HV BATTERY > INSTALLATION

for Preparation Click here



1. INSTALL BATTERY PACK WIRE


    A108320

  1. Connect the 2 clamps, then install the battery pack wire on the HV battery lower case.



    A111107

  1. Connect the clamp, then install the battery pack wire on the HV battery lower case.



2. INSTALL BATTERY PACKING NO.2


    A111962

  1. Install the battery packing No.2 to the HV battery lower case.

    NOTICE:
    Make sure that there is no clearance between the battery packing and the lower case.



3. INSTALL BATTERY COVER


    A111961

  1. Install the battery cover to the HV battery lower case.

    NOTICE:
    Be suer to attach the butyl tape portion of the battery cover securely to the lower case.



4. INSTALL HV BATTERY LOWER CASE


    A108319E01

  1. Install the HV battery lower case on the vehicle.

  1. Connect the connector and clamp on the HV battery lower case.



5. INSTALL HYBRID VEHICLE RELAY ASSEMBLY


    A115319

  1. Install the hybrid vehicle relay assembly with the 3 nuts.

    Torque:
    4.5 N*m{ 46 kgf*cm , 40 in.*lbf }



6. INSTALL ELECTRIC VEHICLE BATTERY PLUG ASSEMBLY


    A115321

  1. Install the EV battery plug with the 2 bolts and nut.

    Torque:
    Bolt:
    5.4 N*m{ 55 kgf*cm , 48 in.*lbf }
    Nut:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf }



    A115322E01

  1. Connect the connector and clamps.



7. INSTALL BATTERY COOLING BLOWER ASSEMBLY


    A115320

  1. Install the 3 battery cooling blower assemblies with the 9nuts.

    Torque:
    4.5 N*m{ 46 kgf*cm , 40 in.*lbf }



    A115323E01

  1. Connect each battery cooling blower assembly connector and clamp.



8. INSTALL HV BATTERY

CAUTION:
Wear insulating gloves and protective glasses.



  1. Attach the bar-code label. (In case that the lower case is not replaced)



      A114401

    1. Attach the new label to immediate right of the original one.

      HINT:
      A bar-code label is supplied with the new battery.



  1. Attach the bar-code label. (In case that the lower case is replaced)



      A111108

    1. Attach the new label to the original position.

      HINT:
      A bar-code label is supplied with the new lower case.



  1. Install the HV battery RH.



      A109950

    1. Install the main battery cable on the HV battery RH with a new nut.

      Torque:
      5.4 N*m{ 55 kgf*cm , 48 in.*lbf }

      NOTICE:
      Be sure to engage the plastic cover securely.



      2. A109949

    2. Install the main battery cable No.2 on the HV battery RH with a new nut.

      Torque:
      5.4 N*m{ 55 kgf*cm , 48 in.*lbf }

      NOTICE:
      Be sure to engage the plastic cover securely.



      3. A109847E01

    3. Install the HV battery RH.

      NOTICE:
      After installing the HV battery RH, pull the ropes for lifting out the battery toward the front of the vehicle to eliminate any slack in the ropes.



      4. A112663E01

    4. Install the battery room ventilation hose.

      NOTICE:
      Align the projections of the battery room ventilation hose and the rubber tube, and install the hose.



      5. A108317E01

    5. Connect the clamp.



      6. A108316

    6. Connect the main battery cable with the nut and connector.

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



      7. A108315

    7. Connect the 2 clamps.



  1. Install the HV battery CTR.



      A109845E01

    1. Install the HV battery CTR.

      NOTICE:
      After installing the HV battery CTR, pull the ropes for lifting out the battery toward the front of the vehicle to eliminate any slack in the ropes.



      2. A112662E01

    2. Install the battery room ventilation hose between the HV batteries CTR and RH.

      NOTICE:
      Align the projections of the battery room ventilation hose and the rubber tube, and install the hose.



      3. A108312

    3. Connect the 2 connectors and clamp.



      4. A108311

    4. Connect the 2 connectors on the HV relay assembly.



  1. Install the HV battery LH.



      A109846E01

    1. Install the HV battery LH.

      NOTICE:
      After installing the HV battery LH, pull the ropes for lifting out the battery toward the front of the vehicle to eliminate any slack in the ropes.



      2. A109849

    2. Connect the EV battery plug on the HV battery with a new nut.

      Torque:
      5.4 N*m{ 55 kgf*cm , 48 in.*lbf }

      NOTICE:
      1. Be sure to engage the plastic cover securely.
      2. Insulate the tool with insulting tape.
      3. Do not use the universal joint.



      3. A109848

    3. Connect the main battery cable on the HV battery with a new nut.

      Torque:
      5.4 N*m{ 55 kgf*cm , 48 in.*lbf }

      NOTICE:
      1. Be sure to engage the plastic cover securely.
      2. Insulate the tool with insulting tape.
      3. Do not use the universal joint.



      4. A108257

    4. Connect the wire harness clamp of the battery thermo sensor.



      5. A112661E01

    5. Connect the battery room ventilation hose between the HV batteries LH and CTR.

      NOTICE:
      Align the projections of the battery room ventilation hose and the rubber tube, and install the hose.



9. INSTALL BATTERY SMART UNIT

NOTICE:
Wear insulating gloves and protective glasses.



    A108255

  1. Install the battery smart unit with the 4 bolts.

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



    A108254E01

  1. Connect the 5 connectors and 2 clamps.



10. CHECK HIGH VOLTAGE CABLE CONNECTION

CAUTION:
Wear insulating gloves and protective glasses.



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


    A108335E01

    NOTICE:
    1. The connectors should be connected securely.
    2. The nuts should be fastened securely.
    3. Make sure that the 4 plastic covers are engaged securely.



11. INSTALL BATTERY COVER SUB-ASSEMBLY

CAUTION:
Wear insulating gloves.



  1. Install the battery cover lock striker then push the button to lock.


    A109850E01

  1. Install the battery cover with the 28 bolts and 6 nuts.

    NOTICE:
    Use a ground bolt for position B.

    Torque:
    Bolt A:
    25 N*m{ 255 kgf*cm , 19 ft.*lbf }
    Bolt B:
    25 N*m{ 255 kgf*cm , 19 ft.*lbf }
    Bolt C:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf }
    Nut:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf }



    A108252

  1. Connect the No.3 wire frame with the bolt.

    Torque:
    8.0 N*m{ 82 kgf*cm , 72 in.*lbf }



12. INSTALL HV BATTERY SERVICE HOLE COVER


    A109851E01

  1. Install the battery cover lock striker, then push the button to lock.

  1. Install the battery service hole cover with the 2 bolts.

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



13. INSTALL BATTERY CARRIER DUCT


    A109796

  1. Install the battery carrier duct (RH) with the 2 bolts.

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



    A109795

  1. Install the battery carrier duct (CTR) with the 2 bolts.

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



    A109681

  1. Install the battery carrier duct (LH) with the 2 bolts.

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



14. INSTALL BATTERY CARRIER BRACKET


    A108250

  1. Install the battery carrier bracket with the 2 bolts.

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



15. INSTALL REAR CENTER SEAT INNER BELT ASSEMBLY


    B109592E01

  1. Install the rear center seat inner belt assembly with the bolt.

    Torque:
    42 N*m{ 428 kgf*cm , 31 ft.*lbf }

    NOTICE:
    1. Tighten the bolt while the claws of the rear center seat inner belt assembly are in contact with the vehicle body.
    2. Claw 1 shown in the illustration can have a clearance of up to 2.0 mm (0.08 in.) between the claw and the vehicle body.

    HINT:
    Place the buckle of the rear center seat inner belt assembly on the floor carpet so that the buckle does not interfere with installation of the seat.



16. INSTALL FLOOR CARPET ASSEMBLY FRONT

  1. Install the front floor carpet.



17. INSTALL AIR INTAKE COVER CENTER


    A108249E01

  1. Install the air intake cover with the 2 screws.

  1. Install the 2 hole covers.



18. INSTALL AIR INTAKE COVER


  1. Install the air intake cover RH.



      A108248E01

    1. Install the air intake cover RH with the 2 screws.

    2. Install the 2 hole covers.



  1. Install the air intake cover LH.



      A108247E01

    1. Install the air intake cover LH with the 2 screws.

    2. Install the 2 hole covers.



19. INSTALL REAR SEAT ASSEMBLY LH

  1. Place the rear seat assembly LH in the vehicle and align the adjuster pin with the hole on the vehicle side.

  1. Move the rear seat assembly LH to the rearmost position by operating the rear seat track adjusting handle.

    NOTICE:
    Check that the seat is locked.

  1. Temporarily install the front side of the rear seat assembly LH with the 2 bolts.

  1. Recline the separate rear seatback forward by operating the rear seat lock control lever sub-assembly.

  1. Move the rear seat assembly LH fully forward.

    NOTICE:
    Check that the seat is locked.

  1. Temporarily install the rear side of the rear seat assembly LH with the 3 bolts.

  1. Return the separate rear seatback to the upright position.

  1. Move the rear seat assembly LH to the rearmost position by operating the rear seat track adjusting handle.

    NOTICE:
    Check that the seat is locked.

  1. Fully tighten the 2 bolts on the front side of the rear seat assembly LH in the order of the inner side bolt and then the outer side bolt.

    Torque:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }

  1. Recline the separate rear seatback forward by operating the rear seat lock control lever sub-assembly.

  1. Move the rear seat assembly LH fully forward.

    NOTICE:
    Check that the seat is locked.

  1. Fully tighten the 3 bolts on the rear side of the rear seat assembly LH in the order of the inner rear side bolt, the inner front side bolt, and then the outer side bolt.

    Torque:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }

  1. Return the separate rear seatback to the upright position.

  1. Move the rear seat assembly LH to the rearmost position by operating the rear seat track adjusting handle.

    NOTICE:
    Check that the seat is locked.

  1. Install the floor anchor side of the fold seat stopper band assembly No.2 with the bolt.

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

  1. Install the 3 clips.



20. INSTALL REAR SEAT TRACK BRACKET COVER


21. INSTALL REAR SEAT ASSEMBLY RH

  1. Place the rear seat assembly RH in the vehicle and align the adjuster pin with the hole on the vehicle side.

  1. Move the rear seat assembly RH to the rearmost position by operating the rear seat track adjusting handle.

    NOTICE:
    Check that the seat is locked.

  1. Temporarily install the front side of the rear seat assembly RH with the 2 bolts.

  1. Recline the separate rear seatback forward by operating the rear seat lock control lever sub-assembly.

  1. Move the rear seat assembly RH fully forward.

    NOTICE:
    Check that the seat is locked.

  1. Temporarily install the rear side of the rear seat assembly RH with the 3 bolts.

  1. Return the separate rear seatback to the upright position.

  1. Move the rear seat assembly RH to the rearmost position by operating the rear seat track adjusting handle.

    NOTICE:
    Check that the seat is locked.

  1. Fully tighten the 2 bolts on the front side of the rear seat assembly RH in the order of the inner side bolt and then the outer side bolt.

    Torque:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }

  1. Recline the separate rear seatback forward by operating the rear seat lock control lever sub-assembly.

  1. Move the rear seat assembly RH fully forward.

    NOTICE:
    Check that the seat is locked.

  1. Fully tighten the 3 bolts on the rear side of the rear seat assembly RH in the order of the inner rear side bolt, the inner front side bolt, and then the outer side bolt.

    Torque:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }

  1. Return the separate rear seatback to the upright position.

  1. Move the rear seat assembly RH to the rearmost position by operating the rear seat track adjusting handle.

    NOTICE:
    Check that the seat is locked.

  1. Install the floor anchor side of the fold seat stopper band assembly No.1 with the bolt.

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

  1. Install the 5 clips.



22. INSTALL REAR SEAT TRACK BRACKET COVER


23. INSPECT SLIDE ADJUSTER LOCK SIMULTANEOUSLY

  1. Check that the left and right adjusters lock simultaneously when sliding the seat.

  1. If the left and right adjusters do not lock simultaneously, adjust by loosening the bolts securing the seat.



24. INSTALL SERVICE PLUG GRIP

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



    A115547

  1. Wear insulation gloves, then insert the service plug.

  1. Push down on the grip to lock.

  1. Close the battery service hole cover.

    NOTICE:
    Check that the 2 battery service hole cover clips are securely connected to the battery carrier bracket (click sound).



25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


26. PERFORM INITIALIZATION
Some systems need initialization when reconnecting the battery cable. (Click here)