(Click on below image for larger photo)
Time Required: Approx 1.5-2 hours
Trim panel removal tool
8mm, 10mm, 12mm, 14mm sockets
Wire cutters, wire strippers, wire crimping tool
Zip tie cutters, scissors
#0 flat heat screwdriver
#2 phillips screwdriver, #0 phillips screwdriver
Recommended: Volt meter
1) Open the rear cargo area lift gate and remove the cargo cover & trunk mat (if equipped)
Remove rear cargo area center carpet base
2) Remove the rear cargo storage compartment
4) Fold rear seats down. Remove seat back velcro from battery cover flap.
5) Using the trim panel removal tool, unclip battery cover seatback trim. There are five clips on large panel and four clips on small panel.
6) Remove 10mm bolt from front left corner of hybrid battery trim cover
7) Using trim panel removal tool, remove battery cover by carefully releasing three retainer clips (located in each notch as indicated in photo)
8) Remove two 14mm bolts from left side seat back. Remove left seat back and set aside.
9) Using pin on top of battery disconnect switch handle loop, rotate safety clip lock at least 90 degrees counter clockwise to release safety lock pin.
Remove safety lock pin.
10) Remove the four 10mm nuts from back of battery cover.
Note: The three 10mm bolts on left end of cover do NOT need to be removed.
11) Remove the four 10mm nuts from front of battery cover.
Remove battery cover.
You are now dealing with exposed high voltage module terminals. Do not touch the terminals unless specifically advised by these instructions. Never touch more than one terminal at a time. Be very careful working around the live battery! It can kill you if you do not respect it!
12) Remove 12V Aux battery cover
13) Disconnect 12V Aux battery negative terminal
14) Remove black upholstery clip and remove battery exhaust vent duct
Remove two white upholstery clips and remove white battery fan cover.
TIP: Firmly pull straight up on white battery fan cover to release lower clip.
15) Remove the hybrid battery junction cover by removing the three 10mm nuts (two on top, one at bottom right corner of photo by HV cables).
16) Route the car harness through junction box access passage and secure to wire harness with zip tie as shown.
17) Route car harness through white retainer clip as shown.
18) Using very small (#0) flat head screwdriver, carefully remove black battery module cover all the way across front of battery.
Note there is a small inner clip on each piece that will need to be carefully detached as well. It is not difficult, just take your time and do not rush this step.
19) This is what it will look like when the covers are removed.
20) Install the black HV ground wire to the right most (passenger side) battery module 8mm bolt as shown. Note the diagonal orientation of the connector. This is intentional. Your wire harness may not have the red connector insulation, this is normal.
When tightening the battery module terminal, DO NOT OVERTIGHTEN! These post can break if too much force is used. They should only be torqued to approx 4-5 ft lb.
21) Route the red HV positive wiring through the orange battery wire harness clips as shown.
Install the red HV positive wire to the left most (driver side) battery module 8mm bolt as shown. Note the diagonal orientation of the connector. This is intentional. Your wire harness may not have the red connector insulation, this is normal.
When tightening the battery module terminal, DO NOT OVER TIGHTEN! These post can break if too much force is used. They should only be torqued to approx 4-5 ft lb.
22) Secure to the existing wire harness with two of the provided zip ties as shown.
Leave some slack so that the wires can flex as needed.
23) Reinstall the black battery module covers as shown.
24) BE SURE all top clips are correctly aligned and installed into their proper positions.
25) Lay the battery module cover back onto the battery pack. Do not bolt down yet.
OPTIONAL BUT RECOMMENDED:
26) We highly recommend taking a few extra minutes to clean the hybrid battery cooling fan. The fan has no filter on the intake duct and often becomes clogged with debris. This contributes heavily to the hybrid battery overheating and premature failure.
Remove the hybrid battery cooling fan intake duct by removing the black retention clip. Reach into the fan and clean it in place or carefully remove the three 10mm bolts and remove the fan from the car to clean it.
27) Unplug fan from the chassis main harness.
Plug the hybrid battery cooling fan control box to the vehicle harness plug and fan harness plug.
(Old style non plug-and-play harness shown)
28) Using large zip tie provided, secure hybrid battery cooling fan control box to existing wire harness as shown.
(Old style non plug-and-play harness shown)
29) Reinstall junction box top cover. Do not bolt down yet.
30) IMPORTANT – Test the charger before finishing re-assembly of the vehicle. We recommend that you connect the charger to the car harness before plugging it into the wall and unplug it from the wall before disconnecting it from the car harness.
To perform the initial function test: First, make sure all fingers and tools are clear of all wiring and hybrid battery components. Plug the Charger into the car harness. With the hybrid battery main disconnect still removed, plug the Charger into the wall. After a few seconds, it should read approx 250 volts on the meter and both the charger and hybrid battery cooling fans should be running.
Note in the image at left the hybrid battery main disconnect is not present and the charger is displaying max voltage and no amperage.
31) Next, carefully connect hybrid battery main disconnect.
Once the disconnect is reinstalled, be sure to PUSH THE LARGE ORANGE DISCONNECT RING DOWN TO LOCK IT INTO PLACE!! IT WILL NOT WORK UNLESS LOCKED DOWN. YOU HAVE TO PUSH IT DOWN TO LOCK IT IN PLACE.
(2004-2009 diagram shown, but the locking action is the same.)
32) You should see the voltage drop as the charger voltage equalizes with the voltage level of the battery pack. This should happen quickly. The voltage level should be stable and not fluctuating. All fans should still be running.
Note in the image at left the hybrid battery main disconnect is present and the charger is displaying battery voltage and amperage.
If anything is wrong, stop and contact us. If the fan is ‘pulsing’ (powering on and off) every few seconds, stop and contact us.
This completes the test. Unplug the Charger from the AC power source and disconnect the Charger from the car harness. If the test was successful, you can leave the hybrid battery main disconnect in place.
33) Tighten the eight 10mm hybrid battery cover bolts.
Tighten the three 10mm junction box top cover bolts.
34) Reinstall the white plastic fan cover.
35) Reinstall the battery exhaust vent duct.
36) Secure wire harness to existing wiring using supplied zip tie as shown.
Loosen 12V Aux battery bracket. Install anti-tension ring on inner bracket bolt as shown.
Retighten battery bracket.
37) Reconnect 12V Aux battery negative terminal.
Reinstall 12V Aux battery cover
38) Reassemble the rear cargo area upholstery in the reverse order of removal:
Install the orange safety lock pin.
Install the left rear seat top.
Install the battery cover carpet panel.
Reinstall the 10mm bolt in the front left corner of hybrid battery trim cover.
Install the battery cover seat back trim.
39) Note the proper placement of the seat back velcro flaps.
40) Reinstall the rear cargo storage compartment and route the car harness as shown.
Finish by reinstalling the rear cargo area center carpet base and cargo cover & trunk mat (if equipped).