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HOMESERVICE MANUALSTOYOTA2003PRIUSREPAIR AND DIAGNOSISENGINE PERFORMANCETESTING & DIAGNOSISENGINE CONTROL SYSTEMHV BATTERYREASSEMBLY

2003 Toyota Prius

HV Battery: Reassembly

2003 Toyota PriusSECTION Reassembly

INSTALL BATTERY MODULE
Install the 38 battery modules to the battery carrier.

HINT:
- Packs containing 2 battery module each are arranged in the order of 1 to 19 from the ECU side.
- Starting from the positive terminal of the battery module on the battery ECU side, install 38 battery modules by alternately connecting the positive and negative terminals to the vehicle front side.
INSTALL BATTERY CLAMP BOLT
Install the battery clamp bolt with the 2 bolts.

Torque: 23 N.m (230 kgf.cm, 16 ft.lbf)

Fig 1: Installing Battery Clamp Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RH BATTERY BRACKET
Install the RH battery bracket with the 4 bolts.

Torque: 23 N.m (230 kgf.cm, 16 ft.lbf)

Fig 2: Installing RH Battery Bracket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BATTERY HOSE

Fig 3: Installing Battery Hose
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HV BATTERY THERMISTOR

Fig 4: Installing HV Battery Thermistor
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BATTERY ECU
1. Install the battery ECU with the 2 bolts.
  Torque: 3.3 N.m (33 kgf.cm, 29 in.lbf)
  
  Fig 5: Installing Battery ECU
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the connector for HV battery thermistor.
INSTALL BUS BAR MODULE
1. Install the front bus bar module with the 74 nuts.
  Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)
2. Install the rear RH and LH bus bar modules with the 74 nuts.
  Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)
INSTALL SMR
1. Install the SMR with the 3 bolts.
  Torque: 5.0 N.m (50 kgf.cm, 44 in.lbf)
  
  Fig 6: Installing SMR
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the power cable for SMR with the 2 bolts.
  Torque: 5.0 N.m (50 kgf.cm, 44 in.lbf)
3. Install the SMR cover to the SMR.
4. Connect the connector to the cover for external uniform charger and lock the cover.
5. Connect the power cable for SMR with 2 new nuts.
  Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
  
  Fig 7: Connecting Power Cable For SMR
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the front RH and LH bus bar module protectors.
INSTALL SERVICE PLUG
1. Install the service plug with the 3 bolts.
  Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)
  
  Fig 8: Installing Service Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the wire harness protector with the nut.
  
  Fig 9: Installing Wire Harness Protector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the bus bar module with 2 new nuts.
  Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
  
  Fig 10: Installing Bus Bar Module
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR RH AND LH BUS BAR MODULE PROTECTOR
INSTALL BATTERY COVER
Install the battery cover with the 12 bolts and screw.

Torque:
- Bolt A: 18 N.m (185 kgf.cm, 13 ft.lbf)
- Bolt B: 8.0 N.m (80 kgf.cm, 71 in.lbf)
- Bolt C: 7.0 N.m (70 kgf.cm, 62 in.lbf)
- Screw: 6.0 N.m (61 kgf.cm, 53 in.lbf)
Fig 11: Installing Battery Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BATTERY MODULE SET BOLT
Turn the battery assembly upside down, install the 76 battery module set bolts.

Torque: 4.0 N.m (40 kgf.cm, 35 in.lbf)