TOYOTA PRIUS 2001 Service Repair Manual

HV002±01
B11983N´m (kgf´cm, ft´lbf) : Specified torque
4.0 (41, 35 in.´lbf)
Inner Ventilator Duct
Lower Quarter
Ventilator
RH Battery
Bracket
HV Battery
Rear SeatQuarter Ventilator Duct
Blower Motor
Control Connector
LH Battery Bracket
Power Cable
Battery Carrier Catch Bracket
18 (185, 13)
x6
18 (185, 13)x5
x6
18 (185, 13)
8.0 (80, 71 in.´lbf)
4.0 (41, 35 in.´lbf)
5.0 (50, 44 in.´lbf)
18 (185, 13)
HV±2
± HYBRID VEHICLE CONTROLHV BATTERY
1332 Author: Date:
2001 PRIUS (RM778U)
HV BATTERY
COMPONENTS

B11984N´m (kgf´cm, ft´lbf) : Specified torque
18 (185, 13)
Battery Cover
Busbar Module Protector
Busbar Module
Battery Hose
Service Plug
Assembly
Battery ECU
SMR Battery Clamp Bolt
RH Battery Bracket
HV Battery
Thermistor
Battery Carrier Battery Module
Busbar Module Protector
x38
x38
38 (390, 28)
Service Plug Wire Harness Protector
Busbar Module
38 (390, 28)
6.0 (61, 53 in.´lbf)
8.0 (80, 71 in.´lbf)
6.0 (61, 53 in.´lbf)
SMR Cover
5.0 (50, 44 in.´lbf)
5.0 (50, 44 in.´lbf)
3.3 (33, 29 in.´lbf)
5.0 (50, 44 in.´lbf)
5.0 (50, 44 in.´lbf)
± HYBRID VEHICLE CONTROLHV BATTERY
HV±3
1333 Author: Date:
2001 PRIUS (RM778U)

HV004±01
B11963
B11964
B11965
± HYBRID VEHICLE CONTROLHV BATTERY
HV±5
2001 PRIUS (RM778U)
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.
3. REMOVE SERVICE PLUG
(a) Remove the rear RH and LH busbar module protectors.
(b) Remove the 2 nuts for busbar module.
(c) Remove the nut and wire harness protector.

B12006
B11966
B11967
B11968
B11969
HV±6
± HYBRID VEHICLE CONTROLHV BATTERY
2001 PRIUS (RM778U)
(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.
(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.
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.
6. REMOVE HV BATTERY THERMISTOR
7. REMOVE BATTERY ECU
(a) Disconnect the connector.
(b) Remove the 2 bolts and battery ECU.

B11970
B11971
B11972
± HYBRID VEHICLE CONTROLHV BATTERY
HV±7
2001 PRIUS (RM778U)
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.
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.
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

HV006±01
B11973
B11974
B11970
± HYBRID VEHICLE CONTROLHV BATTERY
HV±9
2001 PRIUS (RM778U) 4/6/01
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)
3. INSTALL RH BATTERY BRACKET
Install the RH battery bracket with the 4 bolts.
Torque: 23 N´m (230 kgf´cm, 16 ft´lbf)
4. INSTALL BATTERY HOSE

B11968
B11969
B11967
B11966
B12006
HV±10
± HYBRID VEHICLE CONTROLHV BATTERY
2001 PRIUS (RM778U) 4/6/01
5. INSTALL HV BATTERY THERMISTOR
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
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.
(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.
9. INSTALL SERVICE PLUG
(a) Install the service plug with the 3 bolts.
Torque: 6.0 N´m (61 kgf´cm, 53 in.´lbf)

B11965
B11964
B11963
A
B
ScrewAA
A AB
B
C
± HYBRID VEHICLE CONTROLHV BATTERY
HV±11
2001 PRIUS (RM778U) 4/6/01
(b) Install the wire harness protector with the nut.
(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
11. INSTALL BATTERY COVER
Install the battery cover with the 12 bolts and screw.
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)
12. 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)

HV007±01
B11992
B11962
B11961
B11960
HV±12
± HYBRID VEHICLE CONTROLHV BATTERY
2001 PRIUS (RM778U)
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)
(b) Install and tighten the 5 bolts for HV battery.
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
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)
(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.
(b) Connect the connector to the SMR.
(c) Connect the connector to the service plug assembly.

± HYBRID VEHICLE CONTROLHV BATTERY
HV±13
2001 PRIUS (RM778U)
6. INSTALL REAR SET (See page BO±82)
7. INSTALL LUGGAGE TRIM (See page BO±25)
8. INSTALL SERVICE PLUG (See page HV±1)