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Battery Current Sensor: Replacement

NOTE:
  • When working on the high voltage systems, always wear insulating gloves. 
  • After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 
  • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. 
  • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. 
  1. PRECAUTION (SEE  PRECAUTION   ) 
  2. REMOVE REAR FLOOR BOARD NO.2 (See  SERVICE PLUG GRIP   ) 
  3. REMOVE DECK FLOOR BOX REAR (See  SERVICE PLUG GRIP   ) 
  4. REMOVE REAR FLOOR BOARD NO.3 (See  SERVICE PLUG GRIP   ) 
  5. DISCONNECT BATTERY NEGATIVE TERMINAL (See  SERVICE PLUG GRIP   ) 
  6. REMOVE SERVICE PLUG GRIP (See  SERVICE PLUG GRIP   ) 
  7. REMOVE DECK TRIM COVER REAR (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  8. REMOVE TONNEAU COVER ASSY (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  9. REMOVE REAR SEAT CUSHION ASSY (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  10. REMOVE REAR FLOOR BOARD NO.1 (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  11. REMOVE REAR SIDE SEAT BACK FRAME LH (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  12. REMOVE REAR FLOOR BOARD NO.4 (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  13. REMOVE DECK FLOOR BOX LH (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  14. REMOVE DECK TRIM SIDE PANEL ASSY LH (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  15. REMOVE BATTERY CARRIER BRACKET (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  16. REMOVE BATTERY CARRIER PANEL NO.6 (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  17. REMOVE BATTERY CURRENT SENSOR 
    NOTE: Wear insulating gloves. 
    1. Remove the terminal cover.
      Fig 1: Removing Terminal Cover
      G02617328Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut, then disconnect the main battery cable.
      Fig 2: Disconnecting Main Battery Cable
      G02617329Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the connector.
    4. Remove the 2 screws and battery current sensor.
      Fig 3: Disconnecting Connector And Removing Screws
      G02617330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL BATTERY CURRENT SENSOR 
    NOTE: Wear insulating gloves. 
    1. Install the battery current sensor with the 2 screws.

      Torque: 1.4 N.m (14 kgf.cm, 12 in.lbf) 

    2. Connect the connector.
      Fig 4: Connecting Connector
      G02617331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the main battery cable with a new nut.

      Torque: 5.6 N.m (57 kgf.cm, 50 in.lbf) 

      Fig 5: Installing Main Battery Cable
      G02617332Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the terminal cover.
      Fig 6: Installing Terminal Cover
      G02617333Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL BATTERY CARRIER PANEL NO.6 (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
    NOTE: Wear insulating gloves. 
  20. INSTALL BATTERY CARRIER BRACKET (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  21. INSTALL DECK TRIM SIDE PANEL ASSY LH 
  22. INSTALL DECK FLOOR BOX LH 
  23. INSTALL REAR FLOOR BOARD NO.4 
  24. INSTALL REAR SIDE SEAT BACK FRAME LH 
  25. INSTALL REAR FLOOR BOARD NO.1 
  26. INSTALL REAR SEAT CUSHION ASSY 
  27. INSTALL TONNEAU COVER ASSY 
  28. INSTALL DECK TRIM COVER REAR 
  29. INSTALL SERVICE PLUG GRIP (See  SERVICE PLUG GRIP   ) 
    NOTE: Wear insulating gloves. 
  30. CONNECT BATTERY NEGATIVE TERMINAL 

    Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf) 

  31. INSTALL REAR FLOOR BOARD NO.3 
  32. INSTALL DECK FLOOR BOX REAR 
  33. INSTALL REAR FLOOR BOARD NO.2 
  34. POWER WINDOW CONTROL SYSTEM INITIALIZE (SEE  INITIALIZATION  ) 
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