HV Relay Assembly: Installation

INSTALL HIGH VOLTAGE FUSE
1. Install the high voltage fuse with the 2 bolts.
  Torque: 4.5 N*m (46 kgf*cm, 40 in.*lbf)
  
  NOTE: Be sure to use a torque wrench to tighten the bolts.
  
  Fig 1: Locating High Voltage Fuse Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HV RELAY ASSEMBLY
1. Install the HV relay assembly with the 3 nuts.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
  
  CAUTION: Wear insulated gloves.
  
  Fig 2: Locating HV Relay Assembly Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the 7 connectors and clamp to the HV relay assembly.
  CAUTION: Wear insulated gloves.
  NOTE:
  - Connect the wire wrapped with red tape to the terminal indicated by the "+" mark of the HV relay and the wire not wrapped with red tape to the terminal indicated by the "-" mark of the HV battery.
  - Make sure that the connectors are engaged securely.
  Fig 3: Locating HV Relay Assembly Connectors With Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 6 BATTERY CARRIER PANEL
1. Install the No. 6 battery carrier panel with the 7 bolts.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
  
  CAUTION: Wear insulated gloves.
  
  NOTE: Do not drop the bolts in the cooling air inlet.
  
  Fig 4: Locating No. 6 Battery Carrier Panel Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BATTERY CARRIER SUB-ASSEMBLY
1. Install the battery carrier sub-assembly with the 2 bolts and 2 nuts.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
  
  CAUTION: Wear insulated gloves.
  
  Fig 5: Installing Battery Carrier Sub-Assembly With Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the 3 connectors and 2 clamps.
  CAUTION: Wear insulated gloves.
  
  Fig 6: Locating Connectors With Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BATTERY BRACKET SUB-ASSEMBLY
1. Pass the stud bolts on the battery carrier through holes A in the battery bracket. Install the battery bracket with the 3 bolts.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
  
  CAUTION: Wear insulated gloves.
  
  NOTE: Be sure to push the bracket onto the carrier when tightening the 3 bolts.
  
  Fig 7: Locating Battery Bracket Sub-Assembly Bolts And Holes
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FRAME WIRE (See INSTALLATION )
INSTALL NO. 3 HV BATTERY EXHAUST DUCT (See INSTALLATION )
REMOVE TOOL BOX
INSTALL LUGGAGE COMPARTMENT FRONT TRIM COVER (See INSTALLATION )
INSTALL ROPE HOOK ASSEMBLY (See INSTALLATION )
INSTALL TOOL BOX
INSTALL LUGGAGE COMPARTMENT TRIM SIDE COVER RH
INSTALL SERVICE PLUG GRIP (See INSTALLATION )
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
INSTALL BATTERY SERVICE HOLE COVER LH (See INSTALLATION )
INSTALL LUGGAGE COMPARTMENT FLOOR MAT
PERFORM INITIALIZATION
1. Perform initialization procedure (see INITIALIZATION (2006/02-2006/07) ).
  NOTE: Some vehicle systems require initialization after reconnecting the cable to the negative battery terminal.