Diesel Data: Automotive Repair
Home >> Toyota >> 2009 >> Prius L4-1.5L (1NZ-FXE) Hybrid >> Repair and Diagnosis >> Hybrid Drive Systems >> Battery System, Hybrid Drive >> Hybrid Battery Bus / Cable >> Service and Repair >> Hybrid Vehicle Control Frame Wire >> Removal

Removal








P112 HYBRID VEHICLE CONTROL: FRAME WIRE: REMOVAL

REMOVAL
CAUTION:
- When working on high voltage systems, always wear insulating gloves.
- 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.
NOTE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU.

1. PRECAUTION
CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/removal, inspection and replacement of parts), be sure to follow the procedures Service Precautions.

2. REMOVE FRONT WHEEL
3. REMOVE REAR NO. 2 FLOOR BOARD Removal
4. REMOVE REAR DECK FLOOR BOX Removal
5. REMOVE REAR NO. 3 FLOOR BOARD Removal
6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

7. REMOVE SERVICE PLUG GRIP Removal
8. REMOVE REAR DECK TRIM COVER Removal
9. REMOVE TONNEAU COVER Removal
10. REMOVE REAR SEAT CUSHION ASSEMBLY Removal
11. REMOVE REAR NO. 1 FLOOR BOARD Removal
12. REMOVE REAR SIDE SEATBACK FRAME LH Removal
13. REMOVE REAR NO. 4 FLOOR BOARD Removal
14. REMOVE DECK FLOOR BOX LH Removal
15. REMOVE DECK TRIM SIDE PANEL LH Removal
16. REMOVE BATTERY CARRIER BRACKET Removal
17. REMOVE REAR DOOR SCUFF PLATE LH





(a) Remove the clip and 4 joints shown in the illustration, and 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 NO. 6 BATTERY CARRIER PANEL Removal
20. REMOVE JUNCTION TERMINAL
CAUTION: Wear insulating gloves.

21. REMOVE FRAME WIRE




CAUTION: Wear insulating gloves.

(a) Remove the 2 nuts, then remove the frame wire from the No. 2 and No. 3 system main relay.
CAUTION: 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 WINDSHIELD WIPER ARM COVER
23. REMOVE FRONT WIPER ARM LH Removal
24. REMOVE FRONT WIPER ARM RH Removal
25. REMOVE HOOD TO COWL TOP SEAL Removal
26. REMOVE COWL TOP VENTILATOR LOUVER LH Removal
27. REMOVE COWL TOP VENTILATOR LOUVER RH Removal
28. REMOVE FRONT WIPER LINK AND WIPER MOTOR ASSEMBLY Removal
29. REMOVE FRONT COWL TOP PANEL OUTER Removal
30. SEPARATE FRAME WIRE




CAUTION: 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 inverter with converter assembly.
(f) Disconnect the clamp, then disconnect the frame wire from the dash panel bracket.
31. REMOVE COLUMN HOLE COVER SILENCER SHEET Removal
32. SEPARATE STEERING INTERMEDIATE SHAFT Removal
33. REMOVE NO. 3 ENGINE UNDER COVER
34. REMOVE NO. 4 ENGINE UNDER COVER CENTER Removal
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 NO. 1 WIRE HARNESS PROTECTOR
CAUTION: Wear insulating gloves.

(a) Remove the 2 nuts, bolt and wire harness protector.
38. SEPARATE FRONT SUSPENSION CROSSMEMBER





(a) Support the front suspension crossmember using a jack.





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




CAUTION: 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 labeled 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 labeled B.
(e) Disconnect the fit-in clamps, then remove the frame wire.





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