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Battery Plug: Replacement

WARNING: This page is about a different car, the 2004 Toyota Prius. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
  • When working on the high voltage systems, always wear insulating gloves.
  • After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU.
  • 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.
  1. PRECAUTION (See  PRECAUTION  ) 
  2. REMOVE REAR FLOOR BOARD NO. 2 (See  SERVICE PLUG GRIP  ) 
  3. REMOVE DECK FLOOR BOX REAR (See  SERVICE PLUG GRIP  ) 
  4. REMOVE REAR FLOOR BOARD NO. 3 (See  SERVICE PLUG GRIP  ) 
  5. DISCONNECT BATTERY NEGATIVE TERMINAL (See  SERVICE PLUG GRIP  ) 
  6. REMOVE SERVICE PLUG GRIP (See  SERVICE PLUG GRIP  ) 
  7. REMOVE DECK TRIM COVER REAR (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  8. REMOVE TONNEAU COVER ASSY (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  9. REMOVE REAR SEAT CUSHION ASSY (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  10. REMOVE REAR FLOOR BOARD NO. 1 (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  11. REMOVE REAR SIDE SEAT BACK FRAME LH (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  12. REMOVE REAR SIDE SEAT BACK FRAME RH (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  13. REMOVE REAR FLOOR BOARD NO. 4 (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  14. REMOVE DECK FLOOR BOX LH (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  15. REMOVE DECK TRIM SIDE PANEL ASSY LH (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  16. REMOVE DECK TRIM SIDE PANEL ASSY RH (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  17. REMOVE BATTERY CARRIER BRACKET (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  18. REMOVE QUARTER VENT DUCT INNER NO. 2 (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  19. REMOVE BATTERY BRACKET REINFORCEMENT (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  20. REMOVE QUARTER VENT DUCT (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  21. REMOVE BATTERY CARRIER PANEL NO. 6 (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  22. REMOVE JUNCTION TERMINAL (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
    NOTE: Wear insulating gloves.
  23. REMOVE FRAME WIRE (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
    NOTE: Wear insulating gloves.
  24. REMOVE HV BATTERY ASSY (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  25. REMOVE BATTERY COVER SUB-ASSY (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  26. REMOVE BATTERY CLAMP PAD (BATTERY CARRIER CUSHION NO. 1) 
    NOTE: Wear insulating gloves.
    1. Peel off the bonded parts, then remove the battery clamp pad (the battery carrier cushion No. 1).
      Fig 1: Removing Battery Clamp Pad (Battery Carrier Cushion No. 1)
      G00950477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE WIRING HARNESS PROTECTOR COVER NO. 1 
    1. Flip open the wiring harness protector cover.
    2. Remove the 2 nuts, then disconnect the service plug.
    3. Remove the wiring harness protector cover No. 1.
      Fig 2: Removing Wiring Harness Protector Cover No. 1
      G00950478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE BATTERY PLUG 
    1. Disconnect the connector clamp.
    2. Remove the 2 bolts, then disconnect the service plug from the upper battery carrier.
      Fig 3: Removing Battery Plug
      G00950479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Flip open the wiring harness protector cover No. 4 shown in the illustration, then remove the service plug from the junction block.
      Fig 4: Locating Wiring Harness Protector Cover No. 4 And Junction Block
      G00950480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL BATTERY PLUG 
    1. Temporarily fasten the service plug.
    2. Install the service plug to the upper battery carrier with the 2 bolts.

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

    3. Assemble the connector clamp.
  30. INSTALL WIRING HARNESS PROTECTOR COVER NO. 1 
    1. Temporarily fasten the wiring harness protector cover No. 1 to the service plug.
    2. Install the wiring harness protector cover No. 1 through the service plug with 2 new nuts.

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

  31. INSTALL BATTERY CLAMP PAD (BATTERY CARRIER CUSHION NO. 1) 
    NOTE: Wear insulating gloves.
    1. Install a new clamp pad (the battery carrier cushion No. 1).
      Fig 5: Installing Battery Clamp Pad (Battery Carrier Cushion No. 1)
      G00950481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL BATTERY COVER SUB-ASSY (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  33. INSTALL HV BATTERY ASSY (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  34. INSTALL FRAME WIRE (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
    NOTE: Wear insulating gloves.
  35. INSTALL JUNCTION TERMINAL (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
    NOTE: Wear insulating gloves.
  36. INSTALL BATTERY CARRIER PANEL NO. 6 (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  37. INSTALL QUARTER VENT DUCT (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  38. INSTALL BATTERY BRACKET REINFORCEMENT (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  39. INSTALL QUARTER VENT DUCT INNER NO. 2 (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  40. INSTALL BATTERY CARRIER BRACKET (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  41. INSTALL DECK TRIM SIDE PANEL ASSY RH 
  42. INSTALL DECK TRIM SIDE PANEL ASSY LH 
  43. INSTALL DECK FLOOR BOX LH 
  44. INSTALL REAR FLOOR BOARD NO. 4 
  45. INSTALL REAR SIDE SEAT BACK FRAME RH 
  46. INSTALL REAR SIDE SEAT BACK FRAME LH 
  47. INSTALL REAR FLOOR BOARD NO. 1 
  48. INSTALL REAR SEAT CUSHION ASSY 
  49. INSTALL TONNEAU COVER ASSY 
  50. INSTALL DECK TRIM COVER REAR 
  51. INSTALL SERVICE PLUG GRIP (See  SERVICE PLUG GRIP  ) 
    NOTE: Wear insulating gloves.
  52. CONNECT BATTERY NEGATIVE TERMINAL 

    Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf) 

  53. INSTALL REAR FLOOR BOARD NO. 3 
  54. INSTALL DECK FLOOR BOX REAR 
  55. INSTALL REAR FLOOR BOARD NO. 2 
  56. POWER WINDOW CONTROL SYSTEM INITIALIZE (See  INITIALIZATION  ) 
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