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Main Battery Cable No. 2: 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 WIRING HARNESS PROTECTOR COVER NO. 3 
    NOTE: Wear insulating gloves.
    Fig 1: Removing Wiring Harness Protector Cover No. 3
    G00950467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE BATTERY CARRIER CUSHION NO. 3 (See  MAIN BATTERY CABLE  ) 
    NOTE: Wear insulating gloves.
  28. REMOVE MAIN BATTERY CABLE NO. 2 
    NOTE: Wear insulating gloves.
    1. Remove the terminal cover shown in the illustration.
      Fig 2: Removing Terminal Cover
      G00950468Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut, then disconnect the system main relay terminal and main battery cable No. 2 from the system main relay No. 2.
    3. Remove the nut, then disconnect the frame wire from the main battery cable No. 2.
    4. Remove the main battery cable No. 2 from the HV battery.
      Fig 3: Disconnecting System Main Relay Terminal And Main Battery Cable No. 2
      G00950469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL MAIN BATTERY CABLE NO. 2 
    NOTE: Wear insulating gloves.
    1. Temporarily fasten the main battery cable No. 2 to the HV battery.
    2. Install the main battery cable No. 2 to the frame wire No. 2 with a new nut.

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

    3. Temporarily fasten the main battery cable and system main relay terminal, in that order, to the system main relay No. 3, then tighten the new nut.

      Torque: 5.6 N.m (57 kgf.cm, 50 in.lbf) 

      Fig 4: Installing System Main Relay Terminal And Main Battery Cable No. 2
      G00950470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the terminal cover shown in the illustration.
      Fig 5: Installing Terminal Cover
      G00950471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL BATTERY CARRIER CUSHION NO. 3 (See  MAIN BATTERY CABLE  ) 
    NOTE: Wear insulating gloves.
  31. INSTALL WIRING HARNESS PROTECTOR COVER NO. 3 
    NOTE: Wear insulating gloves.
    Fig 6: Installing Wiring Harness Protector Cover No. 3
    G00950472Courtesy 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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