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Home >> Toyota >> 2006 >> Prius >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Battery Management Systems >> P112 Hybrid Battery Control System >> Battery Plug >> Removal

Battery Plug: Removal

CAUTION:
  • When working on the high voltage systems, always wear insulating gloves.
  • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle.
  • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes.
NOTE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU.
  1. PRECAUTION 
    CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/removal, inspection and replacement of parts), be sure to follow the procedures (see PRECAUTION  ).
  2. REMOVE REAR NO. 2 FLOOR BOARD (See  REMOVAL  ) 
  3. REMOVE REAR DECK FLOOR BOX (See  REMOVAL  ) 
  4. REMOVE REAR NO. 3 FLOOR BOARD (See  REMOVAL  ) 
  5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
  6. REMOVE SERVICE PLUG GRIP (See  REMOVAL   ) 
  7. REMOVE HV BATTERY ASSEMBLY 
    1. Remove the HV battery from the vehicle (see REMOVAL  ).
  8. REMOVE BATTERY COVER (See  DISASSEMBLY   ) 
  9. REMOVE BATTERY CLAMP PAD 
    CAUTION: Wear insulating gloves.
    1. Peel off the bonded parts, then remove the battery clamp pad (the battery carrier cushion).
      Fig 1: Removing Battery Clamp Pad
      G04473948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE NO. 1 WIRE HARNESS PROTECTOR COVER 
    1. Open the wire harness protector cover.
    2. Remove the 2 nuts, then disconnect the service plug.
    3. Remove the wire harness protector cover.
      Fig 2: Removing Wire Harness Protector Cover
      G04473949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE BATTERY PLUG 
    1. Disconnect the connector clamp.
    2. Remove the 2 bolts, then disconnect the service plug from the upper battery carrier.
      Fig 3: Disconnecting Connector Clamp
      G04473950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Open the wire harness protector cover as shown in the illustration. Then remove the service plug from the junction block.
      Fig 4: Removing Service Plug From Junction Block
      G04473951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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