Battery Bus Junction Board: Service and Repair
JUNCTION BLOCK ASSYREPLACEMENT
NOTICE:
^ When working on the high voltage systems, always wear insulating gloves.
^ After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU.
^ Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle.
^ After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes.
1. PRECAUTION
2. REMOVE REAR FLOOR BOARD NO.2
3. REMOVE DECK FLOOR BOX REAR
4. REMOVE REAR FLOOR BOARD NO.3
5. DISCONNECT BATTERY NEGATIVE TERMINAL
6. REMOVE SERVICE PLUG GRIP
7. REMOVE DECK TRIM COVER REAR
8. REMOVE TONNEAU COVER ASSY
9. REMOVE REAR SEAT CUSHION ASSY
10. REMOVE REAR FLOOR BOARD NO.1
11. REMOVE REAR SIDE SEAT BACK FRAME LH
12. REMOVE REAR SIDE SEAT BACK FRAME RH
13. REMOVE REAR FLOOR BOARD NO.4
14. REMOVE DECK FLOOR BOX LH
15. REMOVE DECK TRIM SIDE PANEL ASSY LH
16. REMOVE DECK TRIM SIDE PANEL ASSY RH
17. REMOVE BATTERY CARRIER BRACKET
18. REMOVE QUARTER VENT DUCT INNER NO.2
19. REMOVE BATTERY BRACKET REINFORCEMENT
20. REMOVE QUARTER VENT DUCT
21. REMOVE BATTERY CARRIER PANEL NO.6
22. REMOVE JUNCTION TERMINAL
NOTICE: Wear insulating gloves.
23. REMOVE FRAME WIRE
NOTICE: Wear insulating gloves.
24. REMOVE HV BATTERY ASSY
25. REMOVE BATTERY COVER SUB-ASSY
26. REMOVE WIRING HARNESS PROTECTOR COVER NO.2
NOTICE: Wear insulating gloves.
27. REMOVE WIRING HARNESS PROTECTOR COVER NO.4
NOTICE: Wear insulating gloves.
28. REMOVE JUNCTION BLOCK ASSY
NOTICE: Wear insulating gloves.
a. Remove the 26 nuts and junction block assembly.
29. INSTALL JUNCTION BLOCK ASSY
NOTICE: Wear insulating gloves.
a. Install the junction block assembly with 26 new nuts.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
30. INSTALL WIRING HARNESS PROTECTOR COVER NO.2
NOTICE: Wear insulating gloves.
31. INSTALL WIRING HARNESS PROTECTOR COVER NO.4
NOTICE: Wear insulating gloves.
32. INSTALL BATTERY COVER SUB-ASSY
33. INSTALL HV BATTERY ASSY
34. INSTALL FRAME WIRE
NOTICE: Wear insulating gloves.
35. INSTALL JUNCTION TERMINAL
NOTICE: Wear insulating gloves.
36. INSTALL BATTERY CARRIER PANEL NO.6
37. INSTALL QUARTER VENT DUCT
38. INSTALL BATTERY BRACKET REINFORCEMENT
39. INSTALL QUARTER VENT DUCT INNER NO.2
40. INSTALL BATTERY CARRIER BRACKET
41. INSTALL DECK TRIM SIDE PANEL ASSY RH
42. INSTALL DECK TRIM SIDE PANEL ASSY LH
43. INSTALL DECK FLOOR BOX LH
44. INSTALL REAR FLOOR BOARD NO.4
45. INSTALL REAR SIDE SEAT BACK FRAME RH
46. INSTALL REAR SIDE SEAT BACK FRAME LH
47. INSTALL REAR FLOOR BOARD NO.1
48. INSTALL REAR SEAT CUSHION ASSY
49. INSTALL TONNEAU COVER ASSY
50. INSTALL DECK TRIM COVER REAR
51. INSTALL SERVICE PLUG GRIP
NOTICE: Wear insulating gloves.
52. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 6.0 Nm (61 kgf-cm, 53 inch lbs.)
53. INSTALL REAR FLOOR BOARD NO.3
54. INSTALL DECK FLOOR BOX REAR
55. INSTALL REAR FLOOR BOARD NO.2
56. POWER WINDOW CONTROL SYSTEM INITIALIZE