GENERATOR CABLE INSTALLATION

PROCEDURE

1. INSTALL GENERATOR CABLE

   Note

   Wear insulated gloves.

   
   

   1. Install the generator cable to the hybrid transaxle assembly with the 3 bolts.

      Torque:

      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note

      Keep the sealing surface of the generator cable and the connector terminal joint free of foreign matter.

   2. Engage the 2 claws to install a new terminal cap.

      Note

      When installing the terminal cap to the generator cable terminal block, keep the sealing surface free of foreign matter.

   3. 

      Place the generator cable connector shell in position and install it with the 3 bolts.

      Torque:

      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

   4. Connect the generator cable clamp to the motor cable bracket.

2. INSTALL RADIATOR PIPE

   
   

   1. Install the radiator pipe with the 2 bolts.

      Torque:

      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

   2. Connect the No. 3 radiator hose, No. 4 water by-pass hose and No. 1 radiator hose with the 3 clamps.

3. INSTALL INVERTER TRAY BRACKET (for 2ZR-FXE)

   Click here

4. INSTALL INVERTER TRAY BRACKET (for 5ZR-FXE)

   Click here

5. INSTALL INVERTER RESERVE TANK ASSEMBLY (for 2ZR-FXE)

   Click here

6. INSTALL INVERTER RESERVE TANK ASSEMBLY (for 5ZR-FXE)

   Click here

7. INSTALL INVERTER WITH CONVERTER ASSEMBLY

   Click here

8. CONNECT WATER HOSE

   Click here

9. CONNECT NO. 2 ENGINE ROOM WIRE

   Click here

10. REMOVE INVERTER COVER

    Click here

11. CONNECT NO. 2 ENGINE WIRE

    Click here

12. CONNECT MOTOR CABLE

    Click here

13. CONNECT GENERATOR CABLE

    Click here

14. CONNECT FRAME WIRE

    Click here

15. CHECK HIGH VOLTAGE CABLE CONNECTION

    Click here

16. INSTALL INVERTER COVER

    Click here

17. INSTALL ENGINE ROOM MAIN WIRE

    Click here

18. INSTALL NO. 1 INVERTER BRACKET

    Click here

19. INSTALL SERVICE PLUG GRIP

    Click here

20. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

21. INSTALL REAR FLOOR BOARD UPPER NO. 3 PLATE

    Click here

22. INSTALL DECK FLOOR BOX RH

    Click here

23. INSTALL REAR NO. 3 FLOOR BOARD

    Click here

24. INSTALL REAR DECK FLOOR BOX

    Click here

25. INSTALL REAR NO. 2 FLOOR BOARD

    Click here

26. ADD COOLANT (for Inverter)

    Click here

27. ADD COOLANT (for Engine)

    for 2ZR-FXE: Click here

    for 5ZR-FXE: Click here

28. INSPECT FOR COOLANT LEAK (for Inverter)

    Click here

29. INSPECT FOR COOLANT LEAK (for Engine)

    for 2ZR-FXE: Click here

    for 5ZR-FXE: Click here

30. INSTALL RADIATOR SUPPORT OPENING COVER

    Click here

31. INSTALL INVERTER COVER ASSEMBLY LH (w/ Cover)

    Click here

32. INSTALL NO. 1 ENGINE UNDER COVER (for 2ZR-FXE)

    Click here

33. INSTALL NO. 1 ENGINE UNDER COVER (for 5ZR-FXE)

    Click here

34. INSTALL FRONT LOWER BUMPER ABSORBER (for 2ZR-FXE)

    Click here

35. INSTALL FRONT LOWER BUMPER ABSORBER (for 5ZR-FXE)

    Click here