Frame Wire

Frame Wire:

REMOVAL

CAUTION:
- When working on high voltage systems, always wear insulating gloves.
- 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.

NOTE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU.

1. PRECAUTION

CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/removal, inspection and replacement of parts), be sure to follow the procedures.

2. REMOVE FRONT WHEEL
3. REMOVE REAR NO. 2 FLOOR BOARD
4. REMOVE REAR DECK FLOOR BOX
5. REMOVE REAR NO. 3 FLOOR BOARD
6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

7. REMOVE SERVICE PLUG GRIP
8. REMOVE REAR DECK TRIM COVER
9. REMOVE TONNEAU COVER
10. REMOVE REAR SEAT CUSHION ASSEMBLY
11. REMOVE REAR NO. 1 FLOOR BOARD
12. REMOVE REAR SIDE SEATBACK FRAME LH
13. REMOVE REAR NO. 4 FLOOR BOARD
14. REMOVE DECK FLOOR BOX LH
15. REMOVE DECK TRIM SIDE PANEL LH
16. REMOVE BATTERY CARRIER BRACKET
17. REMOVE REAR DOOR SCUFF PLATE LH

a. Remove the clip and 4 joints shown in the illustration, and then remove the rear door scuff plate.

18. REMOVE FLOOR SIDE PANEL LH

a. Remove the clip, then roll back the carpet.

b. Remove the clip from the floor side panel.
c. Remove the 3 bolts and floor side panel.

19. REMOVE NO. 6 BATTERY CARRIER PANEL
20. REMOVE JUNCTION TERMINAL

CAUTION: Wear insulating gloves.

21. REMOVE FRAME WIRE

CAUTION: Wear insulating gloves.

a. Remove the 2 nuts, then remove the frame wire from the No. 2 and No. 3 system main relay.

CAUTION: Insulate the removed terminals with insulating tape.

b. Remove the clamps, then remove the frame wire from the rear floor.

c. Remove the 2 clamps, then disconnect the frame wire from the center floor panel.
d. Disconnect the connector.
e. Disconnect the grommet.

22. REMOVE WINDSHIELD WIPER ARM COVER
23. REMOVE FRONT WIPER ARM LH
24. REMOVE FRONT WIPER ARM RH
25. REMOVE HOOD TO COWL TOP SEAL
26. REMOVE COWL TOP VENTILATOR LOUVER LH
27. REMOVE COWL TOP VENTILATOR LOUVER RH
28. REMOVE FRONT WIPER LINK AND WIPER MOTOR ASSEMBLY
29. REMOVE FRONT COWL TOP PANEL OUTER
30. SEPARATE FRAME WIRE

CAUTION: Wear insulating gloves.

a. Flip open the cover of the jump start terminal on the engine room relay block.

b. Remove the side cover by sliding it upward.
c. Remove the nut, then disconnect the frame wire from the engine room relay block.
d. Disconnect the clamp, then disconnect the frame wire from the side member.

e. Remove the 2 frame wire connectors shown in the illustration from the inverter with converter assembly.
f. Disconnect the clamp, then disconnect the frame wire from the dash panel bracket.

31. REMOVE COLUMN HOLE COVER SILENCER SHEET
32. SEPARATE STEERING INTERMEDIATE SHAFT
33. REMOVE NO. 3 ENGINE UNDER COVER
34. REMOVE NO. 4 ENGINE UNDER COVER CENTER
35. REMOVE FRONT FLOOR COVER LH

a. Remove the 6 clips and front floor cover LH.

36. REMOVE FRONT FLOOR COVER CENTER LH

a. Remove the 5 clips and front floor cover center LH.

37. REMOVE NO. 1 WIRE HARNESS PROTECTOR

CAUTION: Wear insulating gloves.

a. Remove the 2 nuts, bolt and wire harness protector.

38. SEPARATE FRONT SUSPENSION CROSSMEMBER

a. Support the front suspension crossmember using a jack.

b. Remove the 4 bolts shown in the illustration from the front suspension crossmember.

39. REMOVE FRAME WIRE

CAUTION: Wear insulating gloves.

a. Remove the 2 bolts shown in the illustration.
b. Disconnect the 2 clamps.
c. Lower the jack a little and remove both nuts labeled A.

NOTE:
- Lower the jack slowly to avoid interfering with objects loaded on the front suspension crossmember.
- Do not remove the jack.

d. Remove both nuts labeled B.

e. Disconnect the fit-in clamps, then remove the frame wire.

INSTALLATION

1. INSTALL FRAME WIRE

CAUTION: Wear insulating gloves.

a. Temporarily fasten the frame wire to the vehicle.
b. Connect the fit-in clamps to the stud in the floor panel, and then install the frame wire with both nuts labeled A.

Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)

c. Install both nuts labeled B shown in the illustration.

Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)

d. As shown in the illustration, point the arrow on the grommet in the front direction, then install the grommet.
e. Install the 2 bolts.

Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)

f. Install the 2 clamps.

2. INSTALL FRONT SUSPENSION CROSSMEMBER

a. Install the front suspension crossmember with the 4 bolts.

Torque:
113 N.m (1,152 kgf.cm, 83 in.lbf) for bolt A

157 N.m (1,601 kgf.cm, 116 in.lbf) for bolt B

b. Remove the jack.

3. INSTALL NO. 1 WIRE HARNESS PROTECTOR

CAUTION: Wear insulating gloves.

a. Install the wire harness protector with the 2 bolts and nut.

Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)

4. INSTALL FRONT FLOOR COVER CENTER LH

a. Install the floor cover with the 5 clips.

5. INSTALL FRONT FLOOR COVER LH

a. Install the floor cover with the 6 clips.

6. INSTALL NO. 3 ENGINE UNDER COVER
7. INSTALL NO. 4 ENGINE UNDER COVER CENTER
8. INSTALL STEERING INTERMEDIATE SHAFT
9. INSTALL COLUMN HOLE COVER SILENCER SHEET
10. INSTALL FRAME WIRE

CAUTION: Wear insulating gloves.

a. Connect the 2 connectors shown in the illustration to the inverter with converter assembly.
b. Connect the clamp to the engine room relay block with the nut.

c. Install the frame wire to the engine room relay block with the nut.

Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)

d. Install the side cover to the engine room relay block.
e. Install the frame wire clamp to the side member.

11. INSTALL FRONT COWL TOP PANEL OUTER
12. INSTALL FRONT WIPER LINK AND WIPER MOTOR ASSEMBLY
13. INSTALL COWL TOP VENTILATOR LOUVER RH
14. INSTALL COWL TOP VENTILATOR LOUVER LH
15. INSTALL HOOD TO COWL TOP SEAL
16. INSTALL FRONT WIPER ARM LH
17. INSTALL FRONT WIPER ARM RH
18. INSTALL FRONT WIPER ARM COVER
19. INSTALL FRAME WIRE

CAUTION: Wear insulating gloves.

a. Connect the grommet.
b. Connect the connector.
c. Install the 2 clamps, then connect the frame wire to the center floor panel.

d. Install the frame wire to the rear floor panel with the clamp.

e. Install the frame wire to the No. 2 and No. 3 system main relay with 2 new nuts.

Torque: 5.6 N.m (57 kgf.cm, 50 in.lbf)

20. INSTALL JUNCTION TERMINAL

CAUTION: Wear insulating gloves.

21. INSTALL NO. 6 BATTERY CARRIER PANEL
22. INSTALL FLOOR SIDE PANEL LH

a. Install the clip.
b. Install the floor side panel with the 3 bolts.

c. Install the carpet with the clip.

23. INSTALL REAR DOOR SCUFF PLATE LH
24. INSTALL BATTERY CARRIER BRACKET
25. INSTALL DECK TRIM SIDE PANEL LH
26. INSTALL DECK FLOOR BOX LH
27. INSTALL REAR NO. 4 FLOOR BOARD
28. INSTALL REAR SIDE SEATBACK FRAME LH
29. INSTALL REAR NO. 1 FLOOR BOARD
30. INSTALL REAR SEAT CUSHION ASSEMBLY
31. INSTALL TONNEAU COVER
32. INSTALL REAR DECK TRIM COVER
33. INSTALL SERVICE PLUG GRIP
34. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
35. INSTALL REAR NO. 3 FLOOR BOARD
36. INSTALL REAR DECK FLOOR BOX
37. INSTALL REAR NO. 2 FLOOR BOARD
38. INSTALL FRONT WHEEL
39. PERFORM INITIALIZATION
a. Perform initialization.

NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.