Name: AllOEMManuals
Address: 316 Brandywine Ave, Streetman, TX, 75859, US
Telephone: +14699867883
Price range: $$

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.

DISCONNECT BATTERY NEGATIVE TERMINAL
REMOVE SERVICE PLUG GRIP (SEE SERVICE PLUG GRIP )
REMOVE ENGINE UNDER COVER LH
REMOVE ENGINE UNDER COVER RH
DRAIN COOLANT (SEE REPLACEMENT )
REMOVE COWL TOP PANEL SUB-ASSY OUTER FRONT (SEE HYBRID CONTROL SYSTEM W/CONVERTER INVERTER ASSY )
REMOVE W/CONVERTER INVERTER ASSY (SEE HYBRID CONTROL SYSTEM W/CONVERTER INVERTER ASSY )
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
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Remove the two bolts from the generator cable.
    
    Fig 2: Removing Generator Cable
    Courtesy 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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 bolts and generator cable.
Fig 4: Removing Generator Cable
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR CABLE
1. Apply a small amount of ATF WS to the generator cable O-ring.
  
  Fig 5: Locating Generator Cable O-Ring
  Courtesy 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.

When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.

• Brakes feel soft, pull hard to one side, or make grinding noises.

• The engine overheats, stalls repeatedly, or misfires under load.

• You are missing required tools, torque specs, or safe lifting equipment.

• You are not confident in the next step or safety outcome.

Safety Warning

Generator Cable: Replacement

Use the Manual With the Right Hardware

When to See a Mechanic

Rather have a pro handle this?