HV BATTERY INSTALLATION

PROCEDURE

1. PRECAUTION

   
   

   1. When disposing of an HV battery, make sure to return it through an authorized collection agent who is capable of handling it safely. If the HV battery is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.

      CAUTION:

      
      

      • Accidents such as electric shock may result if the HV battery is disposed of improperly or abandoned. Therefore, make sure to return all HV batteries through an authorized collection agent.

      • After removing the HV battery, keep it away from water. Exposure to water may cause the HV battery to produce heat, resulting in a fire.

2. INSTALL NO. 5 HYBRID BATTERY INTAKE DUCT

   CAUTION:

   Wear insulated gloves.

   
   

   1. Install the No. 5 hybrid battery intake duct.

3. INSTALL NO. 12 HYBRID VEHICLE BATTERY SHIELD PANEL

   CAUTION:

   Perform work using insulated gloves and insulated tools.

   
   

   1. Connect the intake temperature sensor to the No. 12 hybrid vehicle battery shield panel.

   2. Attach the wire harness clamp.

   3. Install the No. 12 hybrid vehicle battery shield panel with the 2 bolts and 3 nuts.

      Torque:

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

   4. Install the wire harness clamp.

   5. Connect the service plug grip wire harness to the No. 12 hybrid vehicle battery shield panel with the bolt.

      Torque:

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

4. INSTALL NO. 2 HYBRID BATTERY PACK WIRE

   CAUTION:

   Be sure to wear insulated gloves.

   
   

   1. Attach the 3 wire harness clamps to install the No. 2 hybrid battery pack wire.

   2. Connect the connector.

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

   Click here

6. INSTALL NO. 4 HYBRID BATTERY INTAKE DUCT

   
   

   1. Install the No. 4 hybrid battery intake duct to the battery cooling blower assembly with the clip.

7. INSTALL NO. 2 HYBRID VEHICLE BATTERY UPPER COVER BRACKET

   CAUTION:

   Perform work using insulated gloves and insulated tools.

   
   

   1. Install the No. 2 hybrid vehicle battery upper cover bracket with the 2 nuts.

      Torque:

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

8. INSTALL BATTERY SMART UNIT

   Click here

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

   CAUTION:

   Perform work using insulated gloves and insulated tools.

   
   

   1. Install the No. 4 hybrid vehicle battery carrier bracket sub-assembly.

   2. Attach the wire harness clamp.

10. INSTALL HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

    Click here

11. INSTALL BNO. 2 ATTERY PACK WIRE

    
    
    1. 

       Text in Illustration

       *A	w/ Voltage Inverter

       Attach the 5 wire harness clamps to install the No. 2 battery pack wire to the upper hybrid battery cover sub-assembly.

    2. w/ Voltage Inverter:

       Attach the 6 wire harness clamps to install the No. 2 battery pack wire to the upper hybrid battery cover sub-assembly.

12. INSTALL UPPER HYBRID BATTERY COVER SUB-ASSEMBLY

    CAUTION:

    Perform work using insulated gloves and insulated tools.

    
    

    1. Install the upper hybrid battery cover sub-assembly together with the power steering converter wire with the 11 nuts.

       Torque:

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

    2. Attach the 3 wire harness clamps to connect the No. 2 hybrid battery pack wire.

13. INSTALL REAR NO. 1 HYBRID BATTERY SHIELD

    CAUTION:

    Perform work using insulated gloves and insulated tools.

    
    

    1. Install the rear No. 1 hybrid battery shield with the 3 nuts and 2 bolts.

       Torque:

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

    2. Attach the wire harness clamp and connect the connector.

14. INSTALL NO. 2 HYBRID BATTERY INTAKE DUCT

    
    

    1. Install the No. 2 hybrid battery intake duct with the clip.

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

    CAUTION:

    Perform work using insulated gloves and insulated tools.

    
    

    1. Install the battery cooling blower assembly with the nut.

       Torque:

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

       Note

       
       

       • Hold the wire harness and fan, and do not install them.

       • Make sure that foreign matter does not enter the battery cooling blower assembly.

    2. Connect the connector.

    3. Install the 2 nuts.

       Torque:

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

    4. Attach the wire harness clamp.

16. INSTALL VOLTAGE INVERTER ASSEMBLY (w/ Voltage Inverter)

    Click here

17. INSTALL NO. 1 HV BATTERY SHIELD PANEL

    CAUTION:

    Perform work using insulated gloves and insulated tools.

    
    

    1. Install the No. 1 HV battery shield panel with the 4 nuts.

       Torque:

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

18. INSTALL NO. 3 HYBRID BATTERY INTAKE DUCT

    
    

    1. Install the No. 3 hybrid battery intake duct to the No. 4 hybrid battery intake duct with the clip.

19. INSTALL NO. 2 UPPER HYBRID VEHICLE BATTERY CARRIER BRACKET

    
    

    1. Install the No. 2 upper hybrid vehicle battery carrier bracket with the bolt.

       Torque:

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

20. INSTALL NO. 1 UPPER HYBRID VEHICLE BATTERY CARRIER BRACKET

    
    

    1. Install the No. 1 upper hybrid vehicle battery carrier bracket with the bolt.

       Torque:

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

21. INSTALL HV BATTERY

    CAUTION:

    Be sure to wear insulated gloves.

    
    

    1. Prepare 2 pieces of cardboard that are at least 540 mm (1.77 ft.) long and 920 mm (3.01 ft.) wide.

    2. Place the 2 pieces of cardboard on top of one another in the luggage room.

    3. 

       Text in Illustration

       *1	Top piece of cardboard
       *a	Vehicle Front

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

       Note

       
       

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

       • Pass the rope or equivalent as shown in the illustration in order to prevent deformation.

    4. Pull out the rope or equivalent from under the HV battery.

    5. 

       Text in Illustration

       *1	Top piece of cardboard
       *2	Bottom piece of cardboard

       Push the HV battery and top piece of cardboard together into the vehicle, sliding them over the bottom piece of cardboard.

       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.

       • Make sure that the hybrid battery cover sheet attached to the underside of the HV battery does not come off.

    6. Alternately lifting the left and right sides of the HV battery, pull out both pieces of cardboard from under the HV battery.

    7. Temporarily install the 2 nuts for the rear part of the HV battery from the luggage room side.

    8. Temporarily install the 4 bolts for the front part of the HV battery from the cabin side.

    9. Tighten the 2 nuts for the rear part of the HV battery from the luggage room side.

       Torque:

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

    10. Tighten the 4 bolts for the front part of the HV battery from the cabin room side.

        Torque:

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

    11. Connect the 2 connectors.

    12. Connect the connector.

22. INSTALL NO. 1 HYBRID BATTERY CARRIER BRACKET

    

    CAUTION:

    Be sure to wear insulated gloves.

    
    

    1. Temporarily install the No. 1 hybrid battery carrier bracket with the 4 bolts and 2 nuts.

    2. Tighten the 4 bolts and 2 nuts in the order shown in the illustration.

       Torque:

       Bolt

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

       Nut

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

23. INSTALL BRAKE CONTROL POWER SUPPLY ASSEMBLY

    Click here

24. INSTALL NO. 6 HYBRID BATTERY INTAKE DUCT

    
    

    1. Install the No. 6 hybrid battery intake duct with the 2 clips.

25. INSTALL NO. 1 HYBRID BATTERY INTAKE DUCT

    
    

    1. Install the No. 1 hybrid battery intake duct with the 2 clips.

26. CONNECT NO. 4 FLOOR WIRE

    CAUTION:

    Perform work using insulated gloves and insulated tools.

    
    
    1. 

       Text in Illustration

       *a

       Matchmark

       Connect the 2 No. 4 floor wires with the 2 nuts.

       Note

       Be sure to match the red marks on the No. 4 floor wire to the red marks on the hybrid battery junction block assembly and connect the No. 4 floor wire.

       Torque:

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

    2. 

       Text in Illustration

       *a

       Matchmark

       Install the battery shield contact.

       Note

       Align the matchmark when installing the battery shield contact.

27. CHECK HIGH VOLTAGE CABLE CONNECTION CONDITION

    Click here

28. INSTALL NO. 4 HYBRID VEHICLE BATTERY SHIELD SUB-ASSEMBLY

    

    Text in Illustration

    *1	Button
    *a	Push

    CAUTION:

    Perform work using insulated gloves and insulated tools.

    
    

    1. Set the No. 4 hybrid vehicle battery shield sub-assembly in place and temporarily install the 4 nuts.

    2. Insert the battery cover lock striker and then push the button to lock it.

    3. Tighten the 4 nuts.

       Torque:

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

29. INSTALL INNER LUGGAGE COMPARTMENT TRIM COVER LH

    Click here

30. INSTALL INNER LUGGAGE COMPARTMENT TRIM COVER RH

    Click here

31. INSTALL ROPE HOOK

    Click here

32. INSTALL FRONT LUGGAGE COMPARTMENT TRIM COVER

    Click here

33. INSTALL REAR FLOOR FINISH PLATE

    Click here

34. INSTALL REAR LUGGAGE COMPARTMENT TRIM COVER

    Click here

35. INSTALL NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY

    Click here

36. INSTALL NO. 1 LUGGAGE COMPARTMENT TRIM HOOK

    Click here

37. INSTALL REAR LUGGAGE COMPARTMENT TRAY BRACKET LH

    Click here

38. INSTALL REAR LUGGAGE COMPARTMENT TRAY BRACKET RH

    Click here

39. INSTALL ROPE HOOK ASSEMBLY

    Click here

40. INSTALL LUGGAGE COMPARTMENT SIDE TRAY (w/ Spare Tire)

    Click here

41. INSTALL SPARE WHEEL COVER TRAY (w/o Spare Tire)

    Click here

42. INSTALL LUGGAGE COMPARTMENT TRIM BOX (w/o Spare Tire)

    Click here

43. INSTALL SIDE TRIM BOX

    Click here

44. INSTALL LUGGAGE COMPARTMENT TRIM COVER RH

    Click here

45. INSTALL NO. 1 ROOM PARTITION PAD

    
    

    1. Install the No. 1 room partition pad with the 5 clips.

46. INSTALL NO. 2 ROOM PARTITION PAD

    
    

    1. Install the No. 2 room partition pad with the 2 clips.

47. INSTALL NO. 2 PACKAGE TRAY TRIM PANEL ASSEMBLY (w/ Rear Sunshade)

    Click here

48. INSTALL CENTER STOP LIGHT COVER (w/ Rear Sunshade)

    Click here

49. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY

    
    

    1. w/o Rear Sunshade:

       
       

       1. Pass the 3 rear seat belt floor anchors through the package tray trim panel assembly.

       2. Insert the package tray trim panel assembly into the 5 guides and attach the 4 clips to install the package tray trim panel assembly.

       3. Connect the connector.

       4. Attach the 4 claws to install the center stop light cover.

    2. w/ Rear Sunshade:

       
       

       1. Pass the 3 rear seat belt floor anchors through the package tray trim panel assembly.

       2. Insert the package tray trim panel assembly into the rear window shade assembly and attach the 4 clips to install the package tray trim panel assembly.

    3. Attach the 4 claws to install the belt guide of rear seat inner with center belt assembly LH to the package tray trim panel assembly.

    4. Attach the 4 claws to install the rear seat shoulder belt hole cover to the package tray trim panel assembly.

       Tech Tips

       Use the same procedure to install the rear seat shoulder belt hole cover on the other side.

50. INSTALL INNER ROOF SIDE GARNISH LH

    Click here

51. INSTALL REAR SEAT SIDE GARNISH LH

    Click here

52. INSTALL REAR DOOR SCUFF PLATE LH

    Click here

53. INSTALL INNER ROOF SIDE GARNISH RH

    Click here

54. INSTALL REAR SEAT SIDE GARNISH RH

    Click here

55. INSTALL REAR DOOR SCUFF PLATE RH

    Click here

56. INSTALL REAR SEAT ASSEMBLY

    Click here

57. INSTALL SERVICE PLUG GRIP

    Click here

58. INSTALL LOWER HYBRID VEHICLE BATTERY COVER PANEL

    Click here

59. INSTALL NO. 1 SEAT ARMREST CAP

    Click here

60. CONNECT CABLE TO AUXILIARY BATTERY TERMINAL

    Note

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

    
    

    1. 

       Connect cable to the auxiliary battery positive (+) terminal with the nut.

       Torque:

       6.8 N*m  { 69 kgf*cm, 60 in.*lbf }

    2. Install the terminal cover.

    3. Connect cable to the auxiliary battery negative (-) terminal.

       Torque:

       5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

61. INSTALL LUGGAGE COMPARTMENT TRIM COVER LH

    Click here

62. INSTALL LUGGAGE COMPARTMENT FLOOR MAT

    Click here