21–98
HYBRID CONTROL SYSTEM – BATTERY ECU ASSY
BATTERY ECU ASSY
2103Y–01
REPLACEMENT
NOTICE:
When working on the high voltage systems, always wear insulating gloves.
After removing the service plug grip, do not operate the power switch as it may damage the hy-
brid vehicle control ECU.
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.
1. PRECAUTION (See page 21–7)
2. REMOVE REAR FLOOR BOARD NO.2 (See page 21–116)
3. REMOVE DECK FLOOR BOX REAR (See page 21–116)
4. REMOVE REAR FLOOR BOARD NO.3 (See page 21–116)
5. DISCONNECT BATTERY NEGATIVE TERMINAL (See page 21–116)
6. REMOVE SERVICE PLUG GRIP (See page 21–116)
7. REMOVE DECK TRIM COVER REAR (See page 21–54)
8. REMOVE TONNEAU COVER ASSY (See page 21–54)
9. REMOVE REAR SEAT CUSHION ASSY (See page 21–54)
10. REMOVE REAR FLOOR BOARD NO.1 (See page 21–54)
11. REMOVE REAR SIDE SEAT BACK FRAME LH (See page 21–54)
12. REMOVE REAR FLOOR BOARD NO.4 (See page 21–54)
13. REMOVE DECK FLOOR BOX LH (See page 21–54)
14. REMOVE DECK TRIM SIDE PANEL ASSY LH (See page 21–54)
15. REMOVE BATTERY CARRIER BRACKET (See page 21–54)
16. REMOVE BATTERY CARRIER PANEL NO.6 (See page 21–54)
NOTICE:
Wear insulating gloves.
17. REMOVE JUNCTION TERMINAL (See page 21–54)
NOTICE:
Wear insulating gloves.
System Main Battery ECU Assembly 18. REMOVE BATTERY ECU ASSY
Relay Connector NOTICE:
Wear insulating gloves.
(a) Disconnect the system main relay connector.
NOTICE:
Insulate the disconnected connectors with insulating tape.
Battery ECU (b) Disconnect the battery ECU assembly connector.
Assy Connector NOTICE:
A83606 Insulate the disconnected connectors with insulating tape.
2004 Prius – Preliminary Release (RM1075U)
Author: Date: 442
21–99
HYBRID CONTROL SYSTEM – BATTERY ECU ASSY
(c) Disconnect the thermistor connector.
NOTICE:
Insulate the disconnected connectors with insulating tape.
(d) Remove the clamp, then disconnect the frame wire No. 2
connector.
NOTICE:
Insulate the disconnected connectors with insulating tape.
(e) Remove the nut, then disconnect the aluminum shield
wire of the main battery cable.
(f) Remove the 2 screws and battery ECU asssembly.
Thermistor Connector
Frame Wire No. 2 Connector
Clamp
Aluminum Shield Wire
A83605
19. INSTALL BATTERY ECU ASSY
NOTICE:
Wear insulating gloves.
(a) Install the battery ECU assembly with the 2 screws.
Torque: 3.3 N⋅m (34 kgf⋅cm, 29 in.⋅lbf)
(b) Tighten the aluminum shield wire of the main battery
cable together with the battery ECU assembly with a new
nut.
Torque: 3.3 N⋅m (34 kgf⋅cm, 29 in.⋅lbf)
(c) Connect the clamp and frame wire No. 2 connector.
(d) Connect the thermister connector.
Thermistor Connector
Frame Wire No. 2 Connector
Clamp
Aluminum Shield Wire
A83605
2004 Prius – Preliminary Release (RM1075U)
Author: Date: 443
21–100
HYBRID CONTROL SYSTEM – BATTERY ECU ASSY
System Main Battery ECU Assembly (e) Connect the system main relay connector.
Relay Connector (f) Remove the 2 screws and battery ECU assembly.
Battery ECU
Assy Connector
A83606
20. INSTALL JUNCTION TERMINAL (See page 21–54)
NOTICE:
Wear insulating gloves.
21. INSTALL BATTERY CARRIER PANEL NO.6 (See page 21–54)
NOTICE:
Wear insulating gloves.
22. INSTALL BATTERY CARRIER BRACKET (See page 21–54)
23. INSTALL DECK TRIM SIDE PANEL ASSY LH
24. INSTALL DECK FLOOR BOX LH
25. INSTALL REAR FLOOR BOARD NO.4
26. INSTALL REAR SIDE SEAT BACK FRAME LH
27. INSTALL REAR FLOOR BOARD NO.1
28. INSTALL REAR SEAT CUSHION ASSY
29. INSTALL TONNEAU COVER ASSY
30. INSTALL DECK TRIM COVER REAR
31. INSTALL SERVICE PLUG GRIP (See page 21–116)
NOTICE:
Wear insulating gloves.
32. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 6.0 N⋅m (61 kgf⋅cm, 53 in.⋅lbf)
33. INSTALL REAR FLOOR BOARD NO.3
34. INSTALL DECK FLOOR BOX REAR
35. INSTALL REAR FLOOR BOARD NO.2
36. POWER WINDOW CONTROL SYSTEM INITIALIZE (See page 01–28)
2004 Prius – Preliminary Release (RM1075U)
Author: Date: 444
