Main Battery Cable
MAIN BATTERY CABLEREPLACEMENT
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.1
NOTICE: Wear insulating gloves.
27. REMOVE WIRING HARNESS PROTECTOR COVER NO.3
NOTICE: Wear insulating gloves.
28. REMOVE BATTERY CARRIER CUSHION NO.3
NOTICE: Wear insulating gloves.
a. Peel off the bonded parts, then remove the battery carrier cushion No. 3.
29. REMOVE MAIN BATTERY CABLE
NOTICE: Wear insulating gloves.
a. Remove the terminal cover shown in the illustration.
b. Remove the nut, then disconnect the aluminum shield wire.
c. Remove the nut, then disconnect the main battery cable from the system main relay No. 3.
d. Remove the nut, then disconnect the main battery cable from the frame wire No. 2.
e. Remove the main battery cable from the HV battery.
30. INSTALL MAIN BATTERY CABLE
NOTICE: Wear insulating gloves.
a. Temporarily fasten the main battery cable to the HV battery.
b. Install the main battery cable to the frame wire No. 2 with a new nut.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
c. Install the main battery cable to the system main relay No. 3 with a new nut.
Torque: 5.6 Nm (57 kgf-cm, 50 inch lbs.)
d. Install the aluminum shield wire with a new nut.
Torque: 3.3 Nm (34 kgf-cm, 29 inch lbs.)
e. Install the terminal cover shown in the illustration.
31. INSTALL BATTERY CARRIER CUSHION NO.3
NOTICE: Wear insulating gloves.
a. Degrease and clean the installation surface of the battery carrier cushion No. 3.
b. Install a new battery carrier cushion No. 3.
32. INSTALL WIRING HARNESS PROTECTOR COVER NO.1
NOTICE: Wear insulating gloves.
33. INSTALL WIRING HARNESS PROTECTOR COVER NO.3
NOTICE: Wear insulating gloves.
34. INSTALL BATTERY COVER SUB-ASSY
35. INSTALL HV BATTERY ASSY
36. INSTALL FRAME WIRE
NOTICE: Wear insulating gloves.
37. INSTALL JUNCTION TERMINAL
NOTICE: Wear insulating gloves.
38. INSTALL BATTERY CARRIER PANEL NO.6
39. INSTALL QUARTER VENT DUCT
NOTICE: Wear insulating gloves.
40. INSTALL BATTERY BRACKET REINFORCEMENT
41. INSTALL QUARTER VENT DUCT INNER NO.2
42. INSTALL BATTERY CARRIER BRACKET
43. INSTALL DECK TRIM SIDE PANEL ASSY RH
44. INSTALL DECK TRIM SIDE PANEL ASSY LH
45. INSTALL DECK FLOOR BOX LH
46. INSTALL REAR FLOOR BOARD NO.4
47. INSTALL REAR SIDE SEAT BACK FRAME RH
48. INSTALL REAR SIDE SEAT BACK FRAME LH
49. INSTALL REAR FLOOR BOARD NO.1
50. INSTALL REAR SEAT CUSHION ASSY
51. INSTALL TONN7EAU COVER ASSY
52. INSTALL DECK TRIM COVER REAR
53. INSTALL SERVICE PLUG GRIP
NOTICE: Wear insulating gloves.
54. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 6.0 Nm (61 kgf-cm, 53 inch lbs.)
55. INSTALL REAR FLOOR BOARD NO.3
56. INSTALL DECK FLOOR BOX REAR
57. INSTALL REAR FLOOR BOARD NO.2
58. POWER WINDOW CONTROL SYSTEM INITIALIZE