GENERATOR CABLE > REMOVAL

for Preparation Click here

HINT:

(Click here)

NOTICE:

After the power switch is turned off, the navigation receiver assembly (HDD navigation system) records various types of memory and settings. As a result, after turning the power switch off, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-) battery terminal.

1. Disengage the 2 guides <A> as shown in the illustration.
   

2. Disengage the 3 guides <B> and remove the rear No. 2 floor board.
   

1. Remove the rear deck floor box.
   

1. Disengage the 2 guides and remove the rear No. 3 floor board.
   

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).

CAUTION:

1. Wear insulating gloves.
   
2. Remove the service plug grip to interrupt the high voltage circuit at the time of inspection or repair.
   
3. Keep the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.
   
4. All the high voltage wiring connectors are colored in orange.
   

1. Wear insulating gloves and remove the service plug grip after sliding up the lever of the service plug grip as shown in the illustration.
   
   

   
   
   
   

   CAUTION:

   1. Keep the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.
      
   2. After removing the service plug grip, do not touch the high voltage connectors or terminals for 10 minutes.
      

   HINT:

   Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

NOTICE:

Do not remove the reservoir tank cap, cylinder block drain cock plugs and radiator drain cock plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

1. Loosen the radiator drain cock plug and drain the coolant.
   

   HINT:

   Collect the coolant in a container and dispose of it according to the local regulations.

2. Loosen the cylinder block drain cock plug.
   

   HINT:

   The plug is on the back of the generator on the exhaust manifold side.

   
   
   
   
   
   
   

   Text in Illustration 

   *1	Reservoir Tank Cap	*2	Cylinder Block Drain Cock Plug
   *3	Radiator Drain Cock Plug	*4	Air Release Valve

NOTICE:

1. Do not reuse the drained coolant because it may contain foreign objects.
   
2. Collect the drained coolant and measure its volume to establish a benchmark. When adding coolant, make sure to add more coolant than the measured amount.
   

1. Remove the reserve tank cap.
   

   CAUTION:

   To avoid the danger of being burned, do not remove the reserve tank cap while the coolant for the inverter is still hot.

2. Using a hexagon wrench (10 mm), remove the drain plug indicated in the illustration and drain the coolant.
   

   CAUTION:

   Use caution when handling coolant immediately after driving or in summer because it may be hot.

3. Install the plug with a new gasket.
   

   Torque:

   39 N*m{ 397 kgf*cm , 29 ft.*lbf }

1. Remove the 3 clips.
   

2. Disengage the 2 claws and remove the radiator support opening cover.
   

1. Remove the 3 bolts and No. 1 inverter bracket.
   

1. Raise the lock lever and disconnect the inverter with converter connector.
   

2. Disconnect the engine wire from the engine room main wire.
   

3. Remove the bolt.
   

4. Remove the bolt, clamp and clip, and disconnect the engine room main ware.
   

CAUTION:

Wear insulating gloves.

1. Remove the 9 bolts and inverter terminal cover.
   

   NOTICE:

   Make sure to pull the inverter terminal cover straight up, as a connector is connected to the bottom of the cover.

CAUTION:

Wear insulating gloves.

NOTICE:

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

1. Using a voltmeter, measure the voltage between the terminals of the 2 phase connectors.
   

   Standard voltage:

   0 V
   

   HINT:

   Use measuring range of DC 750 V or more on the voltmeter.

CAUTION:

Wear insulating gloves.

NOTICE:

1. Insulate the removed terminals with insulating tape.
   
2. Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter.
   

1. Remove the 4 bolts, and disconnect the frame wire (high voltage cables of the hybrid battery) from the inverter with converter assembly.
   

2. Disconnect the harness clamp.
   

CAUTION:

Wear insulating gloves.

NOTICE:

1. Insulate the removed terminals with insulating tape.
   
2. Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter.
   

1. Remove the 5 bolts, and disconnect the high voltage cables of the generator (MG1) from the inverter with converter assembly.
   

2. Turn back the wire harness cover and release the cable.
   

3. Remove the 5 bolts, and disconnect the high voltage cables of the motor (MG2) from the inverter with converter assembly.
   

4. Disconnect the harness clamp.
   

CAUTION:

Wear insulating gloves.

NOTICE:

1. Insulate the removed terminals with insulating tape.
   
2. Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter.
   

1. Remove the 4 bolts, and disconnect the No. 2 engine wire (high voltage cables for the air conditioning compressor) from the inverter with converter assembly.
   

2. Disconnect the harness clamp.
   

1. Temporarily install the inverter terminal cover with the 9 bolts to prevent any foreign objects or water from entering the inverter with converter assembly.
   

1. Remove the relay block cover.
   

2. Release the 2 clamps, and remove the No. 1 relay block cover.
   

3. Remove the bolt from the No. 2 engine room wire.
   

4. Release the 2 claws, and disconnect the No. 2 engine room wire.
   

5. Connect the No. 2 engine room wire to the protector.
   

1. Release the retainer and disconnect the water hose from the inverter with converter assembly.
   

2. Release the retainer and disconnect the water hose from the inverter with converter assembly.
   

3. Disconnect the coolant hose from the inverter with converter assembly. Put a piece of cloth in the pipe and in the disconnected hose or cover the pipe and hose with plastic bags as shown in the illustration, so that foreign matter doesn't stick to the union or the inside of the connector and to prevent coolant from spilling near the inverter with converter assembly.
   

CAUTION:

Wear insulating gloves.

1. Remove the 3 bolts and inverter with converter assembly.
   

   NOTICE:

   1. Since the inverter with converter assembly is very heavy, 2 people are needed to remove the inverter with converter assembly. When removing the inverter with converter assembly, do not damage the parts around it.
      
   2. To prevent damage, do not hold the inverter with converter assembly by the connectors.
      
   3. To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.
      

1. Remove the 2 bolts and inverter reserve tank assembly.
   

1. Separate the 2 clamps.
   

2. Remove the 5 bolts and inverter tray bracket.
   

1. Disconnect the clamps, No. 1 radiator hose, No. 4 water by-pass hose and No. 3 radiator hose.
   

2. Remove the 2 bolts and radiator pipe.
   

NOTICE:

Wear insulated gloves.

1. Disconnect the generator cable clamp from the motor cable bracket.
   

2. Remove the 3 bolts and slide the generator cable connector shell back.
   

3. Disengage the 2 claws to remove the terminal cap.
   

4. Remove the 3 bolts and generator cable from the hybrid transaxle assembly.