Installation

HYBRID / BATTERY CONTROL: HV BATTERY: INSTALLATION

1. INSTALL NO. 1 BATTERY INSULATOR DUCT

CAUTION:
Be sure to wear insulated gloves and protective goggles.

(a) Install the No. 1 battery insulator duct to the HV battery.

2. INSTALL NO. 2 BATTERY INSULATOR DUCT

CAUTION:
Be sure to wear insulated gloves and protective goggles.

(a) Install the No. 2 battery insulator duct to the HV battery.

3. INSTALL HYBRID BATTERY HOSE ASSEMBLY

CAUTION:
Be sure to wear insulated gloves and protective goggles.

(a) Install the hybrid battery hose assembly to the HV battery.

4. INSTALL UPPER HYBRID BATTERY COVER SUB-ASSEMBLY

CAUTION:
Be sure to wear insulated gloves and protective goggles.

(a) Install the 2 bushings and 2 washers with the 2 bolts.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

(b) Install the upper hybrid battery cover sub-assembly with the 2 bolts and 8 nuts.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

5. INSTALL NO. 2 HYBRID BATTERY SHIELD SUB-ASSEMBLY

CAUTION:
Be sure to wear insulated gloves and protective goggles.

(a) Install the No. 2 hybrid battery shield sub-assembly with the 3 bolts, nut and guide.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

6. INSTALL WIRE HARNESS

CAUTION:
Wear insulated gloves.

(a) Connect the wire harness with the 2 nuts and clamp to the HV battery.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

(b) Install the EV battery plug with the 2 bolts.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

(c) Connect the 5 wire harness clamps to the HV battery.

(d) Install the HV battery thermistor to the HV battery.

7. INSTALL UPPER HYBRID BATTERY COVER SUB-ASSEMBLY

CAUTION:
Wear insulated gloves.

(a) Install the upper hybrid battery cover sub-assembly with the 2 nuts.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

(b) Connect the wire harness with the nut and 3 clamps to the HV battery.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

8. INSTALL HYBRID BATTERY SERVICE PLUG COVER

CAUTION:
Wear insulated gloves.

(a) Install the hybrid battery service plug cover with the 4 nuts.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

9. INSTALL NO. 2 HYBRID BATTERY PACK WIRE

CAUTION:
Wear insulated gloves.

(a) Connect the connector and 4 clamps and install the No. 2 hybrid battery pack wire.

(b) Connect the connector and 3 clamps to the HV battery.

(c) Connect the 2 clamps to the HV battery.

(d) Connect the 2 clamps to the HV battery.

10. INSTALL REAR NO. 1 HYBRID BATTERY SHIELD

CAUTION:
Wear insulated gloves.

(a) Install the rear No. 1 hybrid battery shield with the 2 nuts.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

11. INSTALL FRONT HYBRID BATTERY SHIELD

CAUTION:
Wear insulated gloves.

(a) Install the front hybrid battery shield with the 2 bolts and nut.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

12. INSTALL EARTH WIRE

CAUTION:
Wear insulated gloves.

(a) Install the earth wire with the nut.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

13. INSTALL ELECTRICAL KEY OSCILLATOR Installation

14. INSTALL HV BATTERY

CAUTION:
Wear insulated gloves.

(a) Place a piece of cardboard in the luggage compartment.





Text in Illustration





(b) Using a suitable adaptor such as a rope, install the HV battery while tilting the HV battery.

NOTICE:
Use cardboard or other similar material to protect the HV battery and vehicle body from damage.

(c) Push the HV battery together with the cardboard toward the front of the vehicle.





Text in Illustration





NOTICE:
Align the holes for HV battery holding bolts.

(d) Use a tire lever to hold up the HV battery and pull out the cardboard.





Text in Illustration





(e) Remove the luggage compartment floor mat.

(f) Install the 4 bolts to the HV battery.





Bolt A - Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)

Bolt B - Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)

(g) Connect the battery room ventilation hose with the grommet.





Text in Illustration





NOTICE:
After installing the grommet, make sure that there is no clearance between the grommet and body.

(h) Connect the battery pack wire connector and clamp.

(i) Connect the battery room ventilation hose.

(j) Connect the frame wire clamp.

15. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH

(a) Install the child restraint seat anchor bracket sub-assembly LH with the 2 bolts.





Bolt A - Torque : 20 Nm (204 kgf-cm, 14 ft-lbf)

Bolt B - Torque : 19 Nm (194 kgf-cm, 13 ft-lbf)

16. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY RH

(a) Install the child restraint seat anchor bracket sub-assembly RH with the 2 bolts.





Bolt A - Torque : 20 Nm (204 kgf-cm, 14 ft-lbf)

Bolt B - Torque : 19 Nm (194 kgf-cm, 13 ft-lbf)

(b) Connect the wire harness protector clamp.

17. INSTALL NO. 1 HYBRID BATTERY EXHAUST DUCT

(a) Insert the No. 1 hybrid battery exhaust duct with the 2 clips.

NOTICE:
Ensure that the duct is installed securely.

18. INSTALL NO. 2 HYBRID BATTERY EXHAUST DUCT

(a) Insert the No. 2 hybrid battery exhaust duct with the clip.

NOTICE:
Ensure that the duct is installed securely.

19. INSTALL HYBRID VEHICLE CONVERTER

CAUTION:
Wear insulated gloves.

(a) Install the hybrid vehicle converter with the 5 nuts.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

(b) Connect the connector to the hybrid vehicle converter.

NOTICE:
Make sure that the connector is fully engaged.

(c) Connect the wire harness with the nut and 4 clamps to the hybrid vehicle converter.





Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

NOTICE:
Be sure to connect the connector to each correct terminal as shown in the illustration.

20. INSTALL INVERTER TERMINAL

CAUTION:
Wear insulated gloves.

(a) Install the bolt, nut and inverter terminal.

Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

(b) Connect the frame wire and install the nut.

Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

21. INSTALL NO. 3 HYBRID BATTERY EXHAUST DUCT Installation

22. INSTALL BATTERY SMART UNIT

HINT
Installation.

23. INSTALL BATTERY COOLING BLOWER ASSEMBLY

HINT
Installation.

24. INSTALL AUXILIARY BATTERY Installation

25. INSTALL INNER LUGGAGE COMPARTMENT TRIM COVER Installation

26. INSTALL ROPE HOOK Installation

27. INSTALL FRONT LUGGAGE COMPARTMENT TRIM COVER Installation

28. INSTALL NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY

29. INSTALL REAR FLOOR FINISH PLATE Installation

30. INSTALL TOOL WITH STAY BOX SUB-ASSEMBLY

31. INSTALL REAR SEATBACK ASSEMBLY

HINT
Installation.

32. INSTALL SERVICE PLUG GRIP Installation

33. INSTALL BATTERY SERVICE HOLE COVER Installation

34. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Installation

35. INSTALL LUGGAGE COMPARTMENT FLOOR MAT Installation