Hybrid Battery Bus / Cable: Service and Repair
REMOVAL1. OBSERVE PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE SERVICE PLUG GRIP
4. REMOVE DECK BOARD SUB-ASSEMBLY
5. REMOVE DECK FLOOR BOX REAR
6. REMOVE REAR FLOOR FINISH PLATE
7. REMOVE DECK FLOOR BOX FRONT
8. REMOVE DECK BOARD SUB-ASSEMBLY NO.2
9. REMOVE DECK BOARD SUB-ASSEMBLY NO.3
10. REMOVE DECK SIDE TRIM BOX RH
11. REMOVE DECK SIDE TRIM BOX LH
12. REMOVE DECK BOARD CHECK NO.1
13. REMOVE POWER STEERING CONVERTER COVER
14. SEPARATE POWER STEERING CONVERTER ASSEMBLY
a. Remove the nut, and disconnect the No.3 wire frame from the power steering converter assembly.
b. Remove the 4 connectors and clamp, and disconnect the No.3 wire frame from the power steering converter assembly.
15. REMOVE REAR SEAT TRACK BRACKET C0VERINNERR
16. REMOVE REAR SEAT ASSEMBLY LH
17. REMOVE REAR SEAT TRACK BRACKET C0VERINNERR
18. REMOVE REAR SEAT ASSEMBLY RH
19. REMOVE AIR INTAKE COVER
20. REMOVE AIR INTAKE COVER CENTER
21. SEPARATE FLOOR CARPET ASSEMBLY FRONT
22. REMOVE HYBRID VEHICLE BATTERY SERVICE HOLE COVER
23. DISCONNECT HYBRID VEHICLE RELAY ASSEMBLY
CAUTION: Wear insulating gloves.
NOTE: Insulate the removed terminals with insulating tape.
a. Remove the bolt, then disconnect the frame wire No.3.
b. Disconnect the No.3 wire frame connector to the hybrid vehicle relay assembly.
c. Remove the 2 nuts, and disconnect the hybrid vehicle relay assembly.
24. REMOVE ENGINE ROOM SIDE LH COVER
25. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH
26. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH
27. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
28. REMOVE WINDSHIELD WIPER LINK ASSEMBLY
29. REMOVE COWL TOP PANEL SUB-ASSEMBLY OUTER
30. REMOVE COOL AIR INTAKE DUCT SEAL
31. REMOVE AIR CLEANER CAP W/INLET
32. REMOVE AIR CLEANER W/RESONATOR
33. REMOVE INVERTER BRACKET NO.5
34. REMOVE POWER STEERING ECU ASSEMBLY
35. REMOVE INVERTER RESERVE TANK SUB-ASSEMBLY
a. Remove the 2 bolts and inverter reserve tank sub-assembly.
36. REMOVE POWER STEERING ECU BRACKET
37. REMOVE INVERTER COVER
38. DISCONNECT W/ CONVERTER INVERTER ASSEMBLY
CAUTION: Wear insulating gloves.
NOTE:
- Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly.
- Insulate the removed terminals with insulating tape.
- Do not allow any foreign objects or water drops to enter the w/ converter inverter assembly.
a. Remove the 5 bolts, and disconnect the No.3 wire frame (high voltage cable of the rear motor) to thew/ converter inverter assembly. (for 4WD)
b. Remove the bolt and lift the lever to disconnect the No.3 wire frame from the w/ converter inverter assembly.
39. INSTALL INVERTER COVER
40. DISCONNECT REAR TRACTION W/ TRANSAXLE MOTOR ASSEMBLY (for 4WD)
CAUTION: Wear insulating gloves.
NOTE: Insulate the removed terminals with insulating tape.
a. Disconnect the 2 connectors and clamp from the rear traction w/ transaxle motor assembly.
b. Remove the 2 nuts, and disconnect the No.3 wire frame from the rear traction w/ transaxle motor assembly.
41. REMOVE WIRING HARNESS PROTECTOR
a. Remove the 4 nuts and wiring harness protector.
42. REMOVE NO.3 WIRE FRAME (for 2WD)
a. Remove the No.3 wire frame.
CAUTION: Wear insulating gloves.
NOTE: Insulate the removed terminals with insulating tape.
1. Disconnect the 2 connectors and clamp as shown in the illustration. (A)
2. Disconnect the 2 clamps as shown in the illustration. (B)
3. Disconnect the clamp as shown in the illustration. (C)
4. Disconnect the clamp as shown in the illustration. (D)
5. Remove the 2 nuts and bolt shown in the illustration and remove the No.3 wire frame. (E)
6. Disconnect the 3 clamps as shown in the illustration. (F)
7. Disconnect the clamp shown in the illustration and remove the No.3 wire frame. (G)
8. Remove the 5 nuts and No.3 wire frame. (H)
43. REMOVE NO.3 WIRE FRAME (for 4WD)
a. Remove the No.3 wire frame.
CAUTION: Wear insulating gloves.
NOTE: Insulate the removed terminals with insulating tape.
1. Disconnect the 2 connectors and clamp as shown in the illustration. (A)
2. Disconnect the clamps as shown in the illustration. (B)
3. Disconnect the clamp as shown in the illustration. (C)
4. Disconnect the clamp as shown in the illustration. (D)
5. Remove the 2 nuts and bolt shown in the illustration and remove the No.3 wire frame. (E)
6. Disconnect the 3 clamps as shown in the illustration. (F)
7. Disconnect the clamp shown in the illustration and remove the No.3 wire frame. (G)
8. Remove the 6 nuts and No.3 wire frame. (H)
INSTALLATION
1. INSTALL NO.3 WIRE FRAME (for 2WD)
a. Install the No.3 wire frame.
CAUTION: Wear insulating gloves.
1. Install the No.3 wire frame with the 5 nuts. (H)
Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf)
2. Pass the No.3 wire frame into the cabin and connect the clamp shown in the illustration. (G)
3. Connect the 3 clamps as shown in the illustration. (F)
4. Pass the No.3 wire frame into the cabin and install the 2 nuts and bolt shown in the illustration. (E)
Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf)
5. Connect the clamp as shown in the illustration.(D)
6. Connect the clamp as shown in the illustration.(C)
7. Connect the 2 clamps as shown in the illustration. (B)
8. Connect the 2 connectors and clamp as shown in the illustration. (A)
2. INSTALL NO.3 WIRE FRAME (for 4WD)
a. Install the No.3 wire frame.
CAUTION: Wear insulating gloves.
1. Install the No.3 wire frame with the 6 nuts. (H)
Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf)
2. Pass the No.3 wire frame into the cabin and connect the clamp shown in the illustration. (G)
3. Connect the 3 clamps as shown in the illustration. (F)
4. Pass the No.3 wire frame into the cabin and install the 2 nuts and bolt shown in the illustration. (E)
Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf)
5. Connect the clamp as shown in the illustration.(D)
6. Connect the clamp as shown in the illustration.(C)
7. Connect the 2 clamps as shown in the illustration. (B)
8. Connect the 2 connectors and clamp as shown in the illustration. (A)
3. INSTALL WIRING HARNESS PROTECTOR
a. Install the wiring harness protector with the 4 nuts.
Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf)
4. INSTALL REAR TRACTION W/ TRANSAXLE MOTOR ASSEMBLY (for 4WD)
CAUTION: Wear insulating gloves.
a. Connect the No.3 wire frame with the 2 nuts to the rear traction w/ transaxle motor assembly.
Torque: 15 N.m (153 kgf.cm, 11 ft.lbf)
b. Connect the 2 connectors and clamp to the rear traction w/ transaxle motor assembly.
5. CHECK HIGH VOLTAGE CABLE CONNECTION
6. REMOVE INVERTER COVER
7. CONNECT W/ CONVERTER INVERTER ASSEMBLY
CAUTION: Wear insulating gloves.
NOTE:
- Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly.
- Do not allow any foreign objects or water drops to enter the w/ converter inverter assembly.
a. After connecting the cable, press the lever down to connect the No.3 wire frame with the bolt to the w/converter inverter assembly.
Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
b. Connect the No.3 wire frame (high voltage cable of the rear motor) with the 5 bolts to the w/ converter inverter assembly. (for 4WD)
Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
8. CHECK HIGH VOLTAGE CABLE CONNECTION
9. INSTALL INVERTER COVER
10. INSTALL POWER STEERING ECU BRACKET
11. CONNECT INVERTER RESERVE TANK SUB-ASSEMBLY
a. Connect the inverter reserve tank with the 2 bolts to the w/ converter inverter assembly.
Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
12. INSTALL POWER STEERING ECU ASSEMBLY
13. INSTALL INVERTER BRACKET NO.5
14. INSTALL AIR CLEANER W/RESONATOR
15. INSTALL AIR CLEANER CAP W/INLET
16. INSTALL COOL AIR INTAKE DUCT SEAL
17. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER
18. INSTALL WINDSHIELD WIPER LINK ASSEMBLY
19. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
20. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH
21. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH
22. INSTALL ENGINE ROOM SIDE LH COVER
23. CONNECT HYBRID VEHICLE RELAY ASSEMBLY
CAUTION: Wear insulating gloves.
a. Connect the No.3 wire frame with the 2 nuts to the hybrid vehicle relay assembly.
Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
b. Connect the No.3 wire frame connector to the hybrid vehicle relay assembly.
c. Install the No.3 wire frame with the bolt.
Torque: 8.0 N.m (82 kgf.cm, 80 in.lbf)
24. CHECK HIGH VOLTAGE CABLE CONNECTION
25. INSTALL HYBRID VEHICLE BATTERY SERVICE HOLE COVER
26. INSTALL FLOOR CARPET ASSEMBLY FRONT
27. INSTALL AIR INTAKE COVER CENTER
28. INSTALL AIR INTAKE COVER
29. INSTALL REAR SEAT ASSEMBLY LH
30. INSTALL REAR SEAT TRACK BRACKET COVER
31. INSTALL REAR SEAT ASSEMBLY RH
32. INSTALL REAR SEAT TRACK BRACKET COVER
33. INSPECT SLIDE ADJUSTER LOCK SIMULTANEOUSLY
34. CONNECT POWER STEERING CONVERTER ASSEMBLY
a. Connect the 4 connectors and clamp to the power steering converter assembly.
b. Connect the No.3 wire frame with the nut to the power steering converter assembly.
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
35. CHECK HIGH VOLTAGE CABLE CONNECTION
36. INSTALL POWER STEERING CONVERTER COVER
37. INSTALL DECK BOARD CHECK NO.1
39. INSTALL DECK SIDE TRIM BOX LH
40. INSTALL DECK BOARD SUB-ASSEMBLY NO.2
41. INSTALL DECK BOARD SUB-ASSEMBLY NO.3
42. INSTALL DECK FLOOR BOX FRONT
43. INSTALL REAR FLOOR FINISH PLATE
44. INSTALL DECK FLOOR BOX REAR
45. INSTALL DECK BOARD SUB-ASSEMBLY
46. INSTALL SERVICE PLUG GRIP
47. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
48. PERFORM INITIALIZATION
Some systems need initialization when reconnecting the battery cable.