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Section 2: Wire Harness Repair Procedure

1. Remove the negative (-) terminal from the battery.





2. Remove the panel and scuff plate (near Power switch).





3. Disengage the 2 claws and clip and remove the upper instrument panel finish panel (located to the right of the steering column cover).





4. Remove lower instrument panel finish panel assembly (located lower left side of steering column cover).





5. Remove upper instrument panel finish panel sub-assembly (located just above steering column cover).





6. Remove left (driver) side front door scuff plate.





7. Remove left (driver) cowl side trim sub-assembly (also called kick panel cover).

8. Remove left (driver) side front seat.

Refer to the Technical Information System (TIS), 2012 model year Prius V Repair Manual:

^ Vehicle Interior - Seat - "Seat Front Seat Assembly:

9. Remove audio amplifier cover. This is located just below where the driver seat was removed in the previous step.





A. Disengage the 2 clips and 2 claws.

B. Remove audio amplifier cover





10. Follow the next steps to install the NEW sub-wire harness. Highlighted (Green) line in Figure 8 shows the approximate route of the new sub-wire harness. The (red) circles show the location of connectors LI1 and L30.





A. Disconnect the lower section of connector LI1 (Blue color).

B. Install both connectors from the new sub-wire harness into the both sections of connector LI1.

C. Install sound insulation sheet to around the electrical connectors not secured to the dash panel.

NOTE

Sound insulation sheet is included with the new sub-wire harness kit.





D. Route new sub-wire harness. Attach tie wraps at red arrow locations to secure the new sub-wire harness.





11. Continue to route the new sub-wire harness along the left side rocker panel area. When the new sub-wire harness is routed near the driver seat front mount area, route the new sub-wire harness under the carpet to the audio amplifier area.

12. Remove the tape from the end of the new sub-wire harness (if present) so that the 4 wires in the loom can be accessed.








13. Unplug connectors L30 and L31 from the audio amplifier.





14. Remove the tape from the end of the audio amplifier harness and move the 4 wires out of the loom with BLACK GREEN BLUE and LIGHT GREEN insulation.

15. Install the BLACK wire from the new sub-wire harness to the audio amplifier circuit.

NOTE

A total of 6 wires in both the new sub-wire harness and audio amplifier harness are to be cut and reattached. These wires are in either the new sub-wire harness or audio amplifier harness. In this step, ONLY the BLACK wire is serviced.





A. Identify the BLACK wire at the audio amplifier L30 connector terminal 24.





B. At a 60 mm (2.36 in.) distance from the amplifier electrical connector cut the BLACK wire.





C. Identify the BLACK wire at the new sub-wire harness attached to a white 2-terminal connector and then cut this wire 10 mm (0.39 in.) from the white electrical connector.





D. Remove 8 mm (0.32 in.) of insulation from the end of the BLACK wire.

E. Remove 8 mm (0.32 in.) of insulation from the end of the BLACK wire from the new sub-wire harness.

F. Install the thermo tubing on the BLACK wire in the new sub-wire harness.

NOTE

Move thermo tubing away from the BLACK wire ends so that thermo tubing does NOT interfere with the next wire crimping operation.





G. Install a barrel sleeve onto each of the recently modified BLACK wires.








H. Place the sleeve into the 1.25 mm crimp die of the SST.

SST: 009042-2C100





I. With the sleeve correctly placed in the SST and wire fully inserted into the sleeve crimp one side of the sleeve in the area shown by closing the handles fully until they release. Crimp the other wire in the same manner.





J. Lightly tug on each connection to ensure that the wire is securely crimped.





K. Move the thermo tubing along on the referenced wire in a manner that it covers the metal sleeve. Center the thermo tubing over the center of the barrel sleeve.








L. Using a heat gun heat the thermo tubing until it shrinks and seals the repaired connection.

16. Install the GREEN wire from the new sub-wire harness to the audio amplifier circuit.





A. Identify the GREEN wire (NOT the LIGHT GREEN wire) at L30 connector terminal 9.





B. At a 60 mm (2.36 in.) distance from the amplifier electrical connector cut the GREEN wire.





C. Identify the GREEN wire at the new sub-wire harness attached to a white 2-terminal connector and then cut this wire 10 mm (0.39 in.) from the white electrical connector.





D. Remove 8 mm (0.32 in.) of insulation from the end of the GREEN wire.

E. Remove 8 mm (0.32 in.) of insulation from the end of the GREEN new sub-wire harness.

F. Install the thermo tubing on the GREEN wire in the new sub-wire harness.

NOTE

Move thermo tubing away from the GREEN wire ends so that thermo tubing does not interfere with the next wire crimping operation.





G. Install a barrel sleeve onto each of the recently modified GREEN wires.





H. Crimp the sleeve to attach referenced wires. Also insulate wires by applying thermo tubing on affected area. Apply steps 15H to 15L for the referenced wires.

17. Install the BLUE wire from the new sub-wire harness to the audio speaker circuit.





A. Identify the BLUE wire at the audio amplifier L30 connector, terminal 30.





B. At a 60 mm (2.36 in.) distance from the amplifier electrical connector, cut the BLUE wire.





C. Identify the BLUE wire at the new sub-wire harness attached to a white 2-terminal connector and then cut this wire 10 mm (0.39 in.) from the white electrical connector.





D. Remove 8 mm (0.32 in.) of insulation from the BLUE wire.

E. Remove 8 mm (0.32 in.) of insulation from the end of the BLUE wire in the new sub-wire harness.

F. Install the thermo tubing on the BLUE wire in the new sub-wire harness.

NOTE

Move thermo tubing away from the wire ends so that thermo tubing does not interfere with the next wire crimping operation.








G. Install a barrel sleeve onto each of the recently modified BLUE wires.

H. Crimp the sleeve to attach referenced wires. Also insulate wires by applying thermo tubing on affected area. Apply steps 15H to 15L for the referenced wires.

18. Install the LIGHT GREEN wire from the new sub-wire harness to the audio speaker circuit.





A. Identify the LIGHT GREEN wire at the audio amplifier L30 connector, terminal 15.





B. At a 60 mm (2.36 in.) distance from the amplifier electrical connector cut the LIGHT GREEN wire.





C. Identify the LIGHT GREEN wire at the new sub-wire harness attached to a white 2-terminal connector and then cut this wire 10 mm (0.39 in.) from the white electrical connector.





D. Remove 8 mm (0.32 in.) of insulation from the end of the LIGHT GREEN wire.

E. Remove 8 mm (0.32 in.) of insulation from the end of the LIGHT GREEN new sub-wire harness.

F. Install the thermo tubing on the LIGHT GREEN wire in the new sub-wire harness.

NOTE

Move thermo tubing away from the LIGHT GREEN wire ends so that thermo tubing does not interfere with the next wire crimping operation.





G. Install a barrel sleeve onto each of the recently modified LIGHT GREEN wires.





H. Crimp the sleeve to attach referenced wires. Also insulate wires by applying thermo tubing on affected area. Apply steps 15H to 15L for the referenced wires.

19. Install the BLUE wire from the audio amplifier to the BLACK from the DCM circuit.





A. Identify the BLUE wire at the audio amplifier L30 connector terminal 30.

B. Identify the BLACK wire from the speaker circuit harness.

NOTE

This should be the ONLY BLACK wire coming from the harness that is cut.





C. Remove 8 mm (0.32 in.) of insulation from the end of the BLUE wire.





D. Remove 8 mm (0.32 in.) of insulation from the end of the BLACK wire.

E. Install the thermo tubing on the BLACK wire on the harness that goes towards the center console.

NOTE

Move thermo tubing away from the wire ends so that thermo tubing does not interfere with the next wire crimping operation.





F. Install a barrel sleeve onto each of the recently modified wires.





G. Crimp the sleeve to attach referenced wires. Also insulate wires by applying thermo tubing on affected area. Apply steps 15H to 15L for the referenced wires.

20. Install the LIGHT GREEN wire from the audio amplifier to the GREEN wire from the DCM circuit.





A. Identify the LIGHT GREEN wire at the audio amplifier L30 connector terminal 15.

B. Identify the GREEN wire from the speaker circuit harness.

NOTE

This should be the ONLY GREEN wire coming from the harness that is cut.





C. Remove 8 mm (0.32 in.) of insulation from the end of the GREEN wire.





D. Remove 8 mm (0.32 in.) of insulation from the end of the LIGHT GREEN wire.

E. Install the thermo tubing on the LIGHT GREEN wire on the harness that goes towards the center console.

NOTE

Move thermo tubing away from the wire ends so that thermo tubing does not interfere with the next wire crimping operation.





F. Install a barrel sleeve onto each of the recently modified GREEN wires.





G. Crimp the sleeve to attach referenced wires. Also insulate wires by applying thermo tubing on affected area. Apply steps 15H to 15L for the referenced wires.


21. Reattach electrical connectors L30 and L31 to the audio amplifier.


22. Reinstall cover on audio amplifier.


23. Install the left (driver) side front seat.

Refer to TIS 2012 model year Prius V Repair Manual:

^ Vehicle Interior - Seat - "Seat Front Seat Assembly: Installation"

24. Reinstall the removed dash trim panels.

Perform steps 2 - 7 in reverse order.

25. Reinstall the negative battery terminal.
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