Generator Cable: Replacement

NOTE:

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.

DISCONNECT BATTERY NEGATIVE TERMINAL
REMOVE SERVICE PLUG GRIP (SEE SERVICE PLUG GRIP )
REMOVE ENGINE UNDER COVER LH
REMOVE ENGINE UNDER COVER RH
DRAIN COOLANT (SEE REPLACEMENT )
REMOVE COWL TOP PANEL SUB-ASSY OUTER FRONT (SEE HYBRID CONTROL SYSTEM W/CONVERTER INVERTER ASSY )
REMOVE W/CONVERTER INVERTER ASSY (SEE HYBRID CONTROL SYSTEM W/CONVERTER INVERTER ASSY )
REMOVE GENERATOR CABLE
1. Zero bolt confirmation process.
  NOTE: Ensure that insulated gloves are worn when carrying out this procedure.
  1. Remove the 4 bolts and power cable cover.
    
    Fig 1: Removing Power Cable Cover
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Remove the two bolts from the generator cable.
    
    Fig 2: Removing Generator Cable
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
  
  Fig 3: Inspecting Voltage Between Each Of 3 Phase AC Terminals (U To V, V To W, U To W) And Body Earth
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 bolts and generator cable.
Fig 4: Removing Generator Cable
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR CABLE
1. Apply a small amount of ATF WS to the generator cable O-ring.
  
  Fig 5: Locating Generator Cable O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the generator cable as shown in the illustration.
  NOTE:
  - Connect by aligning the letters U, V and W.
  - Ensure that no foreign objects are attached to the O-ring when connecting the cables.
  Fig 6: Connecting Generator Cable
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the generator cable (terminals) with the 3 bolts.
  1. Torque: 8.5 N.m (87 kgf.cm, 71 in.lbf)
  Fig 7: Installing Generator Cable
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the generator cable with the 2 bolts.
  1. Torque: 5.8 N.m (59 kgf.cm, 51 in.lbf)
  Fig 8: Locating Generator Cable Bolts For Installation
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Apply seal packing 1281 in a continuous line of beads (diameter 1.5 mm) to the power cable cover.
  NOTE:
  - 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.
  Fig 9: Applying Seal Packing On Power Cable Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the power cable cover with the 4 bolts.
  1. Torque: 4.8 N.m (49 kgf.cm, 42 in.lbf)
Fig 10: Installing Power Cable Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL W/CONVERTER INVERTER ASSY (SEE HYBRID CONTROL SYSTEM W/CONVERTER INVERTER ASSY )
INSTALL COWL TOP PANEL SUB-ASSY OUTER FRONT (SEE HYBRID CONTROL SYSTEM W/CONVERTER INVERTER ASSY )
INSTALL ENGINE UNDER COVER RH
INSTALL ENGINE UNDER COVER LH
INSTALL SERVICE PLUG GRIP (SEE SERVICE PLUG GRIP )
CONNECT BATTERY NEGATIVE TERMINAL
ADD COOLANT (SEE REPLACEMENT )
CHECK FOR ENGINE COOLANT LEAKS (SEE ON-VEHICLE INSPECTION )
PERFORM INITIALIZATION (SEE INTRODUCTION )