HV–2

HYBRID VEHICLE CONTROL – HV BATTERY

HV BATTERY
HV002–01

COMPONENTS
4.0 (41, 35 in.·lbf)

Inner Ventilator Duct

Lower Quarter
Ventilator

Quarter Ventilator Duct

4.0 (41, 35 in.·lbf)

18 (185, 13)
18 (185, 13)
x6
RH Battery
Bracket
Blower Motor
Control Connector

18 (185, 13)
x5
18 (185, 13)
x6
HV Battery
LH Battery Bracket
8.0 (80, 71 in.·lbf)

Rear Seat Power Cable

5.0 (50, 44 in.·lbf)

Battery Carrier Catch Bracket

N·m (kgf·cm, ft·lbf) : Specified torque B11983

2001 PRIUS (RM778U)

Author: Date: 1332

 HV–3
HYBRID VEHICLE CONTROL – HV BATTERY

8.0 (80, 71 in.·lbf)

18 (185, 13)
6.0 (61, 53 in.·lbf)
Battery Cover

Busbar Module Protector

Wire Harness Protector

Busbar Module
Service Plug
Battery Hose
6.0 (61, 53 in.·lbf)

Service Plug 3.3 (33, 29 in.·lbf)

Assembly
5.0 (50, 44 in.·lbf)
Battery ECU

Battery Clamp Bolt

RH Battery Bracket 5.0 (50, 44 in.·lbf)

SMR
SMR Cover

38 (390, 28)
38 (390, 28)
HV Battery
Battery Module Thermistor
Busbar Module

Battery Carrier

Busbar Module Protector

5.0 (50, 44 in.·lbf) x38 x38

N·m (kgf·cm, ft·lbf) : Specified torque 5.0 (50, 44 in.·lbf)
B11984

2001 PRIUS (RM778U)

Author: Date: 1333

 HV–5
HYBRID VEHICLE CONTROL – HV BATTERY
HV004–01

DISASSEMBLY
1. REMOVE BATTERY MODULE SET BOLT
Turn the battery assembly upside down, remove the 76 battery
module bolts.
NOTICE:
When turning it over, prevent the flange from being de-
formed.
HINT:
When not removing a battery module, skip the operation of step
1.

2. REMOVE BATTERY COVER

Remove the 12 bolts, screw and battery cover.

B11963

3. REMOVE SERVICE PLUG

(a) Remove the rear RH and LH busbar module protectors.
(b) Remove the 2 nuts for busbar module.

B11964

(c) Remove the nut and wire harness protector.

B11965

2001 PRIUS (RM778U)

HV–6
HYBRID VEHICLE CONTROL – HV BATTERY

(d) Remove the 3 bolts and service plug assembly.

4. REMOVE POWER CABLE FOR SMR
(a) Remove the front RH and LH busbar module protectors.

B12006

(b) Remove the 2 nuts, and disconnect the power cable from
the front busbar module.
(c) Remove the SMR cover from the SMR.
(d) Remove 2 bolts, and disconnect the power cable for
SMR.

B11966

5. REMOVE SMR
(a) Using the service plug, turn the interlock counterclock-
wise to unlock.
NOTICE:
When the interlock is damaged, be sure to replace it with
new one.
(b) Remove the 3 bolts and SMR.

B11967

6. REMOVE HV BATTERY THERMISTOR

7. REMOVE BATTERY ECU
(a) Disconnect the connector.

B11968

(b) Remove the 2 bolts and battery ECU.

B11969

2001 PRIUS (RM778U)

 HV–7
HYBRID VEHICLE CONTROL – HV BATTERY

8. REMOVE BATTERY HOSE

9. REMOVE BUSBAR MODULE
(a) Remove the 36 nuts, RH and LH rear busbar modules.
(b) Remove the 36 nuts, RH and LH front busbar modules.

B11970

10. REMOVE BATTERY CLAMP BOLT

Remove the 4 bolts and battery clamp bolt.
CAUTION:
Never remove the battery clamp bolt until 4 hours has
passed after the ignition switch is turned OFF. An explo-
sion due to expansion could occur.

B11971

11. REMOVE RH BATTERY BRACKET

Remove the 2 bolts and RH battery bracket.
CAUTION:
Never remove the RH battery bracket until 4 hours has
passed after the ignition switch is turned OFF. An explo-
sion due to expansion could occur.
12. REMOVE 38 HV BATTERY MODULES

B11972

2001 PRIUS (RM778U)

 HV–9
HYBRID VEHICLE CONTROL – HV BATTERY
HV006–01

REASSEMBLY
1. 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 al-
ternately connecting the positive and negative terminals
to the vehicle front side.

2. INSTALL BATTERY CLAMP BOLT

Install the battery clamp bolt with the 2 bolts.
Torque: 23 N·m (230 kgf·cm, 16 ft·lbf)

B11973

3. INSTALL RH BATTERY BRACKET

Install the RH battery bracket with the 4 bolts.
Torque: 23 N·m (230 kgf·cm, 16 ft·lbf)

B11974

4. INSTALL BATTERY HOSE

B11970

2001 PRIUS (RM778U) 4/6/01

HV–10
HYBRID VEHICLE CONTROL – HV BATTERY

5. INSTALL HV BATTERY THERMISTOR

B11968

6. INSTALL BATTERY ECU

(a) Install the battery ECU with the 2 bolts.
Torque: 3.3 N·m (33 kgf·cm, 29 in.·lbf)
(b) Connect the connector for HV battery thermistor.
7. INSTALL BUSBAR MODULE
(a) Install the front busbar module with the 74 nuts.
Torque: 6.0 N·m (61 kgf·cm, 53 in.·lbf)
(b) Install the rear RH and LH busbar modules with the 74
B11969 nuts.
Torque: 6.0 N·m (61 kgf·cm, 53 in.·lbf)
8. INSTALL SMR
(a) Install the SMR with the 3 bolts.
Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf)
(b) Connect the power cable for SMR with the 2 bolts.
Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf)
(c) Install the SMR cover to the SMR.
(d) Connect the connector to the cover for external uniform
charger and lock the cover.
B11967

(e) Connect the power cable for SMR with the 2 nuts.
Torque: 6.0 N·m (61 kgf·cm, 53 in.·lbf)
(f) Install the front RH and LH busbar module protectors.

B11966

9. INSTALL SERVICE PLUG

(a) Install the service plug with the 3 bolts.
Torque: 6.0 N·m (61 kgf·cm, 53 in.·lbf)

B12006

2001 PRIUS (RM778U) 4/6/01

 HV–11
HYBRID VEHICLE CONTROL – HV BATTERY

(b) Install the wire harness protector with the nut.

B11965

(c) Install the busbar module with 2 new nuts.

Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
10. INSTALL REAR RH AND LH BUSBAR MODULE PRO-
TECTOR

B11964

11. INSTALL BATTERY COVER

A A A B
B
Install the battery cover with the 12 bolts and screw.
Torque:
B 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)
C 12. INSTALL BATTERY MODULE SET BOLT
Screw A A
B11963 Turn the battery assembly upside down, install the 76 battery
module set bolts.
Torque: 4.0 N·m (40 kgf·cm, 35 in.·lbf)

2001 PRIUS (RM778U) 4/6/01

HV–12
HYBRID VEHICLE CONTROL – HV BATTERY
HV007–01

INSTALLATION
1. INSTALL HV BATTERY
(a) Set the HV battery to the body.
(b) Connect the battery hose to the body.
CAUTION:
Since alkaline electrolyte may be got on the hose end,
carry out the operation with considera care.

2. INSTALL BATTERY BRACKET

(a) Install the RH and LH battery bracket with the 13 bolts and
nut.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

B11992

(b) Install and tighten the 5 bolts for HV battery.

Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

B11962

3. INSTALL HIGH TENSION CABLE

(a) Install the earth terminal.
(b) Install the high tension cable with the 2 bolts.
Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf)

B11961

(c) Install the battery carrier catch bracket with the 3 nuts.
Torque: 8.0 N·m (80 kgf·cm, 71 in.·lbf)
NOTICE:
When installing a cover, never fail to pass the interlock but-
ton.
4. INSTALL DUCT (See page HV–32)
5. CONNECT CONNECTOR
(a) Connect the 2 connectors to the battery ECU.
B11960 (b) Connect the connector to the SMR.
(c) Connect the connector to the service plug assembly.
2001 PRIUS (RM778U)
 HV–13
HYBRID VEHICLE CONTROL – HV BATTERY

6. INSTALL REAR SET (See page BO–82)

7. INSTALL LUGGAGE TRIM (See page BO–25)
8. INSTALL SERVICE PLUG (See page HV–1)

2001 PRIUS (RM778U)