2003 Toyota PriusFACTORY OEM SERVICE PROCEDURE

HV Battery: Disassembly

  1. REMOVE BATTERY MODULE SET BOLT 

    Turn the battery assembly upside down, remove the 76 battery module bolts.

    NOTE: When turning it over, prevent the flange from being deformed. 

    HINT:

    When not removing a battery module, skip the operation of step 1.

  2. REMOVE BATTERY COVER 

    Remove the 12 bolts, screw and battery cover.

    Fig 1: Removing Battery Cover
    G03430942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE SERVICE PLUG 
    1. Remove the rear RH and LH bus bar module protectors.
    2. Remove the 2 nuts for bus bar module.
      Fig 2: Removing Bus Bar Module Nuts
      G03430943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the nut and wire harness protector.
      Fig 3: Removing Wire Harness Protector
      G03430944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 3 bolts and service plug assembly.
    Fig 4: Removing Service Plug Assembly
    G03430945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE POWER CABLE FOR SMR 
    1. Remove the front RH and LH bus bar module protectors.
    2. Remove the 2 nuts, and disconnect the power cable from the front bus bar module.
    3. Remove the SMR cover from the SMR.
    4. Remove 2 bolts, and disconnect the power cable for SMR.
      Fig 5: Removing Power Cable For SMR
      G03430946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE SMR 
    1. Using the service plug, turn the interlock counterclockwise to unlock.
      NOTE: When the interlock is damaged, be sure to replace it with new one. 
    2. Remove the 3 bolts and SMR.
      Fig 6: Removing SMR
      G03430947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE HV BATTERY THERMISTOR 
  7. REMOVE BATTERY ECU 
    1. Disconnect the connector.
      Fig 7: Disconnecting Connector
      G03430948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and battery ECU.
      Fig 8: Removing Battery ECU
      G03430949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE BATTERY HOSE 
  9. REMOVE BUS BAR MODULE 
    1. Remove the 36 nuts, RH and LH rear bus bar modules.
    2. Remove the 36 nuts, RH and LH front bus bar modules.
      Fig 9: Removing Bus Bar Module
      G03430950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE BATTERY CLAMP BOLT 

    Remove the 4 bolts and battery clamp bolt.

    CAUTION: Never remove the battery clamp bolt until 4 hours has passed after the ignition switch is turned OFF. An explosion due to expansion could occur. 
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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