Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSTOYOTA2004MATRIX XR, FWD, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 451 (HYBRID VEHICLE CONTROL)HV BATTERYHV BATTERY DISASSEMBLY

2004 Toyota Matrix XR, FWD, Standard

HV Battery Disassembly

2004 Toyota Matrix XR, FWD, StandardSECTION HV Battery Disassembly

WARNING: This page is about a different car, the 2002 Toyota Prius. However, it is still accessible from the selected car via links, so may be relevant.

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.
When not removing a battery module, skip the operation of step ( 1.
Remove battery cover .
Remove the 12 bolts, screw and battery cover.
Remove service plug :
1. Remove the rear RH and LH busbar module protectors.
2. Remove the 2 nuts for busbar module.
  
  Fig 1: Identifying Busbar Terminal Mounting Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the nut and wire harness protector.
  
  Fig 2: Identifying Wire Harness Protector Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 3 bolts and service plug assembly.
  
  Fig 3: Identifying Service Plug Mounting Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove power cable for SMR :
1. Remove the front RH and LH busbar module protectors.
2. Remove the 2 nuts, and disconnect the power cable from the front busbar module.
  
  Fig 4: Identifying Power Cable To Front Busbar Module Mounting Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the SMR cover from the SMR.
4. Remove 2 bolts, and disconnect the power cable for SMR.
Remove SMR :
1. Using the service plug, turn the interlock counterclockwise to unlock.
2. Remove the 3 bolts and SMR.
  
  Fig 5: Identifying SMR Mounting Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove HV battery thermistor .

Fig 6: Identifying Battery Thermistor
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove battery ECU :
1. Disconnect the connector.
2. Remove the 2 bolts and battery ECU.
  
  Fig 7: Identifying Battery ECU Mounting Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove battery hose .
Remove busbar module :
1. Remove the 36 nuts, RH and LH rear busbar modules.
2. Remove the 36 nuts, RH and LH front busbar modules.
Remove battery clamp bolt .

Fig 8: Identifying Battery Clamp
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Remove the 4 bolts and battery clamp bolt.

WARNING: 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.
Remove RH battery bracket .
Remove the 2 bolts and RH battery bracket.

Fig 9: Identifying Battery Bracket To Battery Carrier Mounting Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002