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.

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 (see INVERTER WITH CONVERTER ).
REMOVE FRONT WHEEL
REMOVE REAR NO. 2 FLOOR BOARD (See REMOVAL )
REMOVE REAR DECK FLOOR BOX (See REMOVAL )
REMOVE REAR NO. 3 FLOOR BOARD (See REMOVAL )
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent air bag and seat belt pretensioner activation.
REMOVE SERVICE PLUG GRIP (See REMOVAL )
REMOVE REAR DECK TRIM COVER (See REMOVAL )
REMOVE TONNEAU COVER (See REMOVAL )
REMOVE REAR SEAT CUSHION ASSEMBLY (See REMOVAL )
REMOVE REAR NO. 1 FLOOR BOARD (See REMOVAL )
REMOVE REAR SIDE SEATBACK FRAME LH (See REMOVAL )
REMOVE REAR NO. 4 FLOOR BOARD (See REMOVAL )
REMOVE DECK FLOOR BOX LH (See REMOVAL )
REMOVE DECK TRIM SIDE PANEL LH (See REMOVAL )
REMOVE BATTERY CARRIER BRACKET (See REMOVAL )
REMOVE REAR DOOR SCUFF PLATE LH
1. Remove the clip and 4 joints shown in the illustration, and then remove the rear door scuff plate.
  
  Fig 1: Identifying Clip And Joints
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FLOOR SIDE PANEL LH
1. Remove the clip, then roll back the carpet.
  
  Fig 2: Removing Carpet With Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the clip from the floor side panel.
3. Remove the 3 bolts and floor side panel.
REMOVE NO. 6 BATTERY CARRIER PANEL (See REMOVAL )
REMOVE JUNCTION TERMINAL
CAUTION: Wear insulating gloves.

Fig 3: Removing Floor Side Panel LH
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRAME WIRE
CAUTION: Wear insulating gloves.
1. 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.
  
  Fig 4: Removing Frame Wire From No 2 And No 3 System Main Relay
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the clamps, then remove the frame wire from the rear floor.
  
  Fig 5: Removing Frame Wire To Rear Floor Panel With Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 clamps, then disconnect the frame wire from the center floor panel.
4. Disconnect the connector.
5. Disconnect the grommet.
  
  Fig 6: Disconnecting Grommet And Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WINDSHIELD WIPER ARM COVER
REMOVE FRONT WIPER ARM LH (See REMOVAL )
REMOVE FRONT WIPER ARM RH (See REMOVAL )
REMOVE HOOD TO COWL TOP SEAL (See REMOVAL )
REMOVE COWL TOP VENTILATOR LOUVER LH (See REMOVAL )
REMOVE COWL TOP VENTILATOR LOUVER RH (See REMOVAL )
REMOVE FRONT WIPER LINK AND WIPER MOTOR ASSEMBLY (See REMOVAL )
REMOVE FRONT COWL TOP PANEL OUTER (See REMOVAL )
SEPARATE FRAME WIRE
CAUTION: Wear insulating gloves.
1. Flip open the cover of the jump start terminal on the engine room relay block.
  
  Fig 7: Removing Engine Room Relay Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the side cover by sliding it upward.
3. Remove the nut, then disconnect the frame wire from the engine room relay block.
4. Disconnect the clamp, then disconnect the frame wire from the side member.
  
  Fig 8: Disconnecting Frame Wire From Side Member
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the 2 frame wire connectors shown in the illustration from the inverter with converter assembly.
6. Disconnect the clamp, then disconnect the frame wire from the dash panel bracket.
REMOVE COLUMN HOLE COVER SILENCER SHEET (See )
SEPARATE STEERING INTERMEDIATE SHAFT (See )
REMOVE NO. 3 ENGINE UNDER COVER
REMOVE NO. 4 ENGINE UNDER COVER CENTER (See )

Fig 9: Removing Frame Wire Connectors
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT FLOOR COVER LH
1. Remove the 6 clips and front floor cover LH.
  
  Fig 10: Removing Front Floor Cover LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT FLOOR COVER CENTER LH
1. Remove the 5 clips and front floor cover center LH.
  
  Fig 11: Removing Front Floor Cover Center LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 WIRE HARNESS PROTECTOR
CAUTION: Wear insulating gloves.
1. Remove the 2 nuts, bolt and wire harness protector.
  
  Fig 12: Removing Wire Harness Protector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SEPARATE FRONT SUSPENSION CROSSMEMBER
1. Support the front suspension crossmember using a jack.
  
  Fig 13: Supporting Front Suspension Crossmember Using Jack
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 4 bolts shown in the illustration from the front suspension crossmember.
  
  Fig 14: Removing Front Suspension Crossmember
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRAME WIRE
CAUTION: Wear insulating gloves.
1. Remove the 2 bolts shown in the illustration.
2. Disconnect the 2 clamps.
3. Lower the jack a little and remove both nuts labeled A.
  
  Fig 15: Disconnecting Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Lower the jack slowly to avoid interfering with objects loaded on the front suspension crossmember.
  - Do not remove the jack.
4. Remove both nuts labeled B.
5. Disconnect the fit-in clamps, then remove the frame wire.
  
  Fig 16: Removing Frame Wire
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002