HV BATTERY INSTALLATION


  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)

    CAUTION:

    Perform work using insulated gloves and insulated tools.


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

      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.

  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

    CAUTION:

    Perform work using insulated gloves and insulated tools.


    1. Install the battery smart unit with the 2 nuts.

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

    2. Connect the 3 connectors.

  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 with the nut.

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

    2. Attach the wire harness clamp.

  10. INSTALL POWER STEERING CONVERTER WIRE (for High Voltage)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Attach the 3 wire harness clamps to install the power steering converter wire.

  11. INSTALL HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

    CAUTION:

    Perform work using insulated gloves and insulated tools.

    Note

    If the hybrid battery junction block assembly has been dropped, replace it with a new one.


    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 5 connectors.

  12. INSTALL ELECTRIC VEHICLE FUSE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Install the electric vehicle fuse to the hybrid battery junction block assembly with the 2 screws.

  13. INSTALL POWER STEERING CONVERTER WIRE (for Low Voltage)

    A01FTXLE01
    Text in Illustration
    *A w/ Voltage Inverter

    1. Attach the 5 wire harness clamps to install the power steering converter wire to the upper hybrid battery cover sub-assembly.

    2. w/ Voltage Inverter:

      Attach the 6 wire harness clamps to install the power steering converter wire to the upper hybrid battery cover sub-assembly.

  14. 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.

  15. 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.

  16. INSTALL NO. 2 HYBRID BATTERY INTAKE DUCT


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

  17. 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.

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


    1. for 2AR-FSE:


      1. A01FPZGE01

        Set the voltage inverter assembly in place.

      2. Temporarily install the 2 nuts.

      3. Tighten the 2 nuts in the order shown in the illustration.

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

      4. Connect the connector and attach the clamp.

    2. for 2GR-FXE:


      1. A01FVURE01

        Set the voltage inverter assembly in place.

      2. Temporarily install the 2 nuts.

      3. Tighten the 2 nuts in the order shown in the illustration.

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

      4. Connect the wire harness with the bolt.

      5. Connect the connector.

  19. INSTALL POWER STEERING CONVERTER ASSEMBLY

    CAUTION:

    Perform work using insulated gloves and insulated tools.


    1. Install the power steering converter assembly with the 3 nuts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    2. Connect the 2 wire harnesses with the 2 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    3. Connect the 4 connectors.

  20. INSTALL ECU BRACKET

    CAUTION:

    Perform work using insulated gloves and insulated tools.


    1. Install the ECU bracket with the 2 nuts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  21. 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.

  22. 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 }

  23. 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 }

  24. 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. A01FR3RE02
      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. A01FUQ2E01
      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.

  25. INSTALL NO. 1 HYBRID BATTERY CARRIER BRACKET

    A01FTI7E01

    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 }

  26. INSTALL BRAKE CONTROL POWER SUPPLY ASSEMBLY


    1. Connect the connector.

    2. Hook and the claws of the No. 1 brake control power supply bracket to the body to set it in place.

    3. A01FRVUE01

      Install the brake control power supply assembly with the 2 bolts.

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }

      Note

      Install the bolts in alphabetical order.

  27. INSTALL NO. 6 HYBRID BATTERY INTAKE DUCT


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

  28. INSTALL NO. 1 HYBRID BATTERY INTAKE DUCT


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

  29. CONNECT NO. 4 FLOOR WIRE

    CAUTION:

    Perform work using insulated gloves and insulated tools.


    1. A01FTB5E01
      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. A01FU3PE01
      Text in Illustration
      *a Matchmark

      Install the battery shield contact.

      Note

      Align the matchmark when installing the battery shield contact.

  30. CHECK HIGH VOLTAGE CABLE CONNECTION CONDITION

    CAUTION:

    Wear insulated gloves and protective goggles.


    1. Check that each wire harness is being installed securely.

      A01FR9C
      Text in Illustration
      *1 No. 4 Floor Wire - -

      Note


      • Make sure that the ends of the frame wire are not crossed over each other.

      • Be sure to connect the frame wire to the correct terminals as shown in the illustration.

      • The connectors should be connected securely.

      • The nuts should be fastened securely.

      • Make sure that the 2 plastic covers are engaged securely.

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

    A01FRJDE01
    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 }

  32. INSTALL INNER LUGGAGE COMPARTMENT TRIM COVER LH


    1. Attach the clip to install the luggage compartment trim inner cover LH.

    2. Attach the 2 claws to install the clip.

    3. Install the clip.

  33. INSTALL INNER LUGGAGE COMPARTMENT TRIM COVER RH


    1. Attach the clip to install the luggage compartment trim inner cover RH.

    2. Attach the 2 claws to install the clip.

    3. Install the clip.

  34. INSTALL ROPE HOOK

    Tech Tips

    Use the same procedure for both rope hooks


    1. Install the rope hook.

  35. INSTALL FRONT LUGGAGE COMPARTMENT TRIM COVER


    1. Install the front luggage compartment trim cover with the 3 clips and 2 nuts.

  36. INSTALL REAR FLOOR FINISH PLATE


    1. Attach the 6 clips to install the rear floor finish plate.

    2. Install the 3 clips.

  37. INSTALL REAR LUGGAGE COMPARTMENT TRIM COVER


    1. Attach the 3 guides to install the rear luggage compartment trim cover

    2. Install the 5 clips.

    3. Install the 3 No. 2 luggage compartment trim hooks.

  38. INSTALL NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY


    1. A01FUD3

      Connect the connector.

    2. Attach the 2 claws to install the No. 1 luggage compartment light assembly.

  39. INSTALL NO. 1 LUGGAGE COMPARTMENT TRIM HOOK


    1. Attach the 2 claws to install the No. 1 luggage compartment trim hook.

  40. INSTALL REAR LUGGAGE COMPARTMENT TRAY BRACKET LH


    1. Attach the claw to install the rear luggage compartment tray bracket LH.

    2. Install the clip.

  41. INSTALL REAR LUGGAGE COMPARTMENT TRAY BRACKET RH

    Tech Tips

    Use the same procedure described for the LH side.

  42. INSTALL ROPE HOOK ASSEMBLY

    Tech Tips

    Use the same procedure for all rope hooks.


    1. Install the rope hook assembly with the bolt.

    2. Attach the 2 claws to close the cover.

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


    1. Install the luggage compartment side tray.

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


    1. Install the spare wheel cover tray.

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


    1. Install the luggage compartment trim box.

  46. INSTALL SIDE TRIM BOX


    1. Install the side trim box.

  47. INSTALL LUGGAGE COMPARTMENT TRIM COVER RH


    1. Install the luggage compartment trim cover RH.

  48. INSTALL NO. 1 ROOM PARTITION PAD


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

  49. INSTALL NO. 2 ROOM PARTITION PAD


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

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


    1. Attach the 5 guides and 3 clips to install the No. 2 package tray trim panel assembly.

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


    1. Connect the connector.

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

  52. 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.

  53. INSTALL INNER ROOF SIDE GARNISH LH

    A01FQFNE01
    Text in Illustration
    *1 End Of The Rear Window Shade Assembly
    *2 Guide

    1. w/ Rear Sunshade:


      1. Insert the rear window shade assembly and attach the 3 guides.

      2. Attach the 4 clips to install the inner roof side garnish LH.

        Note

        After installing the inner roof side garnish LH, make sure that the lip of the rear door opening trim weatherstrip LH is not pinched.

    2. w/o Rear Sunshade:


      1. Attach the 4 clips and 3 guides to install the inner roof side garnish LH.

        Note

        After installing the inner roof side garnish LH, make sure that the lip of the rear door opening trim weatherstrip LH is not pinched.

  54. INSTALL REAR SEAT SIDE GARNISH LH


    1. Attach the 4 claws and guide to install the rear seat side garnish LH.

      Note

      After installing the rear seat side garnish LH, make sure that the lip of the rear door opening trim weatherstrip LH is not pinched.

  55. INSTALL REAR DOOR SCUFF PLATE LH


    1. Attach the 10 claws and 3 clips to install the rear door scuff plate LH.

  56. INSTALL INNER ROOF SIDE GARNISH RH

    Tech Tips

    Use the same procedure described for the LH side.

  57. INSTALL REAR SEAT SIDE GARNISH RH

    Tech Tips

    Use the same procedure described for the LH side.

  58. INSTALL REAR DOOR SCUFF PLATE RH

    Tech Tips

    Use the same procedure described for the LH side.

  59. INSTALL REAR SEAT ASSEMBLY

    Click here

  60. INSTALL SERVICE PLUG GRIP

    CAUTION:

    Wear insulated gloves.

    Note

    Before connecting the service plug, check that no parts and tools remain and that the high voltage terminals and connectors are connected securely.

    A01FTIGE01
    Text in Illustration
    *1 Lever - -

    1. Install the service plug grip in the order shown in the illustration.


      1. Insert the service plug grip and rotate the lever.

      2. Slide the lever until a click sound is heard to lock the lever.

  61. INSTALL LOWER HYBRID VEHICLE BATTERY COVER PANEL

    CAUTION:

    Perform work using insulated gloves and insulated tools.


    1. A01FVY2E01
      Text in Illustration
      *1 Arrow

      Install the lower hybrid vehicle battery cover panel with the 4 nuts.

      Tech Tips

      Be sure to install the lower hybrid vehicle battery cover panel with its arrow facing upwards.

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

  62. INSTALL NO. 1 SEAT ARMREST CAP


    1. Attach the 4 guides and 4 claws to install the No. 1 seat armrest cap.

  63. 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. A01FTE7

      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 }

  64. INSTALL LUGGAGE COMPARTMENT TRIM COVER LH


    1. Install the luggage compartment trim cover LH.

  65. INSTALL LUGGAGE COMPARTMENT FLOOR MAT


    1. Install the luggage compartment floor mat.