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GENERATOR CABLE > INSTALLATION

for Preparation Click here



1. INSTALL GENERATOR CABLE

NOTICE:
Wear insulated gloves.

  1. Install the generator cable to the hybrid transaxle assembly with the 3 bolts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }

    NOTICE:
    Keep the sealing surface of the generator cable and the connector terminal joint free of foreign matter.

  1. Engage the 2 claws to install a new terminal cap.

    NOTICE:
    When installing the terminal cap to the generator cable terminal block, keep the sealing surface free of foreign matter.



    C209804

  1. Place the generator cable connector shell in position and install it with the 3 bolts.

    Torque:
    20 N*m{ 204 kgf*cm , 15 ft.*lbf }

  1. Connect the generator cable clamp to the motor cable bracket.



2. INSTALL RADIATOR PIPE

  1. Install the radiator pipe with the 2 bolts.

    Torque:
    19 N*m{ 194 kgf*cm , 14 ft.*lbf }

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



3. INSTALL INVERTER TRAY BRACKET


    A213025E01

  1. Position the inverter tray bracket as shown in the illustration.

  1. Temporarily install bolt B to the inverter tray bracket.

  1. Tighten the 5 bolts to the inverter tray bracket in the order bolt A, bolt C, bolt D, bolt E and bolt B.

    Torque:
    18 N*m{ 184 kgf*cm , 13 ft.*lbf }

  1. Connect the 2 clamps to the inverter tray bracket.



4. INSTALL INVERTER RESERVE TANK ASSEMBLY


    A248099E01

  1. Temporarily install bolt A to the inverter reserve tank assembly.

  1. Tighten the 2 bolts to the inverter reserve tank assembly in the order bolt B and bolt A.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }



5. INSTALL INVERTER WITH CONVERTER ASSEMBLY

CAUTION:
Wear insulating gloves.



    A214665E02

  1. Temporarily install the inverter with converter assembly with the 3 bolts.

    NOTICE:
    1. Since the inverter with converter assembly is very heavy, 2 people are needed to install the inverter with converter assembly. When installing 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. Tighten bolt A.

    Torque:
    12 N*m{ 122 kgf*cm , 8 ft.*lbf }

  1. Tighten the 2 bolts.

    Torque:
    12 N*m{ 122 kgf*cm , 8 ft.*lbf }



6. CONNECT WATER HOSE


    A214662E01

  1. Connect the water hose to the inverter with converter assembly and lock the hose with the retainer.

    NOTICE:
    1. Insert the retainer until a click sound is heard.
    2. Pull on the hose to confirm that the hose is securely connected.
    3. If there is foreign matter on the union or the O-ring, clean it with water and finger scouring.



    A214664E01

  1. Connect the water hose to the inverter with converter assembly and lock the hose with the retainer.

    NOTICE:
    1. Insert the retainer until a click sound is heard.
    2. Pull on the hose to confirm that the hose is securely connected.
    3. If there is foreign matter on the union or the O-ring, clean it with water and finger scouring.



7. CONNECT NO. 2 ENGINE ROOM WIRE

  1. Disconnect the No. 2 engine room wire from the protector.

  1. Connect the No. 2 engine room wire with the bolt and 2 claws.

    Torque:
    8.3 N*m{ 85 kgf*cm , 73 in.*lbf }

    NOTICE:
    Pass the No. 2 engine room wire under the two cooling hoses that pass beside the inverter.

  1. Install the No. 1 relay block cover and 2 clamps.

  1. Install the relay block cover.



8. REMOVE INVERTER COVER

CAUTION:
Wear insulating gloves.

  1. Remove the 9 bolts and inverter cover.

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



9. CONNECT NO. 2 ENGINE WIRE

CAUTION:
Wear insulating gloves.

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



    A248444E01

  1. Temporarily install the No. 2 engine wire (high voltage cables of the air conditioning) and 4 bolts to the inverter assembly by hand.

  1. Fully tighten the 4 bolts.

    Torque:
    Bolt A:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }
    Bolt B:
    9.2 N*m{ 94 kgf*cm , 81 in.*lbf }

    NOTICE:
    Be sure to use a torque wrench to tighten the bolts.

  1. Connect the harness clamp.



10. CONNECT MOTOR CABLE

CAUTION:
Wear insulating gloves.

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



    A248443E01

  1. Temporarily install the high voltage cable of the motor (MG2) and 5 bolts to the inverter assembly by hand.

  1. Fully tighten the 5 bolts.

    Torque:
    Bolt A:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }
    Bolt B:
    9.2 N*m{ 94 kgf*cm , 81 in.*lbf }

    NOTICE:
    Be sure to use a torque wrench to tighten the bolts.

  1. Connect the harness clamp.



11. CONNECT GENERATOR CABLE

CAUTION:
Wear insulating gloves.

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



    A248442E01

  1. Temporarily install the high voltage cable of the generator cable (MG1) and 5 bolts to the inverter assembly by hand.

  1. Fully tighten the 5 bolts.

    Torque:
    Bolt A:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }
    Bolt B:
    9.2 N*m{ 94 kgf*cm , 81 in.*lbf }

    NOTICE:
    Be sure to use a torque wrench to tighten the bolts.



    A215780E02

  1. Install the generator cable and cover.
    Text in Illustration 
    *a
    		Align Mark

    NOTICE:
    Close the cover so that the matchmarks are not visible.



12. CONNECT FRAME WIRE

CAUTION:
Wear insulating gloves.

NOTICE:
  1. Make sure that the interlock is fully engaged.
  2. Do not allow any foreign objects or water to enter the inverter with converter assembly.



    A248445E01

  1. Temporarily install the frame wire (high voltage cables of the hybrid battery) and 4 bolts to the inverter assembly by hand.
    Text in Illustration 
    *1
    		Interlock
    *2
    		High voltage cables of the hybrid battery
    *a
    		Front view of frame wire connector

  1. Fully tighten the 4 bolts.

    Torque:
    Bolt A:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }
    Bolt B:
    9.2 N*m{ 94 kgf*cm , 81 in.*lbf }

    NOTICE:
    1. Be sure to use a torque wrench to tighten the bolts.
    2. Make sure that the interlock are fully engaged.

  1. Connect the 2 harness clamps.



13. CHECK HIGH VOLTAGE CABLE CONNECTION

CAUTION:
Wear insulating gloves.

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



    A214667

  1. Check that each connector and terminal is firmly installed.

    NOTICE:
    Make sure that the bolts are fully tightened.



14. INSTALL INVERTER COVER

CAUTION:
Wear insulating gloves.

NOTICE:
  1. Make sure that the interlock is fully engaged.
  2. Do not allow any foreign objects or water to enter the inverter with converter assembly.



    A231540E01

  1. Install the inverter cover with the 9 bolts to the inverter with converter assembly.
    Text in Illustration 
    *1
    		Interlock

    Torque:
    11 N*m{ 112 kgf*cm , 8 ft.*lbf }



15. INSTALL ENGINE ROOM MAIN WIRE

NOTICE:
  1. Make sure that the connectors are fully engaged.
  2. Do not allow any foreign objects or water to enter the inverter with converter assembly.

  1. Install the bolt, clamp and clip, and connect the engine room main wire.

    Torque:
    12 N*m{ 122 kgf*cm , 9 ft.*lbf }

  1. Install the bolt.

    Torque:
    12 N*m{ 122 kgf*cm , 9 ft.*lbf }



    A214645

  1. Connect the engine wire to the engine room main wire.



    A214648

  1. Connect the connector to the inverter with converter assembly and lock the connector with the lock lever.



16. INSTALL NO. 1 INVERTER BRACKET


    A248080E01

  1. Temporarily install the No. 1 inverter bracket with the 3 bolts.

  1. Tighten the 3 bolts in the order shown in the illustration.

    Torque:
    14 N*m{ 138 kgf*cm , 10 ft.*lbf }



17. INSTALL SERVICE PLUG GRIP

CAUTION:
Wear insulating gloves.

NOTICE:
Before connecting the service plug, check that no parts and tools remain and that the high voltage terminals and connectors are connected securely.



  1. Wear insulated gloves and install the service plug grip in the order shown in the illustration.


    A248487

  1. Rotate the handle of the service plug grip 90° toward the battery and slide it in the direction shown by the arrow until a click sound is heard.



18. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

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



19. INSTALL REAR FLOOR BOARD UPPER NO. 3 PLATE

  1. Engage the 4 claws and 2 guides to install the rear floor board upper No. 3 plate.



20. INSTALL DECK FLOOR BOX RH

  1. Engage the 6 guides.

  1. Install the deck floor box RH with the clip.



21. INSTALL REAR NO. 3 FLOOR BOARD

  1. Install the rear No. 3 floor board.



22. INSTALL REAR DECK FLOOR BOX

  1. Install the rear deck floor box.



23. INSTALL REAR NO. 2 FLOOR BOARD

  1. Install the rear No. 2 floor board.



24. ADD COOLANT (for Inverter)

NOTICE:
  1. Do not reuse the drained coolant because it may contain foreign objects.
  2. If the vehicle is driven with air in the inverter cooling system, damage may occur and the following DTCs may be stored.

    DTC No.
    		Detection Item
    P0A01-726
    		Motor Electronics Coolant Temperature Sensor Circuit Range / Performance
    P0A04-725
    		Motor Electronics Coolant Temperature Sensor Circuit Intermittent
    P0A08-264
    		DC / DC Converter Status Circuit
    P0A78-284
    		Drive Motor "A" Inverter Performance
    P0A78-286
    		Drive Motor "A" Inverter Performance
    P0A7A-322
    		Generator Inverter Performance
    P0A7A-324
    		Generator Inverter Performance
    P0A93-346
    		Inverter Cooling System Performance
    P0A94-553
    		DC / DC Converter Performance
    P0A94-557
    		DC / DC Converter Performance
    P0AEE-277
    		Motor Inverter Temperature Sensor "A" Circuit Range / Performance
    P0AF1-276
    		Drive Motor Inverter Temperature Sensor "A" Circuit Intermittent / Erratic
    P0BCD-315
    		Generator Inverter Temperature Sensor Circuit Range / Performance
    P0BD0-314
    		Generator Inverter Temperature Sensor Circuit Intermittent / Erratic
    P0C39-626
    		DC / DC Converter Temperature Sensor "A" Range / Performance
    P0C3C-625
    		DC / DC Converter Temperature Sensor "A" Intermittent / Erratic
    P0C3E-628
    		DC / DC Converter Temperature Sensor "B" Range / Performance
    P0C41-627
    		DC / DC Converter Temperature Sensor "B" Intermittent / Erratic
    P0C73-776
    		 Motor Electronics Coolant Pump "A" Control Performance



    A248471

  1. Slowly pour coolant into the reserve tank until it reaches the full line.

    Coolant quantity:
    2.1 liters (2.2 US qts, 1.8 Imp. qts.)

  1. When using the intelligent tester:

    1. Connect the intelligent tester to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control / Active Test / Activate the Water Pump.

    4. Keep the coolant at the full line in the reserve tank to compensate for the drop in coolant level when the air bleeds.

      Standard:
      Air bleeding from the inverter cooling system is completed when the noise made by the inverter water pump assembly becomes smaller and the circulation of coolant in the reserve tank improves.

      HINT:
      Loud noise made by the inverter water pump assembly and poor circulation of coolant in the reserve tank indicates that there is air in the cooling system.

  1. When not using the intelligent tester:

    1. Turn the power switch on (READY). [*1]

    2. Turn the power switch off and add coolant to the full line because the coolant level drops as the air bleeds. [*2]

      NOTICE:
      1. Be sure to turn the power switch off before adding SLLC.
      2. Do not work on the components in the engine compartment while the vehicle is in the READY-on state because the engine is in intermittent operation.

    3. Repeat steps [*1] and [*2] until air bleeding from the cooling system is completed.

      Standard:
      Air bleeding from the inverter cooling system is completed when the noise made by the inverter water pump assembly becomes smaller and the circulation of coolant in the reserve tank improves.

      HINT:
      Loud noise made by the inverter water pump assembly and poor circulation of coolant in the reserve tank indicates that there is air in the cooling system.

  1. After the air is completely bled from the cooling system, tighten the reserve tank cap.



    A248471

  1. Add coolant to the full line of the reserve tank.



25. ADD COOLANT (for Engine)

  1. Tighten the radiator drain cock plug.



    A213418E01

  1. Add coolant to B line of the reserve tank.
    Text in Illustration 
    *1
    		B Line

    Standard Capacity:
    Item
    		Capacity
    Engine coolant
    		w/ Exhaust Heat Recirculation System:
    6.9 liters (7.3 US qts, 6.1 lmp. qts)
    w/o Exhaust Heat Recirculation System:
    6.5 liters (6.9 US qts, 5.7 lmp. qts)

    HINT:
    TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a combination of low phosphates and organic acids).

    NOTICE:
    Never use water as a substitute for engine coolant.

  1. Squeeze the radiator hoses several times by hand, and then check the level of the coolant.
    If the coolant level is low, add coolant.

  1. Put the engine in inspection mode (Click here).

  1. Install the reserve tank cap.

  1. Bleed air from the cooling system.

    NOTICE:
    1. Before starting the engine, turn the A/C switch off.
    2. Adjust the heater control to the maximum hot setting.
    3. Adjust the blower speed to the low setting.


    1. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes. (●1)

      HINT:
      The thermostat opening timing can be confirmed by squeezing the inlet radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the hose.

      CAUTION:
      When squeezing the radiator hose:
      1. Wear protective gloves.
      2. Be careful as the radiator hoses are hot.
      3. Keep your hands away from the radiator fans.

    2. Stop the engine and wait until the coolant cools down. Then if the coolant level is below the low line, add coolant so that the level will be between the full and low lines. (●2)

    3. Repeat the steps from (●1) to (●2) until the coolant level of the reserve tank remains above the low line.



    A213418E02

  1. After the engine has cooled down, check that the coolant level is between the full and low lines.
    Text in Illustration 
    *1
    		Full Line
    *2
    		Low Line
    If the coolant level is low, add coolant to the full line on the reserve tank.



26. INSPECT FOR COOLANT LEAK (for Inverter)

  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.



    A248084

  1. Install a radiator cap tester.

  1. Pump the radiator cap tester to 122 kPa (1.2 kgf/ cm2, 18 psi), and then check that the pressure does not drop.

    HINT:
    If the pressure drops, check the hoses, radiator, inverter water pump assembly, inverter with converter, and hybrid vehicle transaxle assembly for leaks.

  1. Reinstall the reserve tank cap.



27. INSPECT FOR COOLANT LEAK (for Engine)

CAUTION:
Do not remove the reserve tank cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

NOTICE:
Before performing each inspection, turn the A/C switch off.

  1. Remove the reserve tank cap.



    A248150

  1. Fill the reserve tank with coolant, and then attach a radiator cap tester.

  1. Put the engine in inspection mode (Click here).

  1. Warm up the engine.

  1. Using a radiator cap tester, increase the pressure inside the radiator to 108 kPa (1.1 kgf/cm2, 16 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator, front exhaust pipe assembly, the heater hose around the engine coolant temperature sensor and engine water pump assembly for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

  1. Remove the radiator cap tester.

  1. Install the reserve tank cap.



28. INSTALL RADIATOR SUPPORT OPENING COVER

  1. Install the radiator support opening cover with the 9 clips.



29. INSTALL INVERTER COVER ASSEMBLY LH (w/ Cover)

  1. Engage the claw and install the inverter cover assembly LH.

  1. Install the 2 clips.



30. INSTALL NO. 1 ENGINE UNDER COVER


31. INSTALL FRONT LOWER BUMPER ABSORBER