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Frame Wire: 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 FRONT WHEELS 
  3. REMOVE REAR FLOOR BOARD NO. 2 (See  SERVICE PLUG GRIP  ) 
  4. REMOVE DECK FLOOR BOX REAR (See  SERVICE PLUG GRIP  ) 
  5. REMOVE REAR FLOOR BOARD NO. 3 (See  SERVICE PLUG GRIP  ) 
  6. DISCONNECT BATTERY NEGATIVE TERMINAL (See  SERVICE PLUG GRIP  ) 
  7. REMOVE SERVICE PLUG GRIP (See  SERVICE PLUG GRIP  ) 
  8. REMOVE DECK TRIM COVER REAR (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  9. REMOVE TONNEAU COVER ASSY (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  10. REMOVE REAR SEAT CUSHION ASSY (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  11. REMOVE REAR FLOOR BOARD NO. 1 (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  12. REMOVE REAR SIDE SEAT BACK FRAME LH (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 BATTERY CARRIER BRACKET (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  17. REMOVE REAR DOOR SCUFF PLATE LH 
    1. Remove the clip and 4 joints shown in the illustration, then remove the rear door scuff plate.
      Fig 1: Removing Rear Door Scuff Plate LH
      G00950663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE FLOOR SIDE PANEL LH 
    1. Remove the clip, then roll back the carpet.
      Fig 2: Removing Carpet Clips
      G00950664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the clip from the floor side panel.
    3. Remove the 3 bolts and floor side panel.
      Fig 3: Removing Clip From Floor Side Panel
      G00950665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE BATTERY CARRIER PANEL NO. 6 (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
    NOTE: Wear insulating gloves.
  20. REMOVE JUNCTION TERMINAL (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
    NOTE: Wear insulating gloves.
  21. REMOVE FRAME WIRE (RR POSITION) 
    NOTE: Wear insulating gloves.
    1. Remove the 2 nuts, then remove the frame wire from the system main relay No. 2 and No. 3.
      NOTE: Insulate the removed terminals with insulating tape.
      Fig 4: Removing Frame Wire From System Main Relay No. 2 And No. 3
      G00950666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the clamps, then remove the frame wire from the rear floor.
      Fig 5: Removing Frame Wire From Rear Floor
      G00950667Courtesy 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 Frame Wire, Connector & Grommet
      G00950668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE FRONT WIPER ARM HEAD CAP (See  WIPER & WASHER  ) 
  23. REMOVE FR WIPER ARM LH (See  WIPER & WASHER  ) 
  24. REMOVE FR WIPER ARM RH (See  WIPER & WASHER  ) 
  25. REMOVE HOOD TO COWL TOP SEAL (See  WIPER & WASHER  ) 
  26. REMOVE COWL TOP VENTILATOR LOUVER LH (See  WIPER & WASHER  ) 
  27. REMOVE COWL TOP VENTILATOR LOUVER RH (See  WIPER & WASHER  ) 
  28. REMOVE WINDSHIELD WIPER LINK ASSY (See  WIPER & WASHER  ) 
  29. REMOVE COWL TOP PANEL SUB-ASSY OUTER FRONT (See  WIPER & WASHER  ) 
  30. SEPARATE FRAME WIRE (FR POSITION) 
    NOTE: Wear insulating gloves.
    1. Flip open the cover of the jump start terminal on the engine room relay block.
      Fig 7: Locating Engine Room Relay Block
      G00950669Courtesy 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
      G00950670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 2 frame wire connectors shown in the illustration from the with converter inverter assembly.
    6. Disconnect the clamp, then disconnect the frame wire from the dash panel bracket.
      Fig 9: Removing 2 Frame Wire Connectors From W/Converter Inverter Assembly
      G00950671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE COLUMN HOLE COVER SILENCER SHEET (See  REPLACEMENT  ) 
  32. SEPARATE STEERING INTERMEDIATE SHAFT (See  REPLACEMENT  ) 
  33. REMOVE ENGINE UNDER COVER RH 
  34. REMOVE ENGINE UNDER COVER LH 
  35. REMOVE FRONT FLOOR COVER LH 
    1. Remove the 6 clips and front floor cover LH.
      Fig 10: Removing 6 Clips And Front Floor Cover LH
      G00950672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE FRONT FLOOR COVER CENTER LH 
    1. Remove the 5 clips and front floor cover center LH.
      Fig 11: Removing 5 Clips And Front Floor Cover Center LH
      G00950673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE WIRING HARNESS PROTECTOR NO. 1 
    NOTE: Wear insulating gloves.
    1. Remove the 2 nuts, bolt and wiring harness protector No. 1.
      Fig 12: Removing Wiring Harness Protector No. 1
      G00950674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. SEPARATE FRONT SUSPENSION CROSSMEMBER SUB-ASSY 
    1. Support the front suspension cross member using a jack.
      Fig 13: Supporting Front Suspension Cross Member Using Jack
      G00950675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 bolts shown in the illustration from the front suspension crossmember.
      Fig 14: Removing 4 Bolts From Front Suspension Crossmember
      G00950676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE FRAME WIRE 
    NOTE: 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 A.
      Fig 15: Disconnecting 2 Clamps
      G00950677Courtesy 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 B.
    5. Disconnect the fit in clamp, then remove the frame wire.
      Fig 16: Disconnecting Fit In Clamp And Removing Frame Wire
      G00950678Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL FRAME WIRE 
    NOTE: Wear insulating gloves.
    1. Temporarily fasten the frame wire to the vehicle.
    2. Connect the fit in clamp to the stud in the floor panel, then install the frame wire with both nuts A.

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

    3. Install both nuts B shown in the illustration.

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

      Fig 17: Installing Both Nuts B
      G00950679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. As shown in the illustration, point the arrow on the grommet in the front direction, then install the grommet.
    5. Install the 2 bolts.

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

    6. Install the 2 clamps.
      Fig 18: Installing Grommet
      G00950680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSY 
    1. Install the front suspension crossmember with the 4 bolts.

      Torque: 

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

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

    2. Remove the jack.
      Fig 19: Installing Front Suspension Crossmember Sub-Assy
      G00950681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL WIRING HARNESS PROTECTOR NO. 1 
    NOTE: Wear insulating gloves.
    1. Install the wiring harness protector No. 1 with the 2 bolts and nut.

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

      Fig 20: Installing Wiring Harness Protector No. 1
      G00950682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL FRONT FLOOR COVER CENTER LH 
  44. INSTALL FRONT FLOOR COVER LH 
  45. INSTALL ENGINE UNDER COVER RH 
  46. INSTALL ENGINE UNDER COVER LH 
  47. INSTALL STEERING INTERMEDIATE SHAFT (See  REPLACEMENT  ) 
  48. INSTALL COLUMN HOLE COVER SILENCER SHEET (See  REPLACEMENT  ) 
  49. INSTALL FRAME WIRE (FR POSITION) 
    NOTE: Wear insulating gloves.
    1. Connect the 2 connectors shown in the illustration to the with converter inverter assembly.
    2. Connect the clamp to the engine room relay block with the nut.
      Fig 21: Connecting 2 Connectors To W/Converter Inverter Assembly
      G00950683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the frame wire to the engine room relay block with the nut.

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

    4. Install the side cover to the engine room relay block.
    5. Install the frame wire clamp to the side member.
      Fig 22: Installing Side Cover To Engine Room Relay Block
      G00950684Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL COWL TOP PANEL SUB-ASSY OUTER FRONT 
  51. INSTALL WINDSHIELD WIPER LINK ASSY (See  WIPER & WASHER  ) 
  52. INSTALL COWL TOP VENTILATOR LOUVER RH 
  53. INSTALL COWL TOP VENTILATOR LOUVER LH 
  54. INSTALL HOOD TO COWL TOP SEAL 
  55. INSTALL FR WIPER ARM LH (See  WIPER & WASHER  ) 
  56. INSTALL FR WIPER ARM RH (See  WIPER & WASHER  ) 
  57. INSTALL FRONT WIPER ARM HEAD CAP 
  58. INSTALL FRAME WIRE (RR POSITION) 
    NOTE: Wear insulating gloves.
    1. Connect the connector.
    2. Install the 2 clamps, then connect the frame wire to the center floor panel.
      Fig 23: Installing 2 Clamps And Connecting Frame Wire To Center Floor Panel
      G00950685Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the frame wire to the rear floor panel with the clamp.
      Fig 24: Installing Frame Wire To Rear Floor Panel With Clamp
      G00950686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the frame wire to the system main relay No. 2 and No. 3 with 2 new nuts.

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

      Fig 25: Installing Frame Wire To System Main Relay No. 2 And No. 3 With 2 New Nuts
      G00950687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. INSTALL JUNCTION TERMINAL (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
    NOTE: Wear insulating gloves.
  60. INSTALL BATTERY CARRIER PANEL NO. 6 (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  61. INSTALL FLOOR SIDE PANEL LH 
    1. Install the clip.
    2. Install the floor side panel with the 3 bolts.
      Fig 26: Installing Clip And Floor Side Panel With 3 Bolts
      G00950688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the carpet with the clip.
      Fig 27: Installing Carpet With Clip
      G00950689Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSTALL REAR DOOR SCUFF PLATE LH 
  63. INSTALL BATTERY CARRIER BRACKET (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  64. INSTALL DECK TRIM SIDE PANEL ASSY LH 
  65. INSTALL DECK FLOOR BOX LH 
  66. INSTALL REAR FLOOR BOARD NO. 4 
  67. INSTALL REAR SIDE SEAT BACK FRAME LH 
  68. INSTALL REAR FLOOR BOARD NO. 1 
  69. INSTALL REAR SEAT CUSHION ASSY 
  70. INSTALL TONNEAU COVER ASSY 
  71. INSTALL DECK TRIM COVER REAR 
  72. INSTALL SERVICE PLUG GRIP (See  SERVICE PLUG GRIP  ) 
    NOTE: Wear insulating gloves.
  73. CONNECT BATTERY NEGATIVE TERMINAL 

    Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf) 

  74. INSTALL REAR FLOOR BOARD NO. 3 
  75. INSTALL DECK FLOOR BOX REAR 
  76. INSTALL REAR FLOOR BOARD NO. 2 
  77. INSTALL FRONT WHEELS 

    Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf) 

  78. POWER WINDOW CONTROL SYSTEM INITIALIZE (See  INITIALIZATION  ) 
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