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GENERATOR CABLE > REMOVAL

for Preparation Click here



1. PRECAUTION

NOTICE:
After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work (Click here).



2. REMOVE REAR NO. 2 FLOOR BOARD

  1. Remove the rear No. 2 floor board.



3. REMOVE REAR DECK FLOOR BOX

  1. Remove the rear deck floor box.



4. REMOVE REAR NO. 3 FLOOR BOARD

  1. Remove the rear No. 3 floor board.



5. REMOVE DECK FLOOR BOX RH


    B270546

  1. Remove the clip.

  1. Disengage the 6 guides and remove the deck floor box RH.



6. REMOVE REAR FLOOR BOARD UPPER NO. 3 PLATE


    B270547

  1. Disengage the 4 claws and 2 guides, and remove the rear floor board upper No. 3 plate.



7. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

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



8. REMOVE SERVICE PLUG GRIP

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. High voltage wiring connectors are orange.



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


    A248488

    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.



9. REMOVE FRONT LOWER BUMPER ABSORBER


10. REMOVE NO. 1 ENGINE UNDER COVER


11. DRAIN COOLANT (for Engine)

NOTICE:
Do not remove the reserve tank cap 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.

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



  1. Remove the reserve tank cap and drain the coolant.


    A251091E01


    Text in Illustration 
    *1
    		Reserve Tank Cap
    		*2
    		Radiator Drain Cock Plug



12. DRAIN COOLANT (for Inverter)

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.



    A214669

  1. 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.

  1. Install the plug with a new gasket.

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



13. REMOVE INVERTER COVER ASSEMBLY LH (w/ Cover)


    A248071

  1. Remove the 2 clips

  1. Disengage the claw and remove the inverter cover assembly LH.



14. REMOVE RADIATOR SUPPORT OPENING COVER


    B269819

  1. Remove the 9 clips and radiator support opening cover.



15. REMOVE NO. 1 INVERTER BRACKET


    A248080

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



16. DISCONNECT ENGINE ROOM MAIN WIRE


    A214647

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



    A214646

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



    A214643

  1. Remove the bolt.



    A214644

  1. Remove the bolt, clamp and clip, and disconnect the engine room main wire.



17. REMOVE INVERTER COVER

CAUTION:
Wear insulating gloves.



    A209686

  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.



18. CHECK TERMINAL VOLTAGE

CAUTION:
Wear insulating gloves.

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



    A248051

  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.



19. DISCONNECT FRAME WIRE

CAUTION:
Wear insulating gloves.

NOTICE:
  1. Insulate the disconnected 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.



    A248473

  1. Disconnect the 2 harness clamps.



    A248441

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



20. DISCONNECT GENERATOR CABLE

CAUTION:
Wear insulating gloves.

NOTICE:
  1. Insulate the disconnected 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.



    A214654

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



    A248442

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



21. DISCONNECT MOTOR CABLE

CAUTION:
Wear insulating gloves.

NOTICE:
  1. Insulate the disconnected 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.



    A214656

  1. Disconnect the harness clamp.



    A248443

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



22. DISCONNECT NO. 2 ENGINE WIRE

CAUTION:
Wear insulating gloves.

NOTICE:
  1. Insulate the disconnected 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.



    A248444

  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.



    A214657

  1. Disconnect the harness clamp.



23. INSTALL INVERTER COVER


    A209686

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



24. DISCONNECT NO. 2 ENGINE ROOM WIRE

  1. Remove the relay block cover.



    A214658

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



    A214659

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

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



    A249815

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



25. DISCONNECT WATER HOSE


    A214661E01

  1. Release the retainer and disconnect the water hose from the inverter with converter assembly.
    Text in Illustration 
    *1
    		Retainer



    A214663E01

  1. Release the retainer and disconnect the water hose from the inverter with converter assembly.
    Text in Illustration 
    *1
    		Retainer



    A209687

  1. 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.



26. REMOVE INVERTER WITH CONVERTER ASSEMBLY

CAUTION:
Wear insulating gloves.



    A214665

  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.



    A148374

  1. Even after the coolant is drained, coolant remains in the inverter due to its internal structure. Therefore, seal or cover the pipes when removing the inverter so that coolant does not spill out.



27. REMOVE INVERTER RESERVE TANK ASSEMBLY


    A248099

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



28. REMOVE INVERTER TRAY BRACKET


    A213025

  1. Separate the 2 clamps.

  1. Remove the 5 bolts and inverter tray bracket.



29. REMOVE RADIATOR PIPE


    C209277

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

  1. Remove the 2 bolts and radiator pipe.



30. REMOVE GENERATOR CABLE

NOTICE:
Wear insulated gloves.



    C209802

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



    C209803

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



    C209805

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



    C209806

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