HV Battery: Disassembly

REMOVE BATTERY MODULE SET BOLT
Turn the battery assembly upside down, remove the 76 battery module bolts.

NOTE: When turning it over, prevent the flange from being deformed.

HINT:

When not removing a battery module, skip the operation of step 1.
REMOVE BATTERY COVER
Remove the 12 bolts, screw and battery cover.

Fig 1: Removing Battery Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SERVICE PLUG
1. Remove the rear RH and LH bus bar module protectors.
2. Remove the 2 nuts for bus bar module.
  
  Fig 2: Removing Bus Bar Module Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the nut and wire harness protector.
  
  Fig 3: Removing Wire Harness Protector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 3 bolts and service plug assembly.
Fig 4: Removing Service Plug Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE POWER CABLE FOR SMR
1. Remove the front RH and LH bus bar module protectors.
2. Remove the 2 nuts, and disconnect the power cable from the front bus bar module.
3. Remove the SMR cover from the SMR.
4. Remove 2 bolts, and disconnect the power cable for SMR.
  
  Fig 5: Removing Power Cable For SMR
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SMR
1. Using the service plug, turn the interlock counterclockwise to unlock.
  NOTE: When the interlock is damaged, be sure to replace it with new one.
2. Remove the 3 bolts and SMR.
  
  Fig 6: Removing SMR
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HV BATTERY THERMISTOR
REMOVE BATTERY ECU
1. Disconnect the connector.
  
  Fig 7: Disconnecting Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 bolts and battery ECU.
  
  Fig 8: Removing Battery ECU
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BATTERY HOSE
REMOVE BUS BAR MODULE
1. Remove the 36 nuts, RH and LH rear bus bar modules.
2. Remove the 36 nuts, RH and LH front bus bar modules.
  
  Fig 9: Removing Bus Bar Module
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 explosion due to expansion could occur.

Fig 10: Removing Battery Clamp Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RH BATTERY BRACKET
Remove the 2 bolts and RH battery bracket.

Fig 11: Removing RH Battery Bracket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

CAUTION: Never remove the RH battery bracket until 4 hours has passed after the ignition switch is turned OFF. An explosion due to expansion could occur.
REMOVE 38 HV BATTERY MODULES