HV Frame Cable Replacement

welcome. sorry no idea, but a great birthday gift! all the best.

 

This focus of this video (by NutzAboutBolts, thanks!!!) is spark plug access, but it describes in detail the steps required to access the rear of engine area. You need to remove the trim at bottom of windshield, wiper arms and motors. Crazy but necessary. Do this and you should get decent access.

 

On the one hand: you maybe wouldn't have this vehicle if the battery hadn't been stolen. On the other hand, the idiots that would do something like cut the cable, they should be... mmm, better not say, lol.

 

Electrocuted by 201 volts? Too bad there were those HV shut-off relays!

 

I don't know if the "v" wagon uses a different HV battery, but dissimilarities might hopefully mean that it is less likely to be stolen.

Best wishes on your endeavor. It's a real nice thing to be doing for your dad.

As far as I can see, a lot of senior citizens are driving really old gas guzzling "boats" or newer sub-compact Kias and Huyndais. Both are less than ideal for them. Unfortunately, that's about all they can afford.

 

That's a real bummer.

Again kindness is a sign of kindness.

This might be a better price;

Toyota Parts - Camelback Toyota Parts - Genuine OEM Parts - Free Shipping

 

Thank you for the link

 

You're welcome.

Quoted from a Department of Energy report from Oak Ridge, TN;


"The conductor size has
decreased significantly from the 2004 to the 2010 Prius (motor and generator are the same), the result of
increased voltage and speed with only a slightly higher power rating. The 2010 Prius conductors contain
50 unbundled, 0.45 mm diameter wires, and in all, is approximately equivalent to an 8 American wire
gauge (AWG) wire."


.If you can get a "pigtail" including where it is cut off at a wrecking yard. I saw a suitable at Harbor Freight for about $55, The red 8 gauge insulated crimp butt connectors can be had at any large electrical supplies outlet.

The conductors would work just as well as a complete cable.

 

The cables are shielded. A close equivalent is probably EXRAD-150-FXSI-10. Joining shielded cable with a butt connector will be challenging, while keeping cable integrity and dielectric rating, and avoiding a fire hazard in the back of your car. Now, if you could find the complete cable assembly in a salvage yard, uncut....

I've never found (well, also haven't looked very hard) any source to order that Exrad cable. I guess if it came down to needing to order a spool of the stuff, I'd go in on a group purchase just to have some around....

-Chap

 

This is at the battery end end. Orientation is standing at the hatch opening, looking in at left/rear corner of battery. I think.



And two pictures at the inverter end:






Addendum: frame wire connection at inverter:



(all the same torque)

 

As far as I can see, those two pictures at the inverter end are for the cables that connect the two transaxle motors, MG1 and MG2. What you'll want to find is the connection of the forward end of your frame cable.

Now, if you sign up over at techinfo.toyota.com (which may set you back a modest $15), you'll have total access to the pictures Mendel sent, the other pictures Mendel didn't send, and answers to whatever other questions might come to your mind during the work. It's hard to overstate how thorough and useful Toyota's manuals are.

-Chap

 

Not 100% sure, but I think they're these?

 

I forgot to answer this part of your question. The answer is, kind of in general, yes, if you know the size, thread pitch, material, and hardness of the fastener and what it is threaded into. There are some general references for that (the book titled Machinery's Handbook is probably the granddaddy of them).

Toyota has used a marking system for their nuts and the heads of their bolts, and the table from nut mark/head mark/size&pitch to "normal" torque is given in the manual (in my 2001 that's pages SS-1 and SS-2, don't know where they'd be in the 2013 but should not be hard to find).

The thing is, there are special applications all over the car with their own specific requirements and torques, so a lot of fasteners will have explicit torques given in the instructions that pertain to that part. The general tables on SS-1 and SS-2 are for the situations where an explicit torque isn't shown.

-Chap