Generator Cable Replacement

GENERATOR CABLE
REPLACEMENT

NOTICE:
^ When working on the high voltage systems, always wear insulated 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. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE SERVICE PLUG GRIP
3. REMOVE ENGINE UNDER COVER LH
4. REMOVE ENGINE UNDER COVER RH
5. DRAIN COOLANT
6. REMOVE COWL TOP PANEL SUB-ASSY OUTER FRONT
7. REMOVE W/CONVERTER INVERTER ASSY
8. REMOVE GENERATOR CABLE
a. Zero bolt confirmation process.

NOTICE: Ensure that insulated gloves are worn when carrying out this procedure.





1. Remove the 4 bolts and power cable cover.





2. Remove the two bolts from the generator cable.





3. Inspect the voltage between each of the 3 phase AC terminals (U to V, V to W, U to W) and body earth using the Toyota electrical tester.
Standard value: 0 V

HINT: Use the Toyota Electrical Tester on measured ranges of DC 400 volts or more.





b. Remove the 3 bolts and generator cable.
9. INSTALL GENERATOR CABLE





a. Apply a small amount of ATF WS to the generator cable O-ring.





b. Connect the generator cable as shown in the illustration.

NOTICE:
^ Connect by aligning the letters U, V and W.
^ Ensure that no foreign objects are attached to the O ring when connecting the cables.





c. Install the generator cable (terminals) with the 3 bolts.
Torque: 8.5 Nm (87 kgf-cm, 71 inch lbs.)





d. Install the generator cable with the 2 bolts.
Torque: 5.8 Nm (59 kgf-cm, 51 inch lbs.)





e. Apply seal packing 1281 in a continuous line of beads (diameter 1.5 mm) to the power cable cover.

NOTICE:
^ Clean and degrease the installation surfaces.
^ Install within 10 minutes of applying seal packing.
^ Ensure that no foreign objects are inserted when the power cable cover is attached.





f. Install the power cable cover with the 4 bolts.
Torque: 4.8 Nm (49 kgf-cm, 42 inch lbs.)
10. INSTALL W/CONVERTER INVERTER ASSY
11. INSTALL COWL TOP PANEL SUB-ASSY OUTER FRONT
12. INSTALL ENGINE UNDER COVER RH
13. INSTALL ENGINE UNDER COVER LH
14. INSTALL SERVICE PLUG GRIP
15. CONNECT BATTERY NEGATIVE TERMINAL
16. ADD COOLANT
17. CHECK FOR ENGINE COOLANT LEAKS
18. PERFORM INITIALIZATION