GENERATOR CABLE REMOVAL

PROCEDURE

1. PRECAUTION

   Note

   After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work Click here.

2. REMOVE REAR NO. 2 FLOOR BOARD

   Click here

3. REMOVE REAR DECK FLOOR BOX

   Click here

4. REMOVE REAR NO. 3 FLOOR BOARD

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5. REMOVE DECK FLOOR BOX RH

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6. REMOVE REAR FLOOR BOARD UPPER NO. 3 PLATE

   Click here

7. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

   Note

   When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

8. REMOVE SERVICE PLUG GRIP

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9. REMOVE FRONT LOWER BUMPER ABSORBER (for 2ZR-FXE)

   Click here

10. REMOVE FRONT LOWER BUMPER ABSORBER (for 5ZR-FXE)

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11. REMOVE NO. 1 ENGINE UNDER COVER (for 2ZR-FXE)

    Click here

12. REMOVE NO. 1 ENGINE UNDER COVER (for 5ZR-FXE)

    Click here

13. DRAIN COOLANT (for Engine)

    for 2ZR-FXE: Click here

    for 5ZR-FXE: Click here

14. DRAIN COOLANT (for Inverter)

    Click here

15. REMOVE INVERTER COVER ASSEMBLY LH (w/ Cover)

    Click here

16. REMOVE RADIATOR SUPPORT OPENING COVER

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17. REMOVE NO. 1 INVERTER BRACKET

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18. DISCONNECT ENGINE ROOM MAIN WIRE

    Click here

19. REMOVE INVERTER COVER

    Click here

20. CHECK TERMINAL VOLTAGE

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21. DISCONNECT FRAME WIRE

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22. DISCONNECT GENERATOR CABLE

    Click here

23. DISCONNECT MOTOR CABLE

    Click here

24. DISCONNECT NO. 2 ENGINE WIRE

    Click here

25. INSTALL INVERTER COVER

    Click here

26. DISCONNECT NO. 2 ENGINE ROOM WIRE

    Click here

27. DISCONNECT WATER HOSE

    Click here

28. REMOVE INVERTER WITH CONVERTER ASSEMBLY

    Click here

29. REMOVE INVERTER RESERVE TANK ASSEMBLY (for 2ZR-FXE)

    Click here

30. REMOVE INVERTER RESERVE TANK ASSEMBLY (for 5ZR-FXE)

    Click here

31. REMOVE INVERTER TRAY BRACKET (for 2ZR-FXE)

    Click here

32. REMOVE INVERTER TRAY BRACKET (for 5ZR-FXE)

    Click here

33. REMOVE RADIATOR PIPE

    
    

    1. 

       Disconnect the 3 clamps, No. 1 radiator hose, No. 4 water by-pass hose and No. 3 radiator hose.

    2. Remove the 2 bolts and radiator pipe.

34. REMOVE GENERATOR CABLE

    Note

    Wear insulated gloves.

    
    

    1. 

       Disconnect the generator cable clamp from the motor cable bracket.

    2. 

       Remove the 3 bolts and slide the generator cable connector shell back.

    3. 

       Disengage the 2 claws to remove the terminal cap.

    4. 

       Remove the 3 bolts and generator cable from the hybrid transaxle assembly.