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Main Battery Cable: 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. 1 
    NOTE: Wear insulating gloves.
    Fig 1: Removing Wiring Harness Protector Cover No. 1
    G00950459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE WIRING HARNESS PROTECTOR COVER NO. 3 
    NOTE: Wear insulating gloves.
  28. REMOVE BATTERY CARRIER CUSHION NO. 3 
    NOTE: Wear insulating gloves.
    1. Peel off the bonded parts, then remove the battery carrier cushion No. 3.
      Fig 2: Identifying Bonded Parts
      G00950460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE MAIN BATTERY CABLE 
    NOTE: Wear insulating gloves.
    1. Remove the terminal cover shown in the illustration.
      Fig 3: Locating Terminal Cover
      G00950461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut, then disconnect the aluminum shield wire.
    3. Remove the nut, then disconnect the main battery cable from the system main relay No. 3.
    4. Remove the nut, then disconnect the main battery cable from the frame wire No. 2.
    5. Remove the main battery cable from the HV battery.
      Fig 4: Disconnecting Aluminum Shield Wire And Main Battery Cable
      G00950462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL MAIN BATTERY CABLE 
    NOTE: Wear insulating gloves.
    1. Temporarily fasten the main battery cable to the HV battery.
    2. Install the main battery cable to the frame wire No. 2 with a new nut.

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

    3. Install the main battery cable to the system main relay No. 3 with a new nut.

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

    4. Install the aluminum shield wire with a new nut.

      Torque: 3.3 N.m (34 kgf.cm, 29 in.lbf) 

      Fig 5: Installing Aluminum Shield Wire And Main Battery Cable
      G00950463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the terminal cover shown in the illustration.
      Fig 6: Installing Terminal Cover
      G00950464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL BATTERY CARRIER CUSHION NO. 3 
    NOTE: Wear insulating gloves.
    1. Degrease and clean the installation surface of the battery carrier cushion No. 3.
    2. Install a new battery carrier cushion No. 3.
      Fig 7: Installing Battery Carrier Cushion No. 3
      G00950465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL WIRING HARNESS PROTECTOR COVER NO. 1 
    NOTE: Wear insulating gloves.
    Fig 8: Installing Wiring Harness Protector Cover No. 1
    G00950466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL WIRING HARNESS PROTECTOR COVER NO. 3 
    NOTE: Wear insulating gloves.
  34. INSTALL BATTERY COVER SUB-ASSY (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  35. INSTALL HV BATTERY ASSY (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  36. INSTALL FRAME WIRE (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
    NOTE: Wear insulating gloves.
  37. INSTALL JUNCTION TERMINAL (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
    NOTE: Wear insulating gloves.
  38. INSTALL BATTERY CARRIER PANEL NO. 6 (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  39. INSTALL QUARTER VENT DUCT (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
    NOTE: Wear insulating gloves.
  40. INSTALL BATTERY BRACKET REINFORCEMENT (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  41. INSTALL QUARTER VENT DUCT INNER NO. 2 (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  42. INSTALL BATTERY CARRIER BRACKET (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  43. INSTALL DECK TRIM SIDE PANEL ASSY RH 
  44. INSTALL DECK TRIM SIDE PANEL ASSY LH 
  45. INSTALL DECK FLOOR BOX LH 
  46. INSTALL REAR FLOOR BOARD NO. 4 
  47. INSTALL REAR SIDE SEAT BACK FRAME RH 
  48. INSTALL REAR SIDE SEAT BACK FRAME LH 
  49. INSTALL REAR FLOOR BOARD NO. 1 
  50. INSTALL REAR SEAT CUSHION ASSY 
  51. INSTALL TONNEAU COVER ASSY 
  52. INSTALL DECK TRIM COVER REAR 
  53. INSTALL SERVICE PLUG GRIP (See  SERVICE PLUG GRIP  ) 
    NOTE: Wear insulating gloves.
  54. CONNECT BATTERY NEGATIVE TERMINAL 

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

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