Battery Plug
BATTERY PLUGREPLACEMENT
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 BATTERY CLAMP PAD (BATTERY CARRIER CUSHION NO.1)
NOTICE: Wear insulating gloves.
a. Peel off the bonded parts, then remove the battery clamp pad (the battery carrier cushion No. 1).
27. REMOVE WIRING HARNESS PROTECTOR COVER NO.1
a. Flip open the wiring harness protector cover.
b. Remove the 2 nuts, then disconnect the service plug.
c. Remove the wiring harness protector cover No. 1.
28. REMOVE BATTERY PLUG
a. Disconnect the connector clamp.
b. Remove the 2 bolts, then disconnect the service plug from the upper battery carrier.
c. Flip open the wiring harness protector cover No. 4 shown in the illustration, then remove the service plug from the junction block.
29. INSTALL BATTERY PLUG
a. Temporarily fasten the service plug.
b. Install the service plug to the upper battery carrier with the 2 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
c. Assemble the connector clamp.
30. INSTALL WIRING HARNESS PROTECTOR COVER NO.1
a. Temporarily fasten the wiring harness protector cover No. 1 to the service plug.
b. Install the wiring harness protector cover No. 1 through the service plug with 2 new nuts.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
31. INSTALL BATTERY CLAMP PAD (BATTERY CARRIER CUSHION NO.1)
NOTICE: Wear insulating gloves.
a. Install a new clamp pad (the battery carrier cushion No. 1).
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