HV BATTERY INSTALLATION


  1. INSTALL NO. 2 HYBRID BATTERY PACK WIRE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Connect the connector.

    2. Attach the 5 clamps to install the No. 2 hybrid battery pack wire.

      Note

      If the wire harness clamp is damaged, replace it with a new one.

  2. INSTALL BATTERY SMART UNIT

    CAUTION:

    Be sure to wear insulated gloves.


    1. Install the battery smart unit with the nut.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    2. Connect the 3 connectors.

  3. INSTALL HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


    1. Install the hybrid battery junction block assembly with the 3 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    2. Connect the 4 connectors.

  4. INSTALL HYBRID BATTERY TERMINAL BLOCK

    A01H0TEE01

    CAUTION:

    Be sure to wear insulated gloves.


    1. Install the hybrid battery terminal block with the 3 nuts and bolt in the order shown in the illustration.

      Torque:
      for bolt
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
      for nut (Except hybrid battery junction block assembly terminal)
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
      for nut (Hybrid battery junction block assembly terminal)
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

      Note

      Be sure to follow the order shown when tightening the nuts and bolt.

  5. INSTALL NO. 4 HYBRID VEHICLE BATTERY SHIELD REINFORCEMENT

    CAUTION:

    Be sure to wear insulated gloves.


    1. Install the No. 4 hybrid vehicle battery shield reinforcement with the 2 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  6. INSTALL POWER STEERING CONVERTER WIRE

    A01GYNG

    CAUTION:

    Be sure to wear insulated gloves.


    1. Install the power steering converter wire with the nut.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    2. Connect the connector.

  7. INSTALL NO. 3 HYBRID BATTERY INTAKE DUCT

    CAUTION:

    Be sure to wear insulated gloves.


    1. Install the No. 3 hybrid battery intake duct and connect the intake air temperature sensor.

  8. INSTALL HV CONVERTER

    CAUTION:

    Be sure to wear insulated gloves.


    1. Install the hybrid vehicle converter with the 4 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    2. Attach the 4 clamps.

      Note

      If a wire harness clamp is damaged, replace it with a new one.

    3. Connect the 3 connectors.

  9. INSTALL NO. 2 HYBRID VEHICLE CONVERTER SIGNAL WIRE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Connect the connector to install the No. 2 hybrid vehicle converter signal wire.

  10. INSTALL CONVERTER COOLING BLOWER BRACKET

    CAUTION:

    Be sure to wear insulated gloves.


    1. Attach the 2 clamps to install the converter cooling blower bracket.

  11. INSTALL HV CONVERTER POWER SUPPLY WIRE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Attach the clamp.

    2. Install the hybrid vehicle converter power supply wire with the nut.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  12. INSTALL CONVERTER COOLING BLOWER

    CAUTION:

    Be sure to wear insulated gloves.


    1. Attach the 2 claws.

    2. Install the converter cooling blower with the 2 nuts and bolt.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    3. Attach the clamp and connect the connector.

  13. INSTALL CONVERTER WIRE BRACKET

    A01GYCWE01

    CAUTION:

    Be sure to wear insulated gloves.


    1. Install the converter wire bracket with the 2 nuts in the direction shown in the illustration.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    2. Attach the clamp.

  14. INSTALL CONVERTER COOLING EXHAUST DUCT

    CAUTION:

    Be sure to wear insulated gloves.


    1. Attach the clamp and 2 claws to install the converter cooling exhaust duct.

    2. Install the clip.

  15. INSTALL NO. 8 HYBRID VEHICLE BATTERY SHIELD SUB-ASSEMBLY

    A01GZIZ

    CAUTION:

    Be sure to wear insulated gloves.


    1. Install the No. 8 hybrid vehicle battery shield sub-assembly as shown in the illustration.

    2. Install the 5 nuts and bolt.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    3. Attach the clamp.

  16. INSTALL NO. 4 HYBRID BATTERY SHIELD PANEL

    CAUTION:

    Be sure to wear insulated gloves.


    1. Install the No. 4 hybrid battery shield panel with the 6 nuts and bolt.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  17. INSTALL REAR HYBRID BATTERY WITH LABEL SHIELD

    A01GW6GE01

    CAUTION:

    Be sure to wear insulated gloves.


    1. Install the rear hybrid battery with label shield with the 2 nuts and 3 bolts in the order shown in the illustration.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  18. INSTALL NO. 1 HYBRID BATTERY INTAKE DUCT

    CAUTION:

    Be sure to wear insulated gloves.


    1. Install the No. 1 hybrid battery intake duct with the 3 clips.

  19. INSTALL BATTERY COOLING BLOWER ASSEMBLY (for Lower Side)

    A01GX7WE01

    CAUTION:

    Be sure to wear insulated gloves.


    1. Attach the 2 claws to install the battery cooling blower assembly (for lower side).

    2. Install the nut and 2 bolts in the order shown in the illustration.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    3. Connect the connector.

    4. Attach the clamp.

  20. INSTALL NO. 4 HYBRID VEHICLE BATTERY CARRIER BRACKET SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


    1. Install the No. 4 hybrid vehicle battery carrier bracket sub-assembly with the 4 nuts and 3 bolts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    2. Install the No. 1 hybrid battery packing as shown in the illustration.

      A01H1B0E02
      Text in Illustration
      *a Align with edge of metal plate (reference point) *b Make sure No. 1 hybrid battery packing does not cover bolt
      *c Align with edge of weld (reference point) *d LH
      *e FR - -

  21. INSTALL NO. 1 HYBRID BATTERY SHIELD SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


    1. Install the No. 1 hybrid battery shield sub-assembly with the 2 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  22. INSTALL NO. 4 HYBRID BATTERY INTAKE DUCT


    1. Attach the 2 claws to install the No. 4 hybrid battery intake duct to the battery cooling blower assembly (for upper side).

  23. INSTALL BATTERY COOLING BLOWER ASSEMBLY (for Upper Side)

    A01GYCOE01

    CAUTION:

    Be sure to wear insulated gloves.


    1. Install the battery cooling blower assembly (for upper side) with the nut and 2 bolts in the order shown in the illustration.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    2. Connect the connector.

  24. INSTALL NO. 6 HYBRID VEHICLE BATTERY SHIELD SUB-ASSEMBLY

    A01H0JLE01

    CAUTION:

    Be sure to wear insulated gloves.


    1. Install the No. 6 hybrid vehicle battery shield sub-assembly with the 3 nuts and 3 bolts in the order shown in the illustration.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  25. SET HV BATTERY IN VEHICLE

    A01H0G1E01
    Text in Illustration
    *a Part A
    *b Vehicle Rear

    CAUTION:

    Be sure to wear insulated gloves.


    1. Place the piece of cardboard in the luggage compartment.

    2. Using a rope or equivalent, set the HV battery onto the piece of cardboard.

      Note


      • Use cardboard or other similar material to protect the HV battery and vehicle body from damage.

      • In order to prevent the hydrogen hose from being damaged, make sure the rope does not extend toward the rear of the vehicle past the part labeled A when lifting the HV battery.

  26. INSTALL POWER STEERING CONVERTER ASSEMBLY

    CAUTION:

    Perform work using insulated gloves and insulated tools.


    1. A01GX6P

      Install the 4 nuts and power steering converter assembly.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    2. A01H0PW

      Connect the 5 connectors.

    3. A01H0XS

      Install the 2 nuts and power steering ECU bracket.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  27. INSTALL HV BATTERY

    A01GW21

    CAUTION:

    Be sure to wear insulated gloves.


    1. Push the HV battery and piece of cardboard together into the vehicle.

      Note


      • When pushing in the HV battery, 2 people are needed. One should work from the luggage compartment side and the other from the cabin side.

      • When pushing in the HV battery, do not allow the wire harnesses and the HV battery case to interfere with the vehicle body.

    2. Pull out the piece of cardboard and remove it.

    3. Temporarily install the 3 bolts for the front part of the HV battery from the cabin side.

    4. A01GZ3KE01

      Install the 2 HV battery brackets with the 4 nuts and 2 bolts in the order shown in the illustration.

      Torque:
      for bolt
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      for nut
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    5. Tighten the 3 bolts for the front part of the HV battery from the cabin side.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    6. Remove the luggage compartment mat sub-assembly.

    7. w/ Spare Tire:

      Take the No. 4 luggage room wire and vehicle wire harness out of the gap, move the spare tire back to its original position and install the bolt.

    8. w/o Spare Tire:

      Remove the deck board assembly and tool box and take the No. 4 luggage room wire and vehicle wire harness out of the bottom of the luggage compartment.

    9. w/ Active Stabilizer Suspension System:

      Connect the 2 connectors to the rear active stabilizer control ECU.

    10. Install the air conditioning tube assembly to the HV battery with the 2 nuts.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    11. Attach the clamp and connect the No. 2 hybrid battery pack wire.

    12. Attach the 4 clamps and install the No. 4 luggage room wire with the 2 nuts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    13. Remove the 3 nuts holding the fusible link block assembly in place, and then attach the 2 clamps with the fusible link block assembly raised.

    14. Connect the 3 connectors.

    15. Install the fusible link block assembly with the 3 nuts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    16. Attach the clamp and connect the 2 connectors.

    17. A01GXJFE02
      Text in Illustration
      *a Nut A
      *b Nut B

      Install the No. 4 luggage room wire and hybrid vehicle converter power supply wire to the fusible link block assembly with the 3 nuts.

      Torque:
      for nut A
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }
      for nut B
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    18. Connect the connector.

    19. Attach the 2 claws.

    20. Attach the 3 claws to install the upper relay block cover.

    21. Attach the claw and install the wire harness protector with the 2 nuts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  28. INSTALL SPARE WHEEL GUARD SUB-ASSEMBLY (w/ Spare Tire)


    1. Install the spare wheel guard sub-assembly with the 2 clips.

  29. INSTALL SPARE WHEEL GUARD SUB-ASSEMBLY (w/o Spare Tire)

  30. INSTALL TOOL BOX (w/o Spare Tire)


    1. A01H04I

      Install the tool box with the 2 clips.

  31. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY (w/o Spare Tire)

  32. CONNECT BATTERY ROOM VENTILATION HOSE

    A01GXASE02
    Text in Illustration
    *a Correct
    *b Incorrect

    1. Connect the battery room ventilation hose to the floor with the grommet.

      Note

      After installing the grommet, make sure that there is no clearance between the grommet and body.

  33. CONNECT FRAME WIRE

    A01H05OE03
    Text in Illustration
    *a Vehicle Rear

    CAUTION:

    Be sure to wear insulated gloves.


    1. Install the battery shield contact as shown in the illustration.

      Note

      Be sure to install the battery shield contact in the correct direction.

    2. A01GZLTE02
      Text in Illustration
      *a Red Mark

      Connect the frame wire to the HV battery with the 2 nuts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

      Note

      Be sure to align the red mark on the frame wire with the red part of the terminal block.

  34. INSTALL NO. 2 HYBRID BATTERY SHIELD SUB-ASSEMBLY

    A01GZCCE02
    Text in Illustration
    *a Battery Cover Lock Striker
    *b Push

    CAUTION:

    Be sure to wear insulated gloves.


    1. Install the No. 2 hybrid battery shield sub-assembly to the HV battery.

    2. Install the No. 2 hybrid battery shield sub-assembly with the 2 nuts in the order shown in the illustration.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    3. Install the battery cover lock striker and push the button.

  35. INSTALL HOLE PLUG


    1. Install the 2 hole plugs.

  36. INSTALL REAR SEAT CONSOLE BOX LOWER BRACKET


    1. Install the rear seat console box lower bracket with the 6 bolts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  37. INSTALL NO. 2 CENTER FLOOR TO BRACE EXTENSION


    1. Install the No. 2 center floor to brace extension with the 3 clips.

  38. INSTALL NO. 1 CENTER FLOOR TO BRACE EXTENSION


    1. Install the No. 1 center floor to brace extension with the 3 clips.

  39. INSTALL REAR COOLER UNIT (w/ Rear Air Conditioning System)

    Click here

  40. INSTALL REAR COOLER UNIT (w/o Rear Air Conditioning System)

    Click here

  41. INSTALL REAR SEAT ASSEMBLY (for Fixed Seat Type)

    Click here

  42. INSTALL REAR SEAT ASSEMBLY (for Power Seat)

    Click here

  43. INSTALL REAR SEAT ASSEMBLY (for Ottoman)

    Click here

  44. INSTALL SERVICE PLUG GRIP

    CAUTION:

    Be sure to wear insulated gloves.


    1. Wear insulated gloves and insert the service plug grip.

    2. Turn the lever of the service plug grip 90° and slide the service plug grip downward until a click sound is heard.

      A01H263E02

  45. INSTALL SERVICE PLUG COVER


    1. Install the service plug cover with the 4 bolts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  46. INSTALL REAR SEAT LOWER CONSOLE BOX COVER (for 4-Passenger with Ottoman)


    1. Attach the 2 hooks and 4 claws to install the rear seat lower console box cover.

  47. INSTALL ARMREST DOOR CAP (except 4-Passenger with Ottoman)


    1. Attach the 2 hooks and 6 claws to install the armrest door cap.

  48. CONNECT CABLE TO BATTERY TERMINAL

    Note

    When disconnecting the cable some systems need to be initialized after the cable is reconnected Click here.

  49. INSTALL BATTERY SERVICE HOLE COVER LH


    1. A01GZIME02
      Text in Illustration
      *A for Standard
      *B for Ottoman

      Attach the battery service hole cover LH with the clip and fastening tape.

  50. INSTALL DECK TRIM SIDE BOARD LH (w/o Spare Tire)


    1. A01GXQQ

      Attach the 2 clips to install the deck trim side board LH.

  51. INSTALL DECK BOARD ASSEMBLY (w/o Spare Tire)

    A01GZ3P

  52. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY (w/ Spare Tire)

    A01GWKI

  53. CHECK SRS WARNING LIGHT

    Click here