Installation
HYBRID BATTERY CONTROL: HV BATTERY: INSTALLATION
INSTALLATION
1. INSTALL NO. 5 HV BATTERY INTAKE DUCT
(a) Install the No. 5 HV battery intake duct with the 3 clips.
CAUTION: Wear insulated gloves.
2. INSTALL NO. 4 HV BATTERY INTAKE DUCT
(a) Install the No. 4 HV battery intake duct with the 2 claws.
CAUTION: Wear insulated gloves.
3. CONNECT BATTERY CARRIER SUB-ASSEMBLY
(a) Place the hybrid vehicle converter on the tool box in the luggage compartment.
NOTE: Protect the tool box in the luggage compartment with a piece of cardboard or other similar object before connecting the battery carrier.
(b) While holding up the hybrid vehicle converter, disconnect the 3 connectors and clamp. Connect the battery pack wire.
CAUTION: Wear insulated gloves.
NOTE: Do not allow the wire harnesses to get pinched when holding up the hybrid vehicle converter.
(c) Install the hybrid vehicle converter with the 4 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
CAUTION: Wear insulated gloves.
(d) Connect the 2 frame wires (high voltage cable) with the 2 connectors and 4 clamps.
CAUTION: Wear insulated gloves.
- Connect the wire wrapped with red tape to the terminal indicated by the "+" mark of the HV relay and the wire not wrapped with red tape to the terminal indicated by the "-" mark of the HV battery.
- Make sure that the connectors are engaged securely.
4. INSTALL NO. 6 BATTERY CARRIER PANEL
(a) Install the No. 6 battery carrier panel with the 7 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
CAUTION: Wear insulated gloves.
NOTE: Do not drop the bolts in the cooling air inlet.
5. INSTALL BATTERY CARRIER SUB-ASSEMBLY
(a) Install the battery carrier sub-assembly with the 2 bolts and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
CAUTION: Wear insulated gloves.
(b) Connect the 3 connectors and 2 clamps.
CAUTION: Wear insulated gloves.
6. INSTALL BATTERY BRACKET SUB-ASSEMBLY
(a) Pass the stud bolts on the battery carrier through holes A in the battery bracket. Install the battery bracket with the 3 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
CAUTION: Wear insulated gloves.
NOTE: Be sure to push the bracket onto the carrier when tightening the 3 bolts.
7. INSTALL BATTERY PACK WIRE
(a) Connect the battery pack wire with the 11 clamps and then connect the 2 connectors.
CAUTION: Wear insulated gloves.
8. INSTALL HV BATTERY
(a) Place a piece of cardboard in the luggage compartment.
(b) Using an engine sling device, install the HV battery while tilting the HV battery 45° at the rear end.
CAUTION: Wear insulated gloves.
NOTE: Place a piece of cardboard or other similar object 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.
CAUTION: Wear insulated gloves.
NOTE: Align the position of the holes for HV battery holding bolts.
(d) Use an extension bar (1000 mm) to hold up the HV battery and pull out the cardboard.
CAUTION: Wear insulated gloves.
NOTE: Before holding up the HV battery, check that the extension bar goes through to the front side of the battery from the cabin side.
(e) Connect the battery pack wire.
(f) Connect the battery room ventilation hose with the clamp and grommet.
- After installing the grommet, make sure that there is no clearance between the grommet and body.
- Visually check that the grommet is securely installed from the bottom of the body.
(g) Install the 3 bolts to the HV battery.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
CAUTION: Wear insulated gloves.
9. REMOVE LUGGAGE COMPARTMENT FLOOR MAT
10. REMOVE TOOL BOX
11. INSTALL UPPER BACK PANEL CORNER PLATE RH
(a) Install the upper back panel corner plate RH with the 6 claws.
12. INSTALL UPPER ROOF SIDE INNER COVER
(a) Install the upper roof side inner cover.
13. INSTALL NO. 1 ROOM PARTITION PAD
(a) Fold down No. 1 room partition pad.
14. INSTALL REAR SEAT BACK ASSEMBLY Installation
15. INSTALL REAR SEAT HEADREST ASSEMBLY CENTER
16. INSTALL REAR SEAT HEADREST ASSEMBLY LH AND RH
17. INSTALL REAR SEAT CUSHION ASSEMBLY Installation
18. INSTALL BATTERY CARRIER BRACKET
(a) Install the battery carrier bracket with the 6 bolts and 4 nuts.
Bolt - Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
Nut - Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
CAUTION: Wear insulated gloves.
19. INSTALL BATTERY COOLING BLOWER ASSEMBLY Installation
20. INSTALL NO. 2 HV BATTERY INTAKE DUCT Installation
21. INSTALL NO. 1 HV BATTERY EXHAUST DUCT
(a) Set the No. 1 HV battery exhaust duct to the beaded portion on the HV battery. Slide the No. 1 HV battery exhaust duct to install it to the HV battery.
CAUTION: Wear insulated gloves.
(b) Install the clip and connector clamp to the No. 1 HV battery exhaust duct.
CAUTION: Wear insulated gloves.
22. INSTALL NO. 2 HV BATTERY EXHAUST DUCT
(a) Install the No. 2 HV battery exhaust duct with the 2 clips.
NOTE: Be sure to engage the claws on the duct securely.
23. INSTALL BATTERY CARRIER
(a) Install the battery carrier with the 3 bolts.
Torque: 4.9 Nm (50 kgf-cm, 43 in-lbf)
24. INSTALL BATTERY
(a) Install the battery.
(b) Install the battery clamp with the nut and bolt.
bolt - Torque: 4.9 Nm (50 kgf-cm, 43 in-lbf)
nut - Torque: 2.9 Nm (30 kgf-cm, 26 in-lbf)
(c) Connect the fuse holder to the battery clamp.
(d) Connect the battery thermometer sensor connector and battery ventilation hose to the battery.
25. CONNECT FRAME WIRE
(a) Install the battery shield contact.
CAUTION: Wear insulated gloves.
NOTE: Be sure to install the battery shield contact in the correct direction.
(b) Connect the 2 frame wires (high voltage cable) with the 2 nuts and clamp.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
CAUTION: Wear insulated gloves.
NOTE: Be sure to match the red marks on the frame wires to the red marks on the HV relay assembly and install the frame wires.
(c) Install the battery cover and press the interlock button.
(d) Secure the battery cover with the 3 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
CAUTION: Wear insulated gloves.
(e) Connect the frame wire (AMD cable) with the nut and clamp.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
CAUTION: Wear insulated gloves.
(f) Connect the frame wire (battery positive cable) with the nut and 2 clamps.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
26. INSTALL NO. 3 HV BATTERY EXHAUST DUCT
(a) Install the No. 3 HV battery exhaust duct with the 2 clips.
CAUTION: Wear insulated gloves.
- Be sure to engage the claws on the duct securely.
- Make sure that the high-voltage terminals and connectors are securely connected.
27. INSTALL LUGGAGE COMPARTMENT FRONT TRIM COVER Installation
28. INSTALL ROPE HOOK ASSEMBLY
(a) Install the 2 rope hook assemblies with the 2 bolts.
29. INSTALL TOOL BOX
30. INSTALL LUGGAGE COMPARTMENT TRIM SIDE COVER RH
31. INSTALL SERVICE PLUG GRIP
CAUTION: Wear insulated gloves.
NOTE: Before connecting the service plug grip, make sure that no parts or tools remain in the luggage compartment.
(a) Wear insulated gloves and insert the service plug grip in the order shown in the illustration.
(b) Tilt the service plug grip 90° and slide it to the left until a "click" sound is heard.
(c) Install the battery service hole cover.
NOTE: Make sure that the battery service hole cover is installed securely.
32. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
33. INSTALL BATTERY SERVICE HOLE COVER LH
(a) Install the battery service hole cover LH with the 2 clips.
34. INSTALL LUGGAGE COMPARTMENT FLOOR MAT
35. PERFORM INITIALIZATION
(a) Perform initialization procedure Repair Instruction - Initialization.
NOTE: Some vehicle systems require initialization after reconnecting the cable to the negative battery terminal.