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Frame Wire No.2: Replacement

NOTE:
  • When working on the high voltage systems, always wear insulating 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. 
  1. PRECAUTION (SEE  PRECAUTION   ) 
  2. REMOVE REAR FLOOR BOARD NO.2 (See  SERVICE PLUG GRIP   ) 
  3. REMOVE DECK FLOOR BOX REAR (See  SERVICE PLUG GRIP   ) 
  4. REMOVE REAR FLOOR BOARD NO.3 (See  SERVICE PLUG GRIP   ) 
  5. DISCONNECT BATTERY NEGATIVE TERMINAL (See  SERVICE PLUG GRIP   ) 
  6. REMOVE SERVICE PLUG GRIP (See  SERVICE PLUG GRIP   ) 
  7. REMOVE DECK TRIM COVER REAR (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  8. REMOVE TONNEAU COVER ASSY (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  9. REMOVE REAR SEAT CUSHION ASSY (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  10. REMOVE REAR FLOOR BOARD NO.1 (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  11. REMOVE REAR SIDE SEAT BACK FRAME LH (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  12. REMOVE REAR SIDE SEAT BACK FRAME RH (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  13. REMOVE REAR FLOOR BOARD NO.4 (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  14. REMOVE DECK FLOOR BOX LH (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  15. REMOVE DECK TRIM SIDE PANEL ASSY LH (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  16. REMOVE DECK TRIM SIDE PANEL ASSY RH (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  17. REMOVE BATTERY CARRIER BRACKET (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  18. REMOVE QUARTER VENT DUCT INNER NO.2 (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  19. REMOVE BATTERY BRACKET REINFORCEMENT (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  20. REMOVE QUARTER VENT DUCT (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  21. REMOVE BATTERY CARRIER PANEL NO.6 (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  22. REMOVE JUNCTION TERMINAL (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
    NOTE: Wear insulating gloves.
  23. REMOVE FRAME WIRE (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
    NOTE: Wear insulating gloves. 
  24. REMOVE HV BATTERY ASSY (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  25. REMOVE BATTERY COVER SUB-ASSY (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  26. REMOVE WIRING HARNESS PROTECTOR COVER NO.1 (See  MAIN BATTERY CABLE   ) 
    NOTE: Wear insulating gloves. 
  27. REMOVE WIRING HARNESS PROTECTOR COVER NO.3 (See  MAIN BATTERY CABLE   ) 
    NOTE: Wear insulating gloves. 
  28. REMOVE BATTERY CARRIER CUSHION NO.3 (See  MAIN BATTERY CABLE   ) 
    NOTE: Wear insulating gloves. 
  29. REMOVE MAIN BATTERY CABLE (See  MAIN BATTERY CABLE   ) 
    NOTE: Wear insulating gloves. 
  30. REMOVE MAIN BATTERY CABLE NO.2 (See  MAIN BATTERY CABLE NO.2   ) 
    NOTE: Wear insulating gloves. 
  31. REMOVE FRAME WIRE NO.2 
    NOTE: Wear insulating gloves. 
    1. Disconnect the temperature sensor connector from the battery ECU.
    2. Remove the clamp, then disconnect the frame wire No. 2 connector from the battery ECU.
      Fig 1: Disconnecting Frame Wire No. 2 Connector From Battery ECU
      G02617300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 26 nuts and frame wire No. 2.
      Fig 2: Locating Nut
      G02617301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL FRAME WIRE NO.2 
    NOTE: Wear insulating gloves. 
    1. Install the frame wire No. 2 with new 26 nuts.

      Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

      Fig 3: Installing Frame Wire No. 2 With Nuts
      G02617302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the frame wire No. 2 connector to the battery ECU, then connect the clamp.
    3. Connect the temperature sensor connector to the battery ECU.
      Fig 4: Connecting Frame Wire Connector To Battery ECU
      G02617303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL MAIN BATTERY CABLE NO.2 (See  MAIN BATTERY CABLE NO.2   ) 
    NOTE: Wear insulating gloves. 
  34. INSTALL MAIN BATTERY CABLE (See  MAIN BATTERY CABLE   ) 
    NOTE: Wear insulating gloves. 
  35. INSTALL BATTERY CARRIER CUSHION NO.3 (See  MAIN BATTERY CABLE   ) 
    NOTE: Wear insulating gloves. 
  36. INSTALL WIRING HARNESS PROTECTOR COVER NO.1 (See  MAIN BATTERY CABLE   ) 
    NOTE: Wear insulating gloves. 
  37. INSTALL WIRING HARNESS PROTECTOR COVER NO.3 (See  MAIN BATTERY CABLE   ) 
    NOTE: Wear insulating gloves. 
  38. INSTALL BATTERY COVER SUB-ASSY (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  39. INSTALL HV BATTERY ASSY (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  40. INSTALL FRAME WIRE (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
    NOTE: Wear insulating gloves. 
  41. INSTALL JUNCTION TERMINAL (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
    NOTE: Wear insulating gloves. 
  42. INSTALL BATTERY CARRIER PANEL NO.6 (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  43. INSTALL QUARTER VENT DUCT (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  44. INSTALL BATTERY BRACKET REINFORCEMENT (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  45. INSTALL QUARTER VENT DUCT INNER NO.2 (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  46. INSTALL BATTERY CARRIER BRACKET (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  47. INSTALL DECK TRIM SIDE PANEL ASSY RH 
  48. INSTALL DECK TRIM SIDE PANEL ASSY LH 
  49. INSTALL DECK FLOOR BOX LH 
  50. INSTALL REAR FLOOR BOARD NO.4 
  51. INSTALL REAR SIDE SEAT BACK FRAME RH 
  52. INSTALL REAR SIDE SEAT BACK FRAME LH 
  53. INSTALL REAR FLOOR BOARD NO.1 
  54. INSTALL REAR SEAT CUSHION ASSY 
  55. INSTALL TONNEAU COVER ASSY 
  56. INSTALL DECK TRIM COVER REAR 
  57. INSTALL SERVICE PLUG GRIP (See  SERVICE PLUG GRIP   ) 
    NOTE: Wear insulating gloves. 
  58. CONNECT BATTERY NEGATIVE TERMINAL 

    Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf) 

  59. INSTALL REAR FLOOR BOARD NO.3 
  60. INSTALL DECK FLOOR BOX REAR 
  61. INSTALL REAR FLOOR BOARD NO.2 
  62. POWER WINDOW CONTROL SYSTEM INITIALIZE (SEE  INITIALIZATION  ) 
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