Battery Control System (Service Information): Removal & Installation Toyota Prius C I facelift

INSTALLATION [12/2013 - ]

1. INSTALL NO. 1 HYBRID BATTERY PACKING WARNING: Be sure to wear insulated gloves and protective goggles. Connect the 2 wire harnesses to the No. 1 hybrid battery packing. Install the No. 1 hybrid battery packing with the 2 clamps.
2. INSTALL UPPER HYBRID BATTERY COVER SUB-ASSEMBLY WARNING: Be sure to wear insulated gloves and protective goggles. Install the upper hybrid battery cover sub-assembly with the 5 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
3. INSTALL NO. 1 HYBRID BATTERY COVER INTAKE DUCT WARNING: Wear insulated gloves. Install the No. 1 hybrid battery cover intake duct with the clip. Install the HV battery thermistor to the No. 1 hybrid battery cover intake duct.
4. INSTALL HYBRID BATTERY JUNCTION BLOCK ASSEMBLY See step 1
5. INSTALL NO. 2 HYBRID BATTERY SHIELD SUB-ASSEMBLY WARNING: Wear insulated gloves. Install the No. 2 hybrid battery shield sub-assembly with the 2 bolts and nut. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
6. INSTALL BATTERY SMART UNIT See step 1
7. INSTALL NO. 2 HYBRID VEHICLE BATTERY CARRIER BRACKET SUB-ASSEMBLY See step 2
8. INSTALL NO. 1 HYBRID BATTERY SHIELD SUB-ASSEMBLY See step 3
9. INSTALL HYBRID BATTERY SERVICE PLUG COVER See step 4
10. INSTALL HV BATTERY WARNING: Wear insulated gloves. NOTE: When removing/installing/moving the HV battery, make sure not to tilt it more than 80°. Install the HV battery with the 2 bolts and 2 nuts. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) Install the 2 clips.
11. CONNECT FRAME WIRE See step 3
12. CONNECT WIRE HARNESS Connect the 2 connectors and 3 clamps.
13. INSTALL NO. 3 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY (w/ Smart Key System) . Refer to «INSTALLATION [12/2013 - ] - Step 1»(ref-651351-S04198198402014081900000)
14. INSTALL NO. 1 HYBRID VEHICLE BATTERY COVER PANEL LH See step 4
15. INSTALL BATTERY COOLING BLOWER ASSEMBLY NOTE: Be sure not to touch the fan part of the battery cooling blower assembly. Do not lift the battery cooling blower assembly using its wire harness. Install the battery cooling blower assembly with the 2 bolts and nut. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) Connect the battery cooling blower assembly connector and engage the clamp to the battery cooling blower assembly.
16. INSTALL NO. 1 HYBRID BATTERY EXHAUST DUCT Install the No. 1 hybrid battery exhaust duct with the clip.
17. INSTALL REAR SEAT CUSHION LEG SUB-ASSEMBLY See step 7
18. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to «INSTALLATION [12/2013 - ] - Step 2»(ref-651322-S10736280392014081900000)
19. INSTALL SERVICE PLUG GRIP Refer to «INSTALLATION [12/2013 - ]»(ref-651170-S24136932772014081900000)

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1. INSPECT AUXILIARY BATTERY VOLTAGE Measure the voltage between the terminals of the auxiliary battery. Standard voltage Approximately 11 V or more HINT: The horn should sound clearly. If the voltage is 10 V or less, either charge the auxiliary battery (charging usually takes about 1 hour), or replace it with an auxiliary battery that is already charged. Check the charge level of the HV battery. Check whether the HV battery warning message is shown in the multi-information display. Confirm if the engine starts. If the engine starts, leave it idling with park (P) selected until the engine stops (self charge has completed). If the engine cannot start, follow the procedure and charge the HV battery. HINT: Before performing external charging, always use the Techstream to perform troubleshooting. Charging time using the THS charger is 10 minutes per charge cycle. The charging time when using a THS charger is a short charging time (when the battery temperature is 25°C (77°F), 10 minutes may be sufficient, if the battery temperature is 0°C (32°F), then three 10 minute charge cycles may be required) for putting the engine in a condition where it can be started (the system can enter the READY-on state). (The THS charger will automatically stop 10 minutes after charging starts.)
2. PREPARATION FOR HV BATTERY CHARGING WARNING: Wear insulated gloves when working on the high voltage system. After removing the service plug grip, do not turn the ignition switch ON (READY) as this may cause a malfunction. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system. After removing the service plug grip, wait 10 minutes before touching any of the high voltage connectors or terminals. HINT: Removing the service plug grip interrupts the high voltage circuit. High voltage wiring connectors are orange. Remove the service plug grip. Refer to «REMOVAL [12/2013 - ]»(ref-651170-S34824767592014081900000) . Remove the inverter terminal cover See step 5 . Remove the inverter cover See step 6 . Check terminal voltage See step 7 . Remove the 4 bolts and disconnect the frame wire. NOTE: Insulate the disconnected terminals with insulating tape. Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter. Measure the resistance according to the value(s) in the table below. HINT: If the shield line of the frame wire is not securely connected to body ground, the THS charger will not operate. The "FAULT" and "CABLE CONNECTION" warning lights will illuminate on the THS charger. Standard Resistance Tester Connection Condition Specified Condition Frame wire connector housing - Body ground Always Below 1 ohms If the result is not as specified, inspect the connection shown in the illustration for proper installation. Refer to «REMOVAL [12/2013 - ]»(ref-651170-S03203770082014081900000) . Connect the THS charger in the order shown by the circled numbers in the illustration. TEXT IN ILLUSTRATION *1 EV Bonding Cable (Green Cable) *2 Low Voltage Cable *3 High Voltage Cable *4 HV Battery *5 Frame Wire *6 Inverter with Converter Assembly *7 EV Bonding Cable *8 Grounded AC 100 to 240 V Receptacle *9 THS Charger - - SST: 09880-10021 09881-10041 SST: 09881-10081 SST: 09882-10080 91553-80616 SST: 09883-00010 SST: 09882-10070 NOTE: Make sure to connect the EV bonding cable first to prevent electrical shock. Connect all THS charger cables in the order shown in the illustration to prevent electrical shock. Connect the EV bonding cable to the inverter with converter assembly. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Connect the EV bonding cable to the THS charger. Install the inverter cover to the inverter with converter assembly. NOTE: Do not allow any foreign matter or water to enter the inverter with converter assembly. Connect the low voltage cables to the positions shown in the illustration, and then tighten the 7 bolts. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) Install the inverter terminal cover See step 13 . Connect the disconnected frame wire to the high voltage cable with the 3 bolts as shown in the illustration. TEXT IN ILLUSTRATION *1 Interlock - - Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Slide the cover as shown in the illustration and install bolt A. NOTE: Make sure that the interlock is fully engaged. Tighten bolt A by hand (do not use any tools). Install the interlock cover over the location where the frame wire is connected. TEXT IN ILLUSTRATION *1 Interlock NOTE: Make sure that the interlock is fully engaged. Connect the low voltage cable and high voltage cable to the THS charger in the order shown by the circled numbers in the illustration. TEXT IN ILLUSTRATION *1 Low Voltage Cable *2 High Voltage Cable Install the service plug grip See step 1 . Connect the negative auxiliary battery terminal. Connect the power input plug of the charger to a grounded AC 100 to 240 V receptacle. NOTE: Always use an AC 100 to 240 V receptacle with a properly functioning ground. The ground is designed to reduce the chance of electric shock if a malfunction occurs. Do not use the charger if any of the pins on its plug have been damaged or removed.
3. HV BATTERY CHARGING Turn the ignition switch to ON (IG). Connect the Techstream to the DLC3. Enter the following menus: Powertrain / Hybrid Control / Active Test / Battery Charge. HINT: During the "Battery Charge" Active Test, check "System Main Relay Status - SMRB" and "System Main Relay Status - SMRG" in the Data List. If the Data List values are not as specified in the table below, turn the Techstream and the ignition switch off and then perform the Charge Battery procedure again. "SMRB" and "SMRG" in Data List during "Battery Charge" Active Test Step Active Test Battery Charge THS charger START switch Data List System Main Relay Status - SMRB Data List System Main Relay Status - SMRG 1 OFF OFF OFF OFF 2 OFF --> ON OFF OFF --> ON OFF --> ON 3 ON OFF --> ON ON ON Make sure that the EMERGENCY STOP switch is in the reset condition (the switch is turned clockwise and released). Make sure that the BREAKER is in the ON position. Turn the THS charger MAIN switch on. HINT: The MAIN indicator will illuminate green. Press the START switch. HINT: When the START switch is turned on, the INITIAL CHECK indicator illuminates and an initial check starts. When the initial check completes successfully, the INITIAL CHECK indicator turns off, the CHARGING indicator illuminates and charging will start at the same time. While the INITIAL CHECK indicator is illuminated, the insulation, 400 V output, emergency stop switch, connector connections and ground connection are inspected. Repeat the charge cycle 3 times. When the last cycle has finished, turn the THS charger MAIN switch off. HINT: Charging time using the THS charger is 10 minutes per charge cycle. The charging time when using a THS charger is a short charging time (when the battery temperature is 25°C (77°F), 10 minutes may be sufficient, if the battery temperature is 0°C (32°F), then three 10 minute charge cycles may be required) for putting the engine in a condition where it can be started (the system can enter the READY-on state). The THS charger will automatically stop 10 minutes after charging starts. There is very little chance of overcharging the HV battery during the second or third charging cycle. The SOC will not likely increase beyond the upper limit because it was low enough to prevent the engine from starting. Even if the SOC was to increase enough to exceed the limit, the hybrid vehicle control ECU will stop the Active Test to prevent overcharging. Cranking the engine once causes the SOC to drop approximately 1%. Charging the HV battery once (10 minutes) using the THS charger restores the SOC approximately 2%. Turn the ignition switch off. Remove the THS charger and install the frame wire. NOTE: Make sure to disconnect the EV bonding cable last. Disconnect the power inlet plug of the charger from the receptacle. Disconnect the negative terminal of the auxiliary battery. Remove the service plug grip See step 6 . Disconnect the high voltage cable and low voltage cable from the THS charger in the order shown by the circled numbers in the illustration. TEXT IN ILLUSTRATION *1 Low Voltage Cable *2 High Voltage Cable Remove the interlock cover from the inverter with converter assembly. Remove the bolt and slide the cover as shown in the illustration. Remove the 3 bolts and disconnect the high voltage cable from the frame wire. Remove the inverter terminal cover See step 5 . Remove the 7 bolts, low voltage cable and inverter cover. Disconnect the EV bonding cable from the THS charger. Remove the bolt and disconnect the EV bonding cable from the inverter with converter assembly. Temporarily install the frame wire (high voltage cables of the hybrid battery) and 4 bolts to the inverter assembly by hand. TEXT IN ILLUSTRATION *1 Interlock *2 High voltage cables of the hybrid battery *a Front view of frame wire connector NOTE: Make sure that the interlock is fully engaged. Fully tighten the 4 bolts. Bolt A Torque: 9.2 N*m (94 kgf*cm, 81 in.*lbf) Bolt B Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTE: Be sure to use a torque wrench to tighten the bolts. Install the inverter cover See step 12 . Install the inverter terminal cover See step 13 . Install the service plug grip. Refer to «INSTALLATION [12/2013 - ]»(ref-651170-S24136932772014081900000) . Check if the engine starts. HINT: If the engine does not start, perform the HV battery charging operation again. Return the vehicle to its original condition.
4. CHECK HV BATTERY AFTER HV BATTERY CHARGE Check for DTCs. Perform the self-charging operation. Start the engine and leave park (P) selected until the engine stops idling. HINT: When the engine stops idling, this indicates that self-charging is complete. Perform any initialization required after the negative terminal of the auxiliary battery is disconnected and reconnected.

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1. REMOVE INVERTER WITH CONVERTER ASSEMBLY Refer to «REMOVAL [12/2013 - ]»(ref-651170-S40052215992014081900000) .
2. REMOVE INVERTER BRACKET ASSEMBLY . Refer to «REMOVAL [12/2013 - ] - Step 20»(ref-651297-S11774150302014081900000)
3. REMOVE INVERTER WATER PUMP ASSEMBLY Disconnect the 2 water hoses. NOTE: Put pieces of cloth into the pipes and in the disconnected hoses to prevent foreign matter from entering the inverter water pump and cooling system. Disconnect the connector. NOTE: Apply insulating tape to the connectors of the wire harness and inverter water pump assembly with motor to prevent the entry of coolant. Remove the 3 bolts and the inverter water pump assembly.
4. REMOVE HV WATER PUMP BRACKET SUB-ASSEMBLY Disconnect the clamp. Remove the 2 bolts and the HV water pump bracket sub-assembly.

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1. INSTALL HV WATER PUMP BRACKET SUB-ASSEMBLY Install the HV water pump bracket sub-assembly with the 2 bolts. Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf) Connect the clamp.
2. INSTALL INVERTER WATER PUMP ASSEMBLY Install the inverter water pump assembly with the 3 bolts. Torque: 6.1 N*m (62 kgf*cm, 54 in.*lbf) NOTE: Do not hold the inverter water pump assembly by the connector terminals when removing or installing it. Connect the connector. Connect the 2 water hoses. TEXT IN ILLUSTRATION *1 Clamp A *2 Clamp B *a Alignment mark (White) *b Alignment Mark (Yellow) *c Rib *d 90° *e 45° NOTE: Connect the water hoses securely up to the rib of the inverter water pump assembly. Make sure to align the alignment marks of the hoses with the ribs of the inverter water pump assembly. Do not remove the pieces of cloth from the pipes and disconnected hoses until installation to prevent foreign matter from entering the inverter water pump and cooling system. Make sure that the clamp A is positioned as shown in the illustration. HINT: Clamp B can be oriented in any angle.
3. INSTALL INVERTER BRACKET ASSEMBLY . Refer to «INSTALLATION [12/2013 - ] - Step 27»(ref-651297-S38431067242014081900000)
4. INSTALL INVERTER WITH CONVERTER ASSEMBLY Refer to «INSTALLATION [12/2013 - ]»(ref-651170-S07777432982014081900000) .

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REMOVAL [12/2013 - ]

1. REMOVE RADIATOR ASSEMBLY (for Inverter Coolant) HINT: The radiator assembly (for inverter coolant) is part of the radiator assembly. If the radiator assembly (for inverter coolant) needs to be replaced, replace the radiator assembly. Refer to «REMOVAL [12/2013 - ]»(ref-651299-S13149756572014081900000) .

1. INSTALL RADIATOR ASSEMBLY (for Inverter Coolant) HINT: The radiator assembly (for inverter coolant) is part of the radiator assembly. If the radiator assembly (for inverter coolant) needs to be replaced, replace the radiator assembly. Refer to «INSTALLATION [12/2013 - ]»(ref-651299-S14236349582014081900000) .

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1. PRECAUTION Refer to «PRECAUTION [12/2013 - ]»(ref-651169-S11524377852014081900000)
2. REMOVE INVERTER WITH CONVERTER ASSEMBLY Refer to «REMOVAL [12/2013 - ]»(ref-651170-S40052215992014081900000) .
3. REMOVE INVERTER BRACKET ASSEMBLY . Refer to «REMOVAL [12/2013 - ] - Step 20»(ref-651297-S11774150302014081900000)
4. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Refer to «REMOVAL [12/2013 - ]»(ref-651352-S13457290802014081900000)
5. REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to «REMOVAL [12/2013 - ] - Step 8»(ref-651322-S19561940502014081900000)
6. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY See step 4
7. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT See step 10
8. REMOVE BATTERY COOLING BLOWER ASSEMBLY See step 12
9. REMOVE NO. 1 HYBRID VEHICLE BATTERY COVER PANEL LH See step 12
10. DISCONNECT CABLE FROM POSITIVE AUXILIARY BATTERY TERMINAL Remove the connector cover. Remove the nut and disconnect the positive auxiliary battery terminal.
11. REMOVE FRAME WIRE WARNING: Wear insulated gloves. NOTE: Insulate the disconnected terminals with insulating tape. Disconnect the connector. Disconnect the 2 connectors. TEXT IN ILLUSTRATION *1 Shielded Wire Ground Disconnect the shielded wire ground. Disconnect the 6 clamps. Disengage the claw and disconnect the frame wire from the engine room junction block assembly. Disconnect the clamp. Disconnect the clamp. Disconnect the clamp. Disconnect the clamp. Remove the 3 nuts. Disconnect the 4 clamps and remove the frame wire. NOTE: The clamps are non-reusable parts.

1. INSTALL FRAME WIRE WARNING: Wear insulated gloves. NOTE: Insulate the removed terminals with insulating tape. Install a frame wire with the 4 new clamps as shown in the illustration. Insert the frame wire into the floor panel hole. Install the 3 nuts as shown in the illustration. Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf) Connect the clamp as shown in the illustration. Connect the clamp as shown in the illustration. Connect the clamp as shown in the illustration. Connect the clamp as shown in the illustration. Connect the frame wire with the claw as shown in the illustration. Connect the 6 clamps as shown in the illustration. Connect the 2 connectors to the engine room junction block assembly as shown in the illustration. NOTE: Make sure that the ends of the frame wire are not crossed over each other. Be sure to connect the ends of the frame wire to the connect terminals. TEXT IN ILLUSTRATION *1 Shielded Wire Ground Connect the shielded wire ground as shown in the illustration. Connect the connector.
2. CONNECT CABLE TO POSITIVE AUXILIARY BATTERY TERMINAL Connect the positive auxiliary battery terminal with the nut. Torque: 7.6 N*m (77 kgf*cm, 67 in.*lbf) Install the terminal cover.
3. INSTALL NO. 1 HYBRID BATTERY EXHAUST DUCT See step 6
4. INSTALL NO. 1 HYBRID VEHICLE BATTERY COVER PANEL LH See step 4
5. INSTALL BATTERY COOLING BLOWER ASSEMBLY See step 15
6. INSTALL REAR SEAT CUSHION LEG SUB-ASSEMBLY See step 7
7. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to «INSTALLATION [12/2013 - ] - Step 2»(ref-651322-S10736280392014081900000)
8. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Refer to «INSTALLATION [12/2013 - ]»(ref-651352-S19402898212014081900000)
9. INSTALL INVERTER BRACKET ASSEMBLY . Refer to «INSTALLATION [12/2013 - ] - Step 27»(ref-651297-S38431067242014081900000)
10. INSTALL INVERTER WITH CONVERTER ASSEMBLY Refer to «INSTALLATION [12/2013 - ]»(ref-651170-S07777432982014081900000) .

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1. INSTALL ACCELERATOR PEDAL SENSOR ASSEMBLY NOTE: Avoid physical shock to the accelerator pedal sensor assembly. Do not disassemble the accelerator pedal sensor assembly. This accelerator pedal sensor assembly does not require lubrication. Do not apply oil or other lubrication to the accelerator pedal sensor assembly. If applied, the accelerator pedal sensor assembly must be replaced. Install the accelerator pedal sensor assembly with the 2 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Connect the accelerator pedal sensor assembly connector.

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1. INSPECT IGCT RELAY Inspect IGCT MAIN relay Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 3 - 5 No auxiliary battery voltage is applied across terminals 1 and 2 10 kohms or higher 3 - 5 Auxiliary battery voltage is applied across terminals 1 and 2 Below 1 ohms If the result is not as specified, replace the relay.

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1. PRECAUTION Refer to «PRECAUTION [12/2013 - ]»(ref-651169-S11524377852014081900000)
2. REMOVE SERVICE PLUG GRIP Refer to «REMOVAL [12/2013 - ]»(ref-651170-S34824767592014081900000)
3. REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to «REMOVAL [12/2013 - ] - Step 8»(ref-651322-S19561940502014081900000)
4. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY See step 4
5. REMOVE INVERTER TERMINAL COVER See step 5
6. REMOVE INVERTER COVER See step 6
7. CHECK TERMINAL VOLTAGE See step 7
8. INSTALL INVERTER COVER See step 11
9. INSTALL INVERTER TERMINAL COVER See step 13
10. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT See step 10
11. REMOVE NO. 3 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY (w/ Smart Key System) . Refer to «REMOVAL [12/2013 - ] - Step 2»(ref-651351-S03744281642014081900000)
12. REMOVE NO. 1 HYBRID VEHICLE BATTERY COVER PANEL LH WARNING: Wear insulated gloves. Using the service plug grip, remove the battery cover lock striker. TEXT IN ILLUSTRATION *1 Service Plug Grip *2 Battery Cover Lock Striker *3 Button *a Projection *b Turn HINT: Insert the projection part of the service plug grip, and turn the button of the battery cover lock striker counterclockwise, and release the lock. Remove the 4 nuts and No. 1 hybrid vehicle battery cover panel LH.
13. DISCONNECT FRAME WIRE WARNING: Wear insulated gloves. NOTE: Insulate the disconnected connectors with insulating tape. Disconnect the 2 connectors shown in the illustration. TEXT IN ILLUSTRATION *1 Shielded Wire Ground Disconnect the shielded wire ground and frame wire.
14. REMOVE NO. 2 HYBRID BATTERY SHIELD SUB-ASSEMBLY WARNING: Wear insulated gloves. Disconnect the connector. Disconnect the connector and clamp. Disconnect the 2 connectors and 3 clamps. Remove the 2 bolts and 2 nuts. Move the HV battery toward the front of the vehicle. TEXT IN ILLUSTRATION *a Front of Vehicle HINT: Move the HV battery to a position where both the No. 2 hybrid battery shield sub-assembly and the hybrid battery junction block assembly can be removed. Remove the 2 bolts, nut and No. 2 hybrid battery shield sub-assembly.
15. REMOVE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY WARNING: Wear insulated gloves. NOTE: Insulate the disconnected terminals with insulating tape. Open the terminal cover. Using an insulated tool, remove the 2 bolts. Disconnect the connector. Remove the 3 bolts and hybrid battery junction block assembly.

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1. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Inspect SMRB. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition P5-1 (CBI) - A-1 (+) Auxiliary battery voltage is not applied between terminals M40- 1 (SMRB) and M40-2 (GND) 10 kohms or higher P5-1 (CBI) - A-1 (+) Auxiliary battery voltage is applied between terminals M40- 1 (SMRB) and M40-2 (GND) Below 1 ohms TEXT IN ILLUSTRATION *a Component without harness connected (Hybrid Battery Junction Block Assembly) Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition M40-1 (SMRB) - M40-2 (GND) -40 to 80°C (-40 to 176°F) 25.0 to 59.0 ohms If the result is not as specified, replace the hybrid battery junction block assembly or electric vehicle fuse. Inspect SMRG. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition c1-1 (-) - P4-1 (CEI) Auxiliary battery voltage is not applied between terminals M40- 3 (SMRG) and M40-2 (GND) 10 kohms or higher c1-1 (-) - P4-1 (CEI) Auxiliary battery voltage is applied between terminals M40- 3 (SMRG) and M40-2 (GND) Below 1 ohms TEXT IN ILLUSTRATION *a Component without harness connected (Hybrid Battery Junction Block Assembly) Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition M40-3 (SMRG) - M40-2 (GND) -40 to 80°C (-40 to 176°F) 25.0 to 59.0 ohms If the result is not as specified, replace the hybrid battery junction block assembly. Inspect SMRP. Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition P4-1 (CEI) - c1-1 (-) Auxiliary battery voltage is not applied between terminals M40- 4 (SMRP) and M40-2 (GND) 10 kohms or higher P4-1 (CEI) - c1-1 (-) Auxiliary battery voltage is applied between terminals M40- 4 (SMRP) and M40-2 (GND) 28.5 to 31.5 ohms TEXT IN ILLUSTRATION *a Component without harness connected (Hybrid Battery Junction Block Assembly) Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition M40-4 (SMRP) - M40-2 (GND) -40 to 80°C (-40 to 176°F) 112 to 274 ohms If the result is not as specified, replace the hybrid battery junction block assembly.

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1. INSTALL HYBRID BATTERY JUNCTION BLOCK ASSEMBLY WARNING: Wear insulated gloves. Install the hybrid battery junction block assembly with the 3 bolts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) Connect the connector to the hybrid battery junction block assembly. NOTE: The connector should be connected securely. Using an insulated tool, install the 2 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) NOTE: Be sure to use a torque wrench to tighten the bolts. Connect the terminal cover. NOTE: The terminal cover should be connected securely.
2. INSTALL NO. 2 HYBRID BATTERY SHIELD SUB-ASSEMBLY WARNING: Wear insulated gloves. Install the No. 2 hybrid battery shield sub-assembly with the 2 bolts and nut. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) Move the HV battery to the installation position. Install the HV battery with the 2 bolts and 2 nuts. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) Connect the 4 connectors and 4 clamps. NOTE: The connector should be connected securely.
3. CONNECT FRAME WIRE WARNING: Wear insulated gloves. Connect the 2 connectors. TEXT IN ILLUSTRATION *1 Shielded Wire Ground NOTE: Make sure that the ends of the frame wire do not cross over each other. The connector should be connected securely. Connect the shielded wire ground.
4. INSTALL NO. 1 HYBRID VEHICLE BATTERY COVER PANEL LH WARNING: Wear insulated gloves. Install the No. 1 hybrid vehicle battery cover panel LH with the 4 nuts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) Install the battery cover lock striker, then push the button to lock it. TEXT IN ILLUSTRATION *1 Battery Cover Lock Striker *2 Button *a Push
5. INSTALL NO. 3 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY . Refer to «INSTALLATION [12/2013 - ] - Step 1»(ref-651351-S04198198402014081900000)
6. INSTALL NO. 1 HYBRID BATTERY EXHAUST DUCT See step 6
7. INSTALL REAR SEAT CUSHION LEG SUB-ASSEMBLY See step 7
8. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to «INSTALLATION [12/2013 - ] - Step 2»(ref-651322-S10736280392014081900000)
9. INSTALL SERVICE PLUG GRIP Refer to «INSTALLATION [12/2013 - ]»(ref-651170-S24136932772014081900000)

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1. REMOVE REAR CONSOLE BOX COVER . Refer to «REMOVAL [12/2013 - ] - Step 1»(ref-651353-S19959032382014081900000)
2. REMOVE EV DRIVE MODE SWITCH (PATTERN SELECT SWITCH ASSEMBLY) Disengage the 2 claws and remove the EV drive mode switch (pattern select switch assembly).

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1. INSPECT EV DRIVE MODE SWITCH (PATTERN SELECT SWITCH ASSEMBLY) Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition G63-4 (S) - G63-1 (E) EV drive mode switch (pattern select switch assembly) being pushed and held Below 1 ohms G63-4 (S) - G63-1 (E) EV drive mode switch (pattern select switch assembly) not pushed 10 kohms or higher TEXT IN ILLUSTRATION *a Component without harness connected (EV Drive Mode Switch (Pattern Select Switch Assembly)) If the result is not as specified, replace the EV drive mode switch (pattern select switch assembly). Apply auxiliary battery voltage between the terminals of the switch, and check the illumination condition of the pattern select switch assembly. Standard Resistance Measurement Condition Specified Condition Auxiliary battery positive (+) --> G63-3 (ILL+) Auxiliary battery negative (-) -->G63-2 (ILL-) Illuminates TEXT IN ILLUSTRATION *a Component without harness connected (EV Drive Mode Switch (Pattern Select Switch Assembly)) If the result is not as specified, replace the EV drive mode switch (pattern select switch assembly).

1. INSTALL EV DRIVE MODE SWITCH (PATTERN SELECT SWITCH ASSEMBLY) Engage the 2 claws to install the EV drive mode switch (pattern select switch assembly).
2. INSTALL REAR CONSOLE BOX COVER . Refer to «INSTALLATION [12/2013 - ] - Step 7»(ref-651353-S27743388512014081900000)

Scheme 131

Scheme 132

1. PRECAUTION WARNING: Before inspecting the high voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high voltage system. After removing the service plug grip, wait for at least 10 minutes before touching any of the high voltage connectors or terminals. After waiting for 10 minutes, check the voltage at the terminals in the inspection point in the inverter with converter assembly. The voltage should be 0 V before beginning work. Refer to «PRECAUTION [12/2013 - ]»(ref-651169-S11524377852014081900000) . NOTE: After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work. Refer to «PRECAUTION [12/2013 - ]»(ref-651169-S11524377852014081900000) . HINT: Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.
2. REMOVE FRONT FLOOR COVER RH . Refer to «REMOVAL [12/2013 - ] - Step 3»(ref-651322-S19561940502014081900000)
3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION [12/2013 - ]»(ref-651169-S40634195862014081900000) .
4. REMOVE FRONT FLOOR COVER LH . Refer to «REMOVAL [12/2013 - ] - Step 4»(ref-651322-S19561940502014081900000)
5. REMOVE FRONT CENTER FLOOR COVER . Refer to «REMOVAL [12/2013 - ] - Step 5»(ref-651322-S19561940502014081900000)
6. REMOVE SERVICE PLUG GRIP WARNING: Wear insulating gloves. Remove the service plug grip to interrupt the high voltage circuit at the time of inspection or repair. Keep the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle. All the high voltage wiring connectors are orange. Wear insulating gloves and remove the service plug grip after sliding up the lever of the service plug grip as shown in the illustration. WARNING: Keep the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle. After removing the service plug grip, do not touch the high voltage connectors or terminals for 10 minutes. HINT: Waiting for at least 10 minutes is required to discharge the high voltage capacitor inside the inverter with converter assembly.

Scheme 133

1. INSPECT SERVICE PLUG GRIP Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition Service plug grip Always Below 1 ohms If the result is not as specified, replace the service plug grip.

Scheme 134

1. INSTALL SERVICE PLUG GRIP WARNING: Wear insulating gloves. NOTE: Before connecting the service plug, check that no parts and tools remain and that the high voltage terminals and connectors are connected securely. Wear insulated gloves and install the service plug grip in the order shown in the illustration. Rotate the handle of the service plug grip 90° toward the battery and slide it in the direction shown by the arrow until a click sound is heard.
2. INSTALL FRONT CENTER FLOOR COVER . Refer to «INSTALLATION [12/2013 - ] - Step 5»(ref-651322-S10736280392014081900000)
3. INSTALL FRONT FLOOR COVER LH . Refer to «INSTALLATION [12/2013 - ] - Step 6»(ref-651322-S10736280392014081900000)
4. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION [12/2013 - ]»(ref-651169-S40634195862014081900000) .
5. INSTALL FRONT FLOOR COVER RH . Refer to «INSTALLATION [12/2013 - ] - Step 7»(ref-651322-S10736280392014081900000)

Scheme 135

Scheme 136

Scheme 137

1. REMOVE FRONT FLOOR COVER RH . Refer to «REMOVAL [12/2013 - ] - Step 3»(ref-651322-S19561940502014081900000)
2. REMOVE FRONT FLOOR COVER LH . Refer to «REMOVAL [12/2013 - ] - Step 4»(ref-651322-S19561940502014081900000)
3. REMOVE FRONT CENTER FLOOR COVER . Refer to «REMOVAL [12/2013 - ] - Step 5»(ref-651322-S19561940502014081900000)
4. REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to «REMOVAL [12/2013 - ] - Step 8»(ref-651322-S19561940502014081900000)
5. REMOVE BATTERY COOLING BLOWER ASSEMBLY NOTE: Be sure not to touch the fan part of the battery cooling blower assembly. Do not lift the battery cooling blower assembly using the wire harness. Disconnect the connector and clamp from the battery cooling blower assembly. Remove the nut, 2 bolts and battery cooling blower assembly.

Scheme 138

Scheme 139

1. INSPECT BATTERY COOLING BLOWER ASSEMBLY Inspect the filter. TEXT IN ILLUSTRATION *a Filter Standard No clogs or damage. NOTE: If the filter is damaged, replace the battery cooling blower assembly. Clean the filter. Remove the battery cooling blower assembly and clean the filter by hand with the filter facing down. NOTE: Do not use water or any other liquids when cleaning the filter. Clean the filter by hand. To prevent damage to the filter, do not use a wire brush or scrubber. Do not hold the battery cooling blower assembly by the wire harness or fan while cleaning the filter. Do not allow any foreign matter to enter the battery cooling blower assembly.

1. INSTALL BATTERY COOLING BLOWER ASSEMBLY Install the battery cooling blower assembly with the nut and 2 bolts. Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) NOTE: Be sure not to touch the fan part of the battery cooling blower assembly. Do not lift the battery cooling blower assembly using the wire harness. Connect the clamp and connector.
2. INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to «INSTALLATION [12/2013 - ] - Step 2»(ref-651322-S10736280392014081900000)
3. INSTALL FRONT CENTER FLOOR COVER . Refer to «INSTALLATION [12/2013 - ] - Step 5»(ref-651322-S10736280392014081900000)
4. INSTALL FRONT FLOOR COVER LH . Refer to «INSTALLATION [12/2013 - ] - Step 6»(ref-651322-S10736280392014081900000)
5. INSTALL FRONT FLOOR COVER RH . Refer to «INSTALLATION [12/2013 - ] - Step 7»(ref-651322-S10736280392014081900000)