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Battery Plug: 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 SIDE SEAT BACK FRAME RH (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  13. REMOVE REAR FLOOR BOARD NO.4 (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  14. REMOVE DECK FLOOR BOX LH (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  15. REMOVE DECK TRIM SIDE PANEL ASSY LH (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  16. REMOVE DECK TRIM SIDE PANEL ASSY RH (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  17. REMOVE BATTERY CARRIER BRACKET (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  18. REMOVE QUARTER VENT DUCT INNER NO.2 (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  19. REMOVE BATTERY BRACKET REINFORCEMENT (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  20. REMOVE QUARTER VENT DUCT (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  21. REMOVE BATTERY CARRIER PANEL NO.6 (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  22. REMOVE JUNCTION TERMINAL (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
    NOTE: Wear insulating gloves.
  23. REMOVE FRAME WIRE (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
    NOTE: Wear insulating gloves.
  24. REMOVE HV BATTERY ASSY (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  25. REMOVE BATTERY COVER SUB-ASSY (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  26. REMOVE BATTERY CLAMP PAD (BATTERY CARRIER CUSHION NO.1) 
    NOTE: Wear insulating gloves.
    1. Peel off the bonded parts, then remove the battery clamp pad (the battery carrier cushion No. 1).
      Fig 1: Removing Battery Clamp Pad
      G02617304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE WIRING HARNESS PROTECTOR COVER NO.1 
    1. Flip open the wiring harness protector cover.
    2. Remove the 2 nuts, then disconnect the service plug.
    3. Remove the wiring harness protector cover No. 1.
      Fig 2: Removing Wiring Harness Protector Cover No.1
      G02617305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE BATTERY PLUG 
    1. Disconnect the connector clamp.
    2. Remove the 2 bolts, then disconnect the service plug from the upper battery carrier.
      Fig 3: Removing Battery Plug
      G02617306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Flip open the wiring harness protector cover No. 4 shown in the illustration, then remove the service plug from the junction block.
      Fig 4: Opening Wiring Harness Protector Cover
      G02617307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL BATTERY PLUG 
    1. Temporarily fasten the service plug.
    2. Install the service plug to the upper battery carrier with the 2 bolts.

      Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

    3. Assemble the connector clamp.
  30. INSTALL WIRING HARNESS PROTECTOR COVER NO.1 
    1. Temporarily fasten the wiring harness protector cover No. 1 to the service plug.
    2. Install the wiring harness protector cover No. 1 through the service plug with 2 new nuts.

      Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

  31. INSTALL BATTERY CLAMP PAD (BATTERY CARRIER CUSHION NO.1) 
    NOTE: Wear insulating gloves. 
    1. Install a new clamp pad (the battery carrier cushion No. 1).
      Fig 5: Installing Clamp Pad
      G02617308Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL BATTERY COVER SUB-ASSY (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  33. INSTALL HV BATTERY ASSY (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  34. INSTALL FRAME WIRE (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
    NOTE: Wear insulating gloves. 
  35. INSTALL JUNCTION TERMINAL (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
    NOTE: Wear insulating gloves. 
  36. INSTALL BATTERY CARRIER PANEL NO.6 (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  37. INSTALL QUARTER VENT DUCT (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  38. INSTALL BATTERY BRACKET REINFORCEMENT (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  39. INSTALL QUARTER VENT DUCT INNER NO.2 (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  40. INSTALL BATTERY CARRIER BRACKET (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  41. INSTALL DECK TRIM SIDE PANEL ASSY RH 
  42. INSTALL DECK TRIM SIDE PANEL ASSY LH 
  43. INSTALL DECK FLOOR BOX LH 
  44. INSTALL REAR FLOOR BOARD NO.4 
  45. INSTALL REAR SIDE SEAT BACK FRAME RH 
  46. INSTALL REAR SIDE SEAT BACK FRAME LH 
  47. INSTALL REAR FLOOR BOARD NO.1 
  48. INSTALL REAR SEAT CUSHION ASSY 
  49. INSTALL TONNEAU COVER ASSY 
  50. INSTALL DECK TRIM COVER REAR 
  51. INSTALL SERVICE PLUG GRIP (See  SERVICE PLUG GRIP   ) 
    NOTE: Wear insulating gloves. 
  52. CONNECT BATTERY NEGATIVE TERMINAL 

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

  53. INSTALL REAR FLOOR BOARD NO.3 
  54. INSTALL DECK FLOOR BOX REAR 
  55. INSTALL REAR FLOOR BOARD NO.2 
  56. POWER WINDOW CONTROL SYSTEM INITIALIZE (SEE  INITIALIZATION  ) 
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