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HV Battery: Installation

  1. INSTALL BATTERY PACK WIRE 
    1. Connect the 2 clamps, then install the battery pack wire on the HV battery lower case.
      Fig 1: Locating Battery Pack Wire Clamps
      G05202023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the clamp, then install the battery pack wire on the HV battery lower case.
      Fig 2: Locating Battery Pack Wire Connector
      G05202022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL BATTERY PACKING NO.2 
    1. Install the battery packing No.2 to the HV battery lower case.
      NOTE: Make sure that there is no clearance between the battery packing and the lower case.
      Fig 3: Installing Battery Packing No 2 To HV Battery Lower Case
      G05202026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL BATTERY COVER 
    1. Install the battery cover to the HV battery lower case.
      Fig 4: Installing Battery Cover To HV Battery Lower Case
      G05202027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be sure to attach the bulgy tape portion of the battery cover securely to the lower case.
  4. INSTALL HV BATTERY LOWER CASE 
    1. Install the HV battery lower case on the vehicle.
    2. Connect the connector and clamp on the HV battery lower case.
      3. Fig 5: Identifying HV Battery Service Hole Cover
      G05202019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL HYBRID VEHICLE RELAY ASSEMBLY (See  INSTALLATION  ) 
  6. INSTALL ELECTRIC VEHICLE BATTERY PLUG ASSEMBLY 
    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) 

      Fig 6: Locating Electric Vehicle Battery Plug Assembly
      G05202018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the connector and clamps.
      Fig 7: Locating Connector And Clamps
      G05202017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL BATTERY COOLING BLOWER ASSEMBLY 
    1. Install the 3 battery cooling blower assemblies with the 9nuts.

      Torque: 4.5 N*m (46 kgf*cm, 40 in.*lbf) 

      Fig 8: Identifying Battery Cooling Blower Assemblies With Nuts
      G05202016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect each battery cooling blower assembly connector and clamp.
      3. Fig 9: Locating Battery Cooling Blower Assembly Connector And Clamp
      G05202015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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)
      Fig 10: Locating Bar-Code Label
      G05202033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Attach the new label to immediate right of the original one.

        HINT:

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

    2. Attach the bar-code label. (In case that the lower case is replaced)
      1. Attach the new label to the original position.

        HINT:

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

        Fig 11: Attaching Bar-Code Label
        G05202034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the HV battery RH.
      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) 

        Fig 12: Locating Main Battery Cable On HV Battery RH With Nut
        G05202035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE: Be sure to engage the plastic cover securely.
      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) 

        Fig 13: Locating Main Battery Cable No 2 On HV Battery RH With Nut
        G05202036Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE: Be sure to engage the plastic cover securely.
      3. Install the HV battery RH.
        NOTE: 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.
        Fig 14: Installing HV Battery RH
        G05202037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Install the battery room ventilation hose.
        Fig 15: Aligning Projections Of Battery Room Ventilation Hose And Rubber Tube
        G05202038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE: Align the projections of the battery room ventilation hose and the rubber tube, and install the hose.
      5. Connect the clamp.
        Fig 16: Locating Clamp
        G05202010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      6. Connect the main battery cable with the nut and connector.

        Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

        Fig 17: Locating Main Battery Cable With Nut And Connector
        G05202009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      7. Connect the 2 clamps.
        Fig 18: Locating Clamps
        G05202008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the HV battery CTR.
      1. Install the HV battery CTR.
        Fig 19: Installing HV Battery CTR
        G05202042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE: 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. Install the battery room ventilation hose between the HV batteries CTR and RH.
        Fig 20: Aligning Projections Of Battery Room Ventilation Hose And Rubber Tube
        G05202043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE: Align the projections of the battery room ventilation hose and the rubber tube, and install the hose.
      3. Connect the 2 connectors and clamp.
        Fig 21: Locating Connectors And Clamp
        G05202005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Connect the 2 connectors on the HV relay assembly.
        Fig 22: Locating Connectors On HV Relay Assembly
        G05202004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the HV battery LH.
      1. Install the HV battery LH.
        Fig 23: Installing HV Battery LH
        G05202046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE: 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. Connect the EV battery plug on the HV battery with a new nut.

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

        Fig 24: Connecting EV Battery Plug On HV Battery
        G05202047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Be sure to engage the plastic cover securely.
        • Insulate the tool with insulting tape.
        • Do not use the universal joint.
      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) 

        Fig 25: Connecting Main Battery Cable On HV Battery
        G05202048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Be sure to engage the plastic cover securely.
        • Insulate the tool with insulting tape.
        • Do not use the universal joint.
      4. Connect the wire harness clamp of the battery thermo sensor.
        Fig 26: Locating Wire Harness Clamp
        G05202000Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Connect the battery room ventilation hose between the HV batteries LH and CTR.
        Fig 27: Locating Battery Room Ventilation Hose And Rubber Tube
        G05202050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE: Align the projections of the battery room ventilation hose and the rubber tube, and install the hose.
  9. INSTALL BATTERY SMART UNIT (See  REMOVAL  ) 
  10. CHECK HIGH VOLTAGE CABLE CONNECTION 
    CAUTION: Wear insulating gloves and protective glasses.
    1. Check that each wire harness is being installed securely.
      Fig 28: Locating Red Tape, No.3 Wire Frame And White Tape With Plastic Cover
      G05202051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure that the No. 3 wire frame do not cross each other.
      • Be sure to connect the No. 3 wire frame to each correct terminal as shown in the illustration.
      • The connectors should be connected securely.
      • The nuts should be fastened securely.
      • 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.
      Fig 29: Locating Battery Cover Lock Striker
      G05202052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the battery cover with the 28 bolts and 6 nuts.
      NOTE: Use a ground bolt for position B.

      Torque: Bolt A 

      25 N*m (255 kgf*cm, 19 ft.*lbf) 

      Bolt B 

      22 N*m (224 kgf*cm, 16 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) 

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

      Torque: 8.0 N*m (82 kgf*cm, 72 in.*lbf) 

      Fig 30: Locating No 3 Wire Frame With Bolt
      G05201801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL HV BATTERY SERVICE HOLE COVER 
    1. Install the battery cover lock striker, then push the button to lock.
      2. Fig 31: Pushing Button To Lock
      G05202054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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 
    1. Install the battery carrier duct (RH) with the 2 bolts.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

      Fig 32: Locating Battery Carrier Duct (RH)
      G05201995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the battery carrier duct (CTR) with the 2 bolts.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

      Fig 33: Locating Battery Carrier Duct (CTR)
      G05201994Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the battery carrier duct (LH) with the 2 bolts.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

      Fig 34: Locating Battery Carrier Duct (LH)
      G05201993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL REAR CENTER SEAT INNER BELT ASSEMBLY  (See REMOVAL )
  15. INSTALL FLOOR BOARD NO.3 
    1. Install the floor board No.3.
      Fig 35: Identifying Floor Board No.3
      G05201992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL FLOOR BOARD NO.2 
    1. Install the floor board No.2.
      Fig 36: Identifying Floor Board No.2
      G05201991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL FLOOR BOARD NO.1 
    1. Install the floor board No.1.
      2. Fig 37: Identifying Floor Board No.1
      G05201990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL FLOOR CARPET ASSEMBLY FRONT 
    1. Install the front floor carpet.
  19. INSTALL AIR INTAKE COVER CENTER 
    1. Install the air intake cover with the 2 screws.
      2. Fig 38: Locating Air Intake Cover With Screws
      G05201989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 hole covers.
  20. INSTALL AIR INTAKE COVER 
    1. Install the air intake cover RH.
      1. Install the air intake cover RH with the 2 screws.
        2. Fig 39: Locating Air Intake Cover RH With Screws
        G05201987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Install the 2 hole covers.
    2. Install the air intake cover LH.
      1. Install the air intake cover LH with the 2 screws.
        2. Fig 40: Locating Air Intake Cover LH With Screws
        G05201985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Install the 2 hole covers.
  21. INSTALL DECK TRIM SIDE PANEL ASSEMBLY LH  (See INSTALLATION )
  22. INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH 
  23. INSTALL ROPE HOOK  (See INSTALLATION )
  24. INSTALL REAR NO.1 SEAT BELT ASSEMBLY OUTER LH  (See INSTALLATION )
  25. INSTALL REAR NO.1 SEAT BELT ASSEMBLY OUTER RH 
  26. INSTALL DECK SIDE TRIM COVER LH (w/ Rear No. 2 Seat)  (See INSTALLATION )
  27. INSTALL DECK SIDE TRIM COVER LH (w/o Rear No. 2 Seat)  (See INSTALLATION )
  28. INSTALL DECK SIDE TRIM COVER RH 
  29. INSTALL REAR DOOR SCUFF PLATE LH (w/ Rear No. 2 Seat)  (See INSTALLATION )
  30. INSTALL REAR DOOR SCUFF PLATE LH (w/o Rear No. 2 Seat)  (See INSTALLATION )
  31. INSTALL REAR DOOR SCUFF PLATE RH 
  32. INSTALL DECK SIDE TRIM BOX LH  (See INSTALLATION )
  33. INSTALL DECK SIDE TRIM BOX RH 
  34. INSTALL JACK CARRIER ASSEMBLY 
  35. INSTALL REAR SEAT RECLINING COVER NO.2 LH (w/ Rear No. 2 Seat)  (See INSTALLATION )
  36. INSTALL REAR SEAT RECLINING COVER NO.2 RH (w/ Rear No. 2 Seat) 
  37. INSTALL BACK DOOR WEATHERSTRIP 
  38. INSTALL REAR FLOOR FINISH PLATE  (See INSTALLATION )
  39. INSTALL DECK FLOOR BOX FRONT (w/o Rear No. 2 Seat)  (See INSTALLATION )
  40. INSTALL DECK FLOOR BOX REAR  (See INSTALLATION )
  41. INSTALL DECK BOARD SUB-ASSEMBLY NO.3 
  42. INSTALL DECK BOARD SUB-ASSEMBLY NO.2 
  43. INSTALL DECK BOARD SUB-ASSEMBLY (w/ Rear No. 2 Seat)  (See INSTALLATION )
  44. INSTALL DECK BOARD SUB-ASSEMBLY (w/o Rear No. 2 Seat)  (See INSTALLATION )
  45. INSTALL TONNEAU COVER ASSEMBLY 
  46. INSTALL REAR NO. 1 SEAT ASSEMBLY LH (w/ Rear No. 2 Seat)  (See INSTALLATION )
  47. INSTALL SEAT TRACK COVER INNER LH (w/ Rear No. 2 Seat) 
  48. INSTALL REAR SEAT TRACK BRACKET COVER INNER LH (w/ Rear No. 2 Seat) 
  49. INSTALL REAR SEAT TRACK COVER LH (w/ Rear No. 2 Seat) 
  50. INSTALL REAR SEAT TRACK BRACKET COVER OUTER (w/ Rear No. 2 Seat) 
  51. INSTALL RECLINING HINGE COVER LH (w/ Rear No. 2 Seat) 
  52. INSTALL REAR NO. 1 SEAT ASSEMBLY RH (w/ Rear No. 2 Seat)  (See INSTALLATION )
  53. INSTALL SEAT TRACK INNER COVER RH (w/ Rear No. 2 Seat) 
  54. INSTALL REAR SEAT TRACK BRACKET COVER INNER RH (w/ Rear No. 2 Seat) 
  55. INSTALL REAR SEAT TRACK COVER RH (w/ Rear No. 2 Seat) 
  56. INSTALL REAR SEAT TRACK BRACKET COVER OUTER (w/ Rear No. 2 Seat) 
  57. INSTALL REAR NO. 1 SEAT ASSEMBLY RH (w/o Rear No. 2 Seat)  (See INSTALLATION )
  58. INSTALL REAR SEAT TRACK BRACKET COVER OUTER (w/o Rear No. 2 Seat) 
  59. INSTALL REAR SEAT TRACK BRACKET COVER OUTER (w/o Rear No. 2 Seat) 
  60. INSTALL REAR NO. 1 SEAT ASSEMBLY LH (w/o Rear No. 2 Seat)  (See INSTALLATION )
  61. INSTALL REAR SEAT TRACK BRACKET COVER OUTER (w/o Rear No. 2 Seat) 
  62. INSTALL REAR SEAT TRACK BRACKET COVER OUTER (w/o Rear No. 2 Seat) 
  63. INSPECT SLIDE ADJUSTER LOCK SIMULTANEOUSLY  (See INSTALLATION )
  64. INSTALL SERVICE PLUG GRIP 
    NOTE: Before connecting the service plug, check that no parts and tools remain and that the high voltage terminals and connectors are connected securely.
    1. Wear insulation gloves, then insert the service plug.
    2. Push down on the grip to lock.
      3. Fig 41: Identifying Clips On Service Plug Grip
      G05201983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Close the reclining hinge cover.
      NOTE: Check that the 2 clips are securely connected to the battery carrier bracket (click sound).
    4. Close the rear door scuff plate LH.
      NOTE: Check that the 2 clips are securely connected to the battery carrier bracket (click sound).
  65. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  66. PERFORM INITIALIZATION 

    Some systems need initialization when disconnecting the cable from the negative battery terminal. (See INITIALIZATION )

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