Battery Plug

Battery Plug:

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.

1. 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.

2. REMOVE REAR NO. 2 FLOOR BOARD
3. REMOVE REAR DECK FLOOR BOX
4. REMOVE REAR NO. 3 FLOOR BOARD
5. 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.

6. REMOVE SERVICE PLUG GRIP
7. REMOVE HV BATTERY ASSEMBLY
a. Remove the HV battery from the vehicle.

8. REMOVE BATTERY COVER




9. REMOVE BATTERY CLAMP PAD

CAUTION: Wear insulating gloves.

a. Peel off the bonded parts, then remove the battery clamp pad (the battery carrier cushion).




10. REMOVE NO. 1 WIRE HARNESS PROTECTOR COVER
a. Open the wire harness protector cover.
b. Remove the 2 nuts, then disconnect the service plug.
c. Remove the wire harness protector cover.

11. REMOVE BATTERY PLUG




a. Disconnect the connector clamp.
b. Remove the 2 bolts, then disconnect the service plug from the upper battery carrier.




c. Open the wire harness protector cover as shown in the illustration. Then remove the service plug from the junction block.

INSTALLATION




1. INSTALL BATTERY PLUG
a. Temporarily fasten the service plug.
b. Install the service plug to the upper battery carrier with the 2 bolts.

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

c. Assemble the connector clamp.

2. INSTALL NO. 1 WIRE HARNESS PROTECTOR COVER
a. Temporarily fasten the wire harness protector cover to the service plug.
b. Install the wiring harness protector cover through the service plug with 2 new nuts.

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




3. INSTALL BATTERY CLAMP PAD

CAUTION: Wear insulating gloves.

a. Install a new clamp pad (the battery carrier cushion).

4. INSTALL BATTERY COVER
5. INSTALL HV BATTERY ASSEMBLY
a. Install the HV battery to the vehicle

6. INSTALL SERVICE PLUG GRIP
7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
8. INSTALL REAR NO. 3 FLOOR BOARD
9. INSTALL REAR DECK FLOOR BOX
10. INSTALL REAR NO. 2 FLOOR BOARD
11. PERFORM INITIALIZATION
a. Perform initialization.

NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.