the clamp to the engine room relay block with the nut.





c. Install the frame wire to the engine room relay block with the nut.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
d. Install the side cover to the engine room relay block.
e. Install the frame wire clamp to the side member.
50. INSTALL COWL TOP PANEL SUB-ASSY OUTER FRONT
51. INSTALL WINDSHIELD WIPER LINK ASSY
52. INSTALL COWL TOP VENTILATOR LOUVER RH
53. INSTALL COWL TOP VENTILATOR LOUVER LH
54. INSTALL HOOD TO COWL TOP SEAL
55. INSTALL FR WIPER ARM LH
56. INSTALL FR WIPER ARM RH
57. INSTALL FRONT WIPER ARM HEAD CAP
58. INSTALL FRAME WIRE (RR POSITION)

NOTICE: Wear insulating gloves.

a. Connect the connector.





b. Install the 2 clamps, then connect the frame wire to the center floor panel.





c. Install the frame wire to the rear floor panel with the clamp.





d. Install the frame wire to the system main relay No. 2 and No. 3 with 2 new nuts.
Torque: 5.6 Nm (57 kgf-cm, 50 inch lbs.)
59. INSTALL JUNCTION TERMINAL

NOTICE: Wear insulating gloves.

60. INSTALL BATTERY CARRIER PANEL NO.6
61. INSTALL FLOOR SIDE PANEL LH
a. Install the clip.





b. Install the floor side panel with the 3 bolts.





c. Install the carpet with the clip.
62. INSTALL REAR DOOR SCUFF PLATE LH
63. INSTALL BATTERY CARRIER BRACKET
64. INSTALL DECK TRIM SIDE PANEL ASSY LH
65. INSTALL DECK FLOOR BOX LH
66. INSTALL REAR FLOOR BOARD NO.4
67. INSTALL REAR SIDE SEAT BACK FRAME LH
68. INSTALL REAR FLOOR BOARD NO.1
69. INSTALL REAR SEAT CUSHION ASSY
70. INSTALL TONNEAU COVER ASSY
71. INSTALL DECK TRIM COVER REAR
72. INSTALL SERVICE PLUG GRIP

NOTICE: Wear insulating gloves.

73. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 6.0 Nm (61 kgf-cm, 53 inch lbs.)
74. INSTALL REAR FLOOR BOARD NO.3
75. INSTALL DECK FLOOR BOX REAR
76. INSTALL REAR FLOOR BOARD NO.2
77. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
78. POWER WINDOW CONTROL SYSTEM INITIALIZE





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