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

2004 Toyota Matrix XR, FWD, Standard

HV Battery Reassembly

2004 Toyota Matrix XR, FWD, StandardSECTION HV Battery Reassembly

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.

Install battery module .
Install the 38 battery modules to the battery carrier.
NOTE:
- 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: Identifying Battery Clamp To Battery Carrier Mounting Bolts
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: Identifying Battery Bracket To Battery Carrier & Clamp Mounting Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install battery hose

Fig 3: Identifying Battery Hoses
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install HV battery thermistor .

Fig 4: Identifying 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) .
2. Connect the connector for HV battery thermistor.
Install busbar module :
1. Install the front busbar module with the 74 nuts.
  Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf) .
2. Install the rear RH and LH busbar modules with the 74 nuts.
  Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf) .
  
  Fig 5: Identifying Battery ECU Mounting Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install SMR :
1. Install the SMR with the 3 bolts.
  Torque: 5.0 N.m (50 kgf.cm, 44 in.lbf) .
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.
  
  Fig 6: Identifying SMR Mounting Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the power cable for SMR with 2 new nuts.
  Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) .
6. Install the front RH and LH busbar module protectors.
  
  Fig 7: Identifying Power Cable To Front Busbar Module Mounting Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install service plug :
1. Install the service plug with the 3 bolts.
  
  Fig 8: Identifying Service Plug Mounting Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf) .
2. Install the wire harness protector with the nut.
  
  Fig 9: Identifying Wire Harness Protector Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the busbar module with 2 new nuts
  
  Fig 10: Identifying Busbar Terminal Mounting Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) .
Install rear RH and LH busbar module protector .
Install battery cover .
Install the battery cover with the 12 bolts and screw.

Fig 11: Identifying Battery Cover Mounting Bolts "A"-"C" & Screw
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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) .
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) .