Toyota Prius: Motor Cable

Toyota Prius (XW60) 2023-2025 Service Manual / Drivetrain / Pa10/pb10/pb12 (hybrid Transmission / Transaxle) / Motor Cable

Removal
Installation

Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during motor cable removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
for 2ZR-FXE: Replacement of ECM	Update ECU security key	Toyota Prius Vehicle Control History (RoB) are stored
	ECU configuration	-
	Perform Toyota Prius Vehicle Identification Number (VIN) registration	DTC is output
for M20A-FXS: Replacement of ECM	Update ECU security key	Toyota Prius Vehicle Control History (RoB) are stored
	ECU configuration	-
	Perform Toyota Prius Vehicle Identification Number (VIN) registration	DTC is output
Replacement of inverter with converter assembly	ECU configuration	-
Replacement of inverter with converter assembly	Resolver learning	DTCs are stored Slight vibration at a Toyota Prius vehicle speed of 5 km/h (3 mph) or less Shock or vibration during acceleration	2ZR-FXE: for M20A-FXS HEV model: for M20A-FXS PHEV Model:
for PHEV Model: Service Plug Grip	High voltage fuse accumulated load history reset	DTCs are stored

CAUTION:

Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.
- 2ZR-FXE:
  Click here
- for M20A-FXS HEV Model:
  Click here
- for M20A-FXS PHEV Model:
  Click here
To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.

HINT:

When the cable is disconnected / reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

Learning completes when Toyota Prius vehicle is driven

Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
Front Camera System	Drive the Toyota Prius vehicle straight ahead at 35 km/h (22 mph) or more for 5 seconds or more.

Learning completes when vehicle is operated normally

Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
1: w/o Power Back Door System 2: w/ Power Back Door System
Power Door Lock Control System*1 Back door opener	Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch.
Power Back Door System*2	Reset back door close position
Air Conditioning System	for HEV Model: After the ignition switch is turned to ON, the servo motor standard position is recognized. for PHEV Model: After the ignition switch is turned to ON, the servo motor and expansion valve standard position is recognized.	-

CAUTION / NOTICE / HINT

COMPONENTS (REMOVAL)

Procedure		Part Name Code
1	INVERTER WITH CONVERTER ASSEMBLY	G9200	-	-	-
2	TERMINAL CAP	82823M		-	-
3	MOTOR CABLE	G1148		-	-

PROCEDURE

1. REMOVE INVERTER WITH CONVERTER ASSEMBLY

for HEV Model: Click here
for PHEV Model: Click here

2. REMOVE TERMINAL CAP

CAUTION:

Be sure to wear insulated gloves.

NOTICE:

Keep the motor cable terminals and their installation area free from foreign matter, water, etc.
Do not touch the waterproof seal of the terminal cap or terminals of the motor cable.

Waterproof Seal

3. REMOVE MOTOR CABLE

CAUTION:

Be sure to wear insulated gloves.

NOTICE:

Keep the motor cable terminals and their installation area free from foreign matter, water, etc.
Do not touch the waterproof seal or terminals of the motor cable.
After removing the motor cable, cover the opening of the hybrid Toyota Prius vehicle transaxle assembly with tape (non-residue type) or equivalent to prevent entry of foreign matter and water.

Waterproof Seal

(1) Using an insulated tool, remove the 6 bolts and motor cable from the hybrid Toyota Prius vehicle transaxle assembly.

Installation

INSTALLATION

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure		Part Name Code
1	MOTOR CABLE	G1148		-	-
2	TERMINAL CAP	82823M		-	-
3	INVERTER WITH CONVERTER ASSEMBLY	G9200	-	-	-

Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)

N*m (kgf*cm, ft.*lbf): Specified torque

PROCEDURE

1. INSTALL MOTOR CABLE

CAUTION:

Be sure to wear insulated gloves.

NOTICE:

To prevent the threads from being damaged, temporarily tighten the 6 bolts by hand.
Do not damage the terminals or hybrid Toyota Prius vehicle transaxle assembly during installation.
Keep the motor cable terminals and their installation area free from foreign matter, water, etc.
Do not touch the waterproof seal or terminals of the motor cable.
Make sure the waterproof seal is not cut or pinched during installation.

Waterproof Seal

(1) Using an insulated tool, install the motor cable to the hybrid Toyota Prius vehicle transaxle assembly with the 6 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

2. INSTALL TERMINAL CAP

CAUTION:

Be sure to wear insulated gloves.

NOTICE:

Keep the motor cable terminals and their installation area free from foreign matter, water, etc.
Do not touch the waterproof seal of the terminal cap or terminals of the motor cable.
Make sure the waterproof seal is not cut or pinched during installation.