Main Battery Cable: Removal

CAUTION:

When working on the high voltage systems, always wear insulating gloves.
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.

NOTE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU.

PRECAUTION
CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/removal, inspection and replacement of parts), be sure to follow the procedures (see PRECAUTION ).
REMOVE REAR NO. 2 FLOOR BOARD (See REMOVAL )
REMOVE REAR DECK FLOOR BOX (See REMOVAL )
REMOVE REAR NO. 3 FLOOR BOARD (See REMOVAL )
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
REMOVE SERVICE PLUG GRIP (See REMOVAL )
REMOVE HV BATTERY ASSEMBLY
1. Remove the HV battery from the vehicle (see REMOVAL ).
REMOVE BATTERY COVER (See DISASSEMBLY )
REMOVE NO. 1 WIRE HARNESS PROTECTOR COVER
CAUTION: Wear insulating gloves.
REMOVE NO. 3 WIRE HARNESS PROTECTOR COVER
CAUTION: Wear insulating gloves.

Fig 1: Removing Wire Harness Protector Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 3 BATTERY CARRIER CUSHION
CAUTION: Wear insulating gloves.
1. Peel off the bonded parts, then remove the battery carrier cushion.
  
  Fig 2: Removing Battery Carrier Cushion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MAIN BATTERY CABLE
CAUTION: Wear insulating gloves.
1. Remove the terminal cover shown in the illustration.
  
  Fig 3: Removing Terminal Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the nut, then disconnect the aluminum shield wire.
3. Remove the nut, then disconnect the main battery cable from the No. 3 system main relay.
4. Remove the nut, then disconnect the main battery cable from the No. 2 frame wire.
5. Remove the main battery cable from the HV battery.
  
  Fig 4: Disconnecting Aluminum Shield Wire
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 MAIN BATTERY CABLE
CAUTION: Wear insulating gloves.
1. Remove the terminal cover shown in the illustration.
  
  Fig 5: Removing Terminal Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the nut, then disconnect the system main relay terminal and No. 2 main battery cable from the No. 2 system main relay.
3. Remove the nut, then disconnect the No. 2 main battery cable from the frame wire.
4. Remove the No. 2 main battery cable from the HV battery.
  
  Fig 6: Disconnecting System Main Relay Terminal And Main Battery Cable
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002