2004 Toyota Matrix Base, 4WDFACTORY OEM SERVICE PROCEDURE

Generator Cable: Replacement

WARNING: This page is about a different car, the 2004 Toyota Prius. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
  • When working on the high voltage systems, always wear insulated 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. DISCONNECT BATTERY NEGATIVE TERMINAL 
  2. REMOVE SERVICE PLUG GRIP (SEE  SERVICE PLUG GRIP  ) 
  3. REMOVE ENGINE UNDER COVER LH 
  4. REMOVE ENGINE UNDER COVER RH 
  5. DRAIN COOLANT (SEE  REPLACEMENT   ) 
  6. REMOVE COWL TOP PANEL SUB-ASSY OUTER FRONT (SEE  HYBRID CONTROL SYSTEM W/CONVERTER INVERTER ASSY  ) 
  7. REMOVE W/CONVERTER INVERTER ASSY (SEE  HYBRID CONTROL SYSTEM W/CONVERTER INVERTER ASSY  ) 
  8. REMOVE GENERATOR CABLE 
    1. Zero bolt confirmation process.
      NOTE: Ensure that insulated gloves are worn when carrying out this procedure.
      1. Remove the 4 bolts and power cable cover.
        Fig 1: Removing Power Cable Cover
        G02921092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Remove the two bolts from the generator cable.
        Fig 2: Removing Generator Cable
        G02921093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Inspect the voltage between each of the 3 phase AC terminals (U to V, V to W, U to W) and body earth using the Toyota electrical tester.

      Standard value: 0 V 

      HINT:

      Use the Toyota Electrical Tester on measured ranges of DC 400 volts or more.

      Fig 3: Inspecting Voltage Between Each Of 3 Phase AC Terminals (U To V, V To W, U To W) And Body Earth
      G02921094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and generator cable.
    Fig 4: Removing Generator Cable
    G02921095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL GENERATOR CABLE 
    1. Apply a small amount of ATF WS to the generator cable O-ring.
      Fig 5: Locating Generator Cable O-Ring
      G02921096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the generator cable as shown in the illustration.
      NOTE:
      • Connect by aligning the letters U, V and W.
      • Ensure that no foreign objects are attached to the O-ring when connecting the cables.
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