Installation
HYBRID / BATTERY CONTROL: HV BATTERY: INSTALLATION
1. INSTALL NO. 2 HYBRID BATTERY PACK WIRE
(a) Connect the 2 clamps and No. 2 hybrid battery pack wire.
2. INSTALL NO. 1 HYBRID BATTERY PACKING
CAUTION:
Be sure to wear insulated gloves and protective goggles.
(a) Install the No. 1 hybrid battery packing with the 2 clamps.
3. INSTALL UPPER HYBRID BATTERY COVER SUB-ASSEMBLY
CAUTION:
Be sure to wear insulated gloves and protective goggles.
(a) Install the upper hybrid battery cover sub-assembly and No. 1 hybrid battery shield sub-assembly with the 3 bolts and 8 nuts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
4. INSTALL NO. 1 HYBRID BATTERY COVER INTAKE DUCT
(a) Install the No. 1 hybrid battery cover intake duct with the 2 clips.
5. INSTALL NO. 4 HYBRID VEHICLE BATTERY CARRIER BRACKET SUB-ASSEMBLY
CAUTION:
Wear insulated gloves.
(a) Install the HV battery thermistor to the No. 4 hybrid vehicle battery carrier bracket sub-assembly.
(b) Install the No. 4 hybrid vehicle battery carrier bracket sub-assembly with the 3 bolts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(c) Connect the 3 wire harness clamps.
6. INSTALL NO. 1 HYBRID VEHICLE BATTERY CARRIER BRACKET SUB-ASSEMBLY
CAUTION:
Wear insulated gloves.
(a) Install the No. 1 hybrid vehicle battery carrier bracket sub-assembly with the 3 nuts.
Text in Illustration
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(b) Install the battery cover lock striker, then push the button to lock it.
(c) Install the electric vehicle battery plug assembly with the bolt as shown in the illustration.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(d) Connect the connector.
NOTICE:
The connector should be connected securely.
7. INSTALL BATTERY SMART UNIT Installation
8. INSTALL HV BATTERY
CAUTION:
Wear insulated gloves.
NOTICE:
Since the HV battery is very heavy, 2 people are needed to install the HV battery. When installing the HV battery, do not damage the parts around it.
(a) Install the HV battery to the vehicle with the 4 bolts.
Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)
(b) Connect the connector and electrical key oscillator clamp.
(c) Install a new No. 3 hybrid vehicle battery carrier sheet.
(d) Install a new No. 2 hybrid vehicle battery carrier sheet.
(e) Install the hybrid vehicle battery lower cover plate.
9. INSTALL REAR CENTER SEAT BACK HINGE SUB-ASSEMBLY
(a) Install the rear center seat back hinge sub-assembly with the 2 bolts.
Torque : 37 Nm (375 kgf-cm, 27 ft-lbf)
10. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH
(a) Install the child restraint seat anchor bracket sub-assembly LH with the 2 bolts.
Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)
11. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY RH
(a) Install the child restraint seat anchor bracket sub-assembly RH with the 2 bolts.
Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)
(b) Connect the wire harness protector clamp.
12. INSTALL NO. 7 HYBRID VEHICLE BATTERY UPPER CARRIER BRACKET
(a) Install the No. 7 hybrid battery upper carrier bracket with the bolt.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(b) Connect the 2 wire harness clamps.
13. INSTALL HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Installation
14. INSTALL FRAME WIRE
CAUTION:
Wear insulated gloves.
(a) Install the frame wire on the hybrid battery junction block with the 2 nuts.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTICE:
* Make sure that the ends of the frame wire are not crossed over each other.
* Be sure to connect the frame wires to the correct terminals.
(b) Connect the clamp and frame wire.
15. CHECK HIGH VOLTAGE CABLE CONNECTION CONDITION
CAUTION:
Wear insulated gloves and protective goggles.
(a) Check that each wire harness is installed securely.
Text in Illustration
NOTICE:
* Make sure that the end of the frame wire are not crossed over each other.
* Be sure to connect the frame wire to the correct terminals 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.
16. INSTALL UPPER HYBRID BATTERY COVER SUB-ASSEMBLY
(a) Install the upper hybrid battery cover sub-assembly with the 4 nuts.
Text in Illustration
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(b) Install the battery cover lock striker, then push the button to lock.
17. INSTALL NO. 1 HYBRID BATTERY EXHAUST DUCT
(a) Insert the No. 1 hybrid battery exhaust duct with the clip.
NOTICE:
Ensure that the duct is installed securely.
18. INSTALL BATTERY COOLING BLOWER ASSEMBLY Installation
19. INSTALL NO. 1 HYBRID BATTERY INTAKE DUCT
NOTICE:
Ensure that the duct is installed securely.
(a) Install the No. 1 hybrid battery intake duct with the 2 clips.
20. INSTALL REAR FLOOR BOARD SPACER
(a) Install the rear floor board spacer with the 2 clips.
21. INSTALL HYBRID BATTERY COVER SHEET
(a) Align the cutout of a new hybrid battery cover sheet with the edge of the upper hybrid battery cover sub-assembly, and then install the hybrid battery cover sheet with the double-sided tape.
Text in Illustration
22. INSTALL HYBRID VEHICLE BATTERY SHIELD SHEET
(a) Align the edge of the tab of a new hybrid vehicle battery shield sheet with the edge of the hybrid battery cover sub-assembly, and then install the hybrid vehicle battery shield sheet with the double-sided tape.
Text in Illustration
(b) Overlap the hybrid vehicle battery shield sheet with the hybrid battery cover sheet, fold the edge as shown in the illustration, and secure it with the double-sided tape.
Text in Illustration
23. INSTALL REAR SEAT SIDE GARNISH RH Installation
24. INSTALL REAR SEAT SIDE GARNISH LH Installation
25. INSTALL REAR DOOR SCUFF PLATE RH Installation
26. INSTALL REAR DOOR SCUFF PLATE LH Installation
27. INSTALL REAR SEAT ASSEMBLY
Installation
28. INSTALL REAR NO. 1 FLOOR BOARD Installation
29. INSTALL REAR NO. 2 FLOOR BOARD SUB-ASSEMBLY Installation
30. INSTALL REAR NO. 1 FLOOR BOARD SUB-ASSEMBLY Installation
31. INSTALL DECK FLOOR BOX LH (w/o Woofer) Installation
32. INSTALL REAR NO. 4 FLOOR BOARD (w/ Woofer) Installation
33. INSTALL REAR NO. 4 FLOOR BOARD (w/o Woofer) Installation
34. INSTALL TONNEAU COVER ASSEMBLY (w/ Tonneau Cover) Installation
35. INSTALL SERVICE PLUG GRIP
Installation