Installation
HYBRID / BATTERY CONTROL: HV RELAY ASSEMBLY: INSTALLATION
1. INSTALL ELECTRIC VEHICLE FUSE
HINT
Perform this procedure only when replacement of the electric vehicle fuse is necessary.
(a) Install the electric vehicle fuse with the 2 bolts.
Torque : 2.1 Nm (21 kgf-cm, 19 in-lbf)
(b) Connect the clamp to the hybrid battery junction block assembly.
2. INSTALL NO. 4 HYBRID VEHICLE BATTERY PACK WIRE
HINT
Perform this procedure only when replacement of the No. 4 hybrid battery pack wire is necessary.
(a) Install the No. 4 hybrid vehicle battery pack wire with the 3 clamps and 2 connectors to the hybrid battery junction block assembly.
3. INSTALL HYBRID BATTERY JUNCTION BLOCK ASSEMBLY
CAUTION:
Be sure to wear insulated gloves and protective goggles.
(a) Install the hybrid battery junction block assembly with the 3 nuts.
Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)
(b) Connect the 2 connectors to the hybrid battery junction block.
NOTICE:
Make sure that the connectors are connected securely.
(c) Connect the 3 connectors to the hybrid battery junction block.
NOTICE:
Make sure that the connectors are connected securely.
(d) Connect the 10 clamps.
4. CONNECT FRAME WIRE
CAUTION:
Wear insulated gloves.
(a) Connect the shielded wire ground.
(b) Using an insulated tool, connect the frame wire with the 2 nuts.
Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)
5. CONNECT ELECTRIC VEHICLE CHARGER WIRE
CAUTION:
Wear insulated gloves.
(a) Connect the shielded wire ground with the nut.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(b) Connect the connector.
NOTICE:
Make sure that the connector is connected securely.
6. INSTALL UPPER HYBRID BATTERY COVER SUB-ASSEMBLY
CAUTION:
Be sure to wear insulated gloves and protective goggles.
(a) Install the upper hybrid battery cover sub-assembly with the 2 bolts and 4 nuts.
Bolt - Torque : 22 Nm (227 kgf-cm, 16 ft-lbf)
Nut - Torque : 22 Nm (221 kgf-cm, 16 ft-lbf)
7. INSTALL NO. 1 HYBRID VEHICLE BATTERY COVER PANEL LH
CAUTION:
Wear insulated gloves.
(a) Install the No. 1 hybrid vehicle battery cover panel LH with the 6 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
8. INSTALL NO. 1 HYBRID VEHICLE BATTERY COVER PANEL RH
CAUTION:
Wear insulated gloves.
(a) Install the No. 1 hybrid vehicle battery cover panel RH with the 6 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the 4 clamps.
9. INSTALL NO. 1 HYBRID VEHICLE BATTERY SHIELD PANEL
CAUTION:
Wear insulated gloves.
(a) Install the No. 1 hybrid vehicle battery shield panel with the 7 nuts.
Torque : 10 Nm (103 kgf-cm, 7 ft-lbf)
(b) Connect the connector and clamp.
(c) Install the electrical key oscillator with the 2 claws and 3 clamp.
10. INSTALL NO. 2 HYBRID VEHICLE BATTERY SHIELD PANEL
CAUTION:
Wear insulated gloves.
(a) Install the No. 2 hybrid vehicle battery shield panel with the 3 nuts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(b) Install the battery cover lock striker, then push the button to lock it.
Text in Illustration
11. INSTALL REAR NO. 1 HYBRID BATTERY SHIELD
CAUTION:
Wear insulated gloves.
(a) Install the rear No. 1 hybrid battery shield with the 9 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Install the battery cover lock striker, then push the button to lock it.
Text in Illustration
(c) Connect the clamp.
(d) Connect the 2 clamps and connector.
12. INSTALL NO. 4 HYBRID VEHICLE BATTERY CARRIER BRACKET
(a) Install the No. 4 hybrid vehicle battery carrier bracket with the bolt.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
13. INSTALL NO. 3 HYBRID BATTERY EXHAUST DUCT
(a) Install the No. 3 hybrid battery exhaust duct (for RH side) with the 2 clips.
Text in Illustration
HINT
Install the No. 3 hybrid battery exhaust duct so that the positioning mark is on the right side of the vehicle.
(b) Install the No. 3 hybrid battery exhaust duct (for LH side) with the 2 clips.
Text in Illustration
HINT
Install the No. 3 hybrid battery exhaust duct so that the positioning mark is on the right side of the vehicle.
14. INSTALL HYBRID BATTERY HOSE ASSEMBLY
(a) Install the hybrid battery hose assembly with the claw and grommet.
Text in Illustration
NOTICE:
Make sure that there is no space or a gap between the grommet and the body.
(b) Connect the clip.
15. INSTALL BATTERY COOLING BLOWER ASSEMBLY (for LH Side) Installation
16. INSTALL BATTERY COOLING BLOWER ASSEMBLY (for RH Side) Installation
17. INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH Installation
18. INSTALL TONNEAU COVER HOLDER CAP (for RH Side)
HINT
Use the same procedure described for the LH side Installation.
19. INSTALL LUGGAGE HOLD BELT STRIKER ASSEMBLY (for RH Side)
HINT
Use the same procedure described for the LH side Installation.
20. INSTALL REAR SIDE SEAT BACK ASSEMBLY RH Installation
21. INSTALL REAR SEAT CUSHION ASSEMBLY Installation
22. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH Installation
23. INSTALL REAR DOOR SCUFF PLATE RH
HINT
Use the same procedure described for the LH side Installation.
24. INSTALL REAR DECK TRIM COVER Installation
25. INSTALL DECK TRIM SERVICE HOLE COVER Installation
26. INSTALL REAR NO. 1 FLOOR BOARD Installation
27. INSTALL REAR NO. 1 FLOOR BOARD SUB-ASSEMBLY Installation
28. INSTALL REAR NO. 2 FLOOR BOARD SUB-ASSEMBLY Installation
29. INSTALL TONNEAU COVER ASSEMBLY (w/ Tonneau Cover) Installation
30. INSTALL DECK FLOOR BOX LH
HINT
Use the same procedure described for the RH side Installation.
31. INSTALL REAR NO. 4 FLOOR BOARD SUB-ASSEMBLY Installation
32. INSTALL REAR NO. 2 FLOOR BOARD Installation
33. INSTALL SERVICE PLUG GRIP
Installation
34. CURRENT SENSOR OFFSET LEARNING
HINT
Perform this procedure when the hybrid battery junction block assembly or power management control ECU has been replaced.
(a) Connect the Techstream to the DLC3.
(b) Turn the power switch on (READY).
(c) Perform a road test.
NOTICE:
Accelerate/decelerate gently. Avoid rapid acceleration/deceleration.
(1) Enter the following menus: Powertrain / Hybrid Control / Data List / Power Resource IB.
(2) Drive the vehicle with the value of Data List item "Power Resource IB" between -50 A and 50 A.
HINT
Distance and driving time are not specified.
(d) Turn the power switch off and leave the vehicle for 30 seconds or more.
(e) Turn the power switch on (IG).
(f) Enter the following menus: Powertrain / Hybrid Control / Data List / Power Resource IB.
(g) Check that the value of "Power Resource IB" is between - 0.5 A and 0.5 A with the power switch on (IG).
NOTICE:
If the value is outside the specified range, perform the road test again.
HINT
* If the power switch is on (IG) and value of "Power Resource IB" is between - 0.5 A and 0.5 A, current sensor offset learning has been completed.
* Even if the current sensor offset learning is not complete, the current sensor value will be corrected by repeating the road test a maximum of 7 times.