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Frame Wire No. 2: 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 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: Removing Clamp And Disconnecting Frame Wire No. 2 Connector
      G00950473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 26 nuts and frame wire No. 2.
      Fig 2: Removing 26 Nuts And Frame Wire No. 2
      G00950474Courtesy 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: Removing Frame Wire No. 2 And 26 Nuts
      G00950475Courtesy 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 Clamp After Connecting Frame Wire No. 2 Connector To Battery ECU
      G00950476Courtesy 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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