HV Battery Disassembly

WARNING: This page is about a different car, the 2002 Toyota Prius. However, it is still accessible from the selected car via links, so may be relevant.

Remove battery module set bolt .
Turn the battery assembly upside down, remove the 76 battery module bolts.

NOTE: When turning it over, prevent the flange from being deformed.
When not removing a battery module, skip the operation of step ( 1.
Remove battery cover .
Remove the 12 bolts, screw and battery cover.
Remove service plug :
1. Remove the rear RH and LH busbar module protectors.
2. Remove the 2 nuts for busbar module.
  
  Fig 1: Identifying Busbar Terminal Mounting Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the nut and wire harness protector.
  
  Fig 2: Identifying Wire Harness Protector Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 3 bolts and service plug assembly.
  
  Fig 3: Identifying Service Plug Mounting Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove power cable for SMR :
1. Remove the front RH and LH busbar module protectors.
2. Remove the 2 nuts, and disconnect the power cable from the front busbar module.
  
  Fig 4: Identifying Power Cable To Front Busbar Module Mounting Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the SMR cover from the SMR.
4. Remove 2 bolts, and disconnect the power cable for SMR.
Remove SMR :
1. Using the service plug, turn the interlock counterclockwise to unlock.
2. Remove the 3 bolts and SMR.
  
  Fig 5: Identifying SMR Mounting Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove battery ECU :
1. Disconnect the connector.
2. Remove the 2 bolts and battery ECU.
  
  Fig 7: Identifying Battery ECU Mounting Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove battery hose .
Remove busbar module :
1. Remove the 36 nuts, RH and LH rear busbar modules.
2. Remove the 36 nuts, RH and LH front busbar modules.
Remove battery clamp bolt .

Fig 8: Identifying Battery Clamp
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Remove the 4 bolts and battery clamp bolt.

WARNING: Never remove the battery clamp bolt until 4 hours has passed after the ignition switch is turned OFF. An explosion due to expansion could occur.
Remove RH battery bracket .
Remove the 2 bolts and RH battery bracket.

Fig 9: Identifying Battery Bracket To Battery Carrier Mounting Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

WARNING: Never remove the RH battery bracket until 4 hours has passed after the ignition switch is turned OFF. An explosion due to expansion could occur.
Remove 38 HV battery modules .