HV BATTERY INSTALLATION

PROCEDURE


  1. INSTALL NO. 2 HYBRID BATTERY EXHAUST DUCT

    CAUTION:

    Wear insulated gloves and use insulated tools.


    1. B002IQRC01
      *1 Hybrid Battery End Plate
      B002HVY Raise Hybrid Battery Stack
      B002I10 Install No. 2 Hybrid Battery Exhaust Duct
      B002H26 Secure Clip

      Raise the hybrid battery stack vertically.

      Note


      • Make sure to hold the hybrid battery stack by the hybrid battery end plates shown in the illustration.

      • Make sure to raise the hybrid battery stack as much as necessary for the removal of the No. 2 hybrid battery exhaust duct.

      • Make sure to raise the hybrid battery stack vertically.

    2. Install the No. 2 hybrid battery exhaust duct to the HV battery, and secure it with the clip.

    3. Install the hybrid battery stack with the 3 nuts.

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

  2. INSTALL NO. 1 HYBRID BATTERY EXHAUST DUCT

    CAUTION:

    Wear insulated gloves and use insulated tools.


    1. B002IRDC01
      *1 Hybrid Battery End Plate
      B002HVY Raise Hybrid Battery Stack
      B002I10 Install No. 2 Hybrid Battery Exhaust Duct
      B002H26 Secure Clip

      Raise the hybrid battery stack vertically.

      Note


      • Make sure to hold the hybrid battery stack by the hybrid battery end plates shown in the illustration.

      • Make sure to raise the hybrid battery stack as much as necessary for the removal of the No. 1 hybrid battery exhaust duct.

      • Make sure to raise the hybrid battery stack vertically.

    2. Install the No. 1 hybrid battery exhaust duct to the HV battery, and secure it with the clip.

    3. Install the hybrid battery stack with the 3 nuts.

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

  3. INSTALL NO. 2 HYBRID BATTERY COVER INTAKE DUCT

    CAUTION:

    Wear insulated gloves and use insulated tools.


    1. B002H4K

      Install the battery cooling blower assembly LH with the 3 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    2. B002HXB

      Install the No. 2 hybrid battery cover intake duct.

  4. INSTALL NO. 1 HYBRID BATTERY COVER INTAKE DUCT

    CAUTION:

    Wear insulated gloves and use insulated tools.


    1. B002JAL

      Install the battery cooling blower assembly RH with the 3 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    2. B002IX8

      Install the No. 1 hybrid battery cover intake duct.

    3. B002JIU

      Connect the intake temperature sensor and wire harness clamp.

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

    CAUTION:

    Wear insulated gloves and use insulated tools.


    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 }

    2. Connect the 4 wire harness clamps.

  6. INSTALL NO. 1 HYBRID VEHICLE BATTERY CARRIER BRACKET SUB-ASSEMBLY

    CAUTION:

    Wear insulated gloves and use insulated tools.


    1. B002I0JC01
      *1 No. 1 Hybrid Vehicle Battery Carrier Bracket Sub-assembly LH Side
      *2 No. 1 Hybrid Vehicle Battery Carrier Bracket Sub-assembly RH Side

      Install the No. 1 hybrid vehicle battery carrier bracket sub-assembly LH side with the 2 nuts.

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

    2. Install the No. 1 hybrid vehicle battery carrier bracket sub-assembly RH side with the 2 nuts.

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

    3. Connect the wire harness clamp to the No. 1 hybrid vehicle carrier bracket sub-assembly LH side.

  7. INSTALL HYBRID BATTERY COVER SUB-ASSEMBLY LH

    CAUTION:

    Wear insulated gloves and use insulated tools.


    1. B002IOZC02
      *a Bolt
      *b Nut

      Install the hybrid battery cover sub-assembly LH with the 4 bolts and 3 nuts.

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

  8. INSTALL HYBRID BATTERY COVER SUB-ASSEMBLY RH

    CAUTION:

    Wear insulated gloves and use insulated tools.


    1. B002KKBC03
      *a Bolt
      *b Nut

      Install the hybrid battery cover sub-assembly RH with the 4 bolts and 3 nuts.

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

  9. INSTALL NO. 2 HYBRID BATTERY PACK WIRE

    CAUTION:

    Wear insulated gloves.


    1. Connect the 2 wire harness clamps and install the No. 2 hybrid battery pack wire.

  10. INSTALL BATTERY VOLTAGE SENSOR

    Click here

  11. INSTALL LOWER NO. 2 HYBRID BATTERY CARRIER PATCH

    Click here

  12. INSTALL HV BATTERY JUNCTION BLOCK ASSEMBLY

    CAUTION:

    Wear insulated gloves and use insulated tools.


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

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    2. B002KEQ

      Connect the 4 connectors.

      Note

      Make sure that the connectors are securely attached.

  13. INSTALL NO. 4 HYBRID BATTERY EXHAUST DUCT


    1. Install the No. 4 hybrid battery exhaust duct to the No. 2 hybrid battery exhaust duct.

  14. INSTALL NO. 3 HYBRID BATTERY EXHAUST DUCT


    1. Install the No. 3 hybrid battery exhaust duct to the No. 1 hybrid battery exhaust duct.

  15. INSTALL HV BATTERY ASSEMBLY

    CAUTION:

    Wear insulated gloves and protective goggles.


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

    2. Install the HV battery assembly from the rear of the vehicle.

      Note


      • Hold the areas shown in the illustration and lift up the HV battery assembly.

      • Since the HV battery assembly is very heavy, 4 people are needed to install the HV battery assembly. When removing the HV battery assembly, do not damage the parts around it.

      • To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.

      • When removing/installing/moving the HV battery assembly, make sure not to tilt it more than 80°.

      B002J1KC01
      *a Areas to be Held

      Tech Tips

      When removing and installing the HV battery, do so from the back door opening.

    3. Lift up the HV battery assembly, and pull out the 4 cables from the HV battery assembly towards the lower side.

      Note


      • To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.

      • Since the HV battery assembly is very heavy, 4 people are needed to install the HV battery assembly. When removing the HV battery assembly, do not damage the parts around it.

    4. B002I5OC02
      *a Bolt
      *b Ground Bolt
      *c Nut

      Install the HV battery assembly with the 6 bolts, 2 nuts and 2 ground bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }
    5. B002HUJ

      Connect the floor carpet mat assembly with the 4 clips.

  16. CONNECT WIRE HARNESS

    CAUTION:

    Wear insulated gloves and use insulated tools.


    1. Connect the connector and wire harness clamp to the battery cooling blower assembly LH.

    2. Connect the connector and wire harness clamp to the battery cooling blower assembly RH.

    3. Connect the 6 wire harness clamps and 2 connectors to the HV battery assembly.

    4. B002HIXC01
      *a Ground Terminal

      Using an insulated tool wrapped with electrical tape, connect the 2 No. 2 frame wires (high-voltage cables) and ground terminal with the 3 nuts.

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

    5. for Power Seat:

      Connect the 3 clamps and No. 2 floor wire.

  17. INSTALL AUXILIARY BATTERY

    Click here

  18. CONNECT CABLE TO POSITIVE AUXILIARY BATTERY TERMINAL

    CAUTION:

    Wear insulated gloves.


    1. A01H60R

      Connect the 3 wire harness clamps and connector.

    2. Connect the positive (+) auxiliary battery terminal.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  19. HIGH VOLTAGE CABLE CONNECTION CONDITION

    Click here

  20. INSTALL NO. 2 HYBRID VEHICLE BATTERY SHIELD REINFORCEMENT

    Click here

  21. INSTALL NO. 1 HYBRID BATTERY INTAKE DUCT


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

  22. INSTALL NO. 2 HYBRID BATTERY INTAKE DUCT


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

  23. INSTALL REAR SEAT ASSEMBLY

    for Manual Seat: Click here

    for Power Seat: Click here

  24. INSTALL NO. 1 INVERTER RESERVE TANK BRACKET (for 2WD)

    Click here

  25. CONNECT INVERTER RESERVE TANK ASSEMBLY

    Click here

  26. CONNECT WIRE HARNESS

    Click here

  27. INSTALL SERVICE PLUG GRIP

    Click here

  28. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

    Click here