How to Install a Hybrid Battery in a Gen 2 Toyota Prius

safety is an important concern when working with the electrical systems of hybrid vehicles particularly when removing and installing hybrid vehicle batteries because of the high voltage that the batteries generate removing and installing hybrid batteries is an inherently dangerous activity and can lead to serious or even fatal injuries suitable training is essential before removing installing or servicing this product which should only be attempted by a qualified technician please attentively watch this video and read the technical specification sheets warnings instructions and safety measures that a company the product using the proper techniques and safety measures for removing installing or servicing hybrid vehicles batteries are your sole responsibility you personally assume all risks and responsibilities for any damage injury or death that result from your misuse of our products or from your failure to use the proper safety equipment or take the proper safety measures if you are not a qualified technician do not attempt to remove install or service hybrid vehicle batteries to complete this installation you will need the following tool deep sockets and eight millimeter ten millimeter twelve millimeter and fourteen millimeter a trim removal tool a ratchet or impact wrench with the six inch extension a cat three one thousand full rated voltmeter and Lee and high voltage loves with leather protectors that art class zero one thousand full rated and remember when working with high voltage hybrid vehicle systems always wear insulating gloves Intel instructed to remove them to begin the installation how are the vehicle off making sure the speedometer display goes dark slide both front seats to their forward most physicians open both rear doors and the rear hatch remove the rear cargo mat cover and trade as well as the side covers that hide the twelve volt battery and storage pockets all up on the plastic cover that hides the rear hatch hinge and remove it from the vehicle using a ten millimeters socket and extension removed revolts securing each side panel next put on your high voltage low remove the orange high voltage battery safety disconnect located to the left front of the rear storage area the safety disconnect is removed by sliding the handle vertically and then pulling out and downward on the handle your high voltage clubs can now be removed until needed later in the installation using a ten millimeters socket remove the two bolts holding cargo ties to the carpeted tray above the high voltage battery disengage the seat belts shoulder harnesses from the rear seat back guides on top of the seat back fold down both rear seat back using a trend to locate and remove to bush in clips that secure the right and left sides of carpeting to the battery pack pull up on the carpet covering the hinge area of the seats and slide the battery cover toward the rear of the vehicle to disengage the clips that hold the cover to the battery top using a fourteen millimeters socket remove the bolts that secure the seat backs to the hinges live both seat backs forward into the floor in front of the seat bottom using a twelve millimeter socket that extension remove the bowl from each seat side panel located at the bottom edge of the panels behind the seat bottom after removing the bolts slide the panels straight up to disengage the retainer and remove it from the vehicle using a trim tool disengage the lips on both side panels behind the carpeted area near the hatch opening all the right side panel towards the center of the vehicle and remove all the left side panel towards the center of the vehicle while disconnecting the wiring to the rear cargo lamps and remove using a ten millimeters socket and trim to remove the cooling duct work from the right side of the battery pack using a twelve millimeter socket remove the bolts securing the bracing for the battery and the side panels as well as the five bolts securing the battery to the floor of the vehicle remove the battery vent hose from the right side of the battery pack what on your high voltage blah using a ten millimeters socket remove the three bolts and two nuts securing the electronics cover to the left side of the battery pack carefully remove the cover by pulling straight up being careful not to distort the cover remove the cable shield wire connector and retain for use with the new battery using a cat re rated volt meter check or voltage across the two terminals to which the orange cables are connected if the voltage at this point is below thirty full it is safe to remove your gloves Intel reinstalling the new battery using an eight millimeter sock removed and retain you nuts securing the cables to the battery live the cables from the battery pack and hope behind to the left seat hinge to prevent damage while removing the battery remove the small wiring connectors from the left rear of the battery pack and disengage the flip securing the hardest to the lower corner of the battery case reinstall the electronics cover on the old battery pack two people are required to safely lift the battery pack from the vehicle wearing mechanics loves due to sharp edges on the battery pack lift up and towards the rear of the vehicle and remove the battery through the rear hatch opening up the vehicle reverse this process to reinstall paying close attention to the following when reinstalling the high voltage safety disconnect at the end of the installation procedure make sure you push the device in while flipping the handle on once the handle is all the way up push straight down on the handle which should travel about one half of an inch downward to engage a safety switch and locked the handle in place once the installation is complete please use the following procedures when packing the original battery core for return shipment in credit the battery core must be intact and returned in the shipping container provided with the replacement battery the core must be the same part type an application as the purchased replacement unit do not right on the shipping container and finally contact the place of purchase for core credit in shipping instructions for technical support visit W. W. W. dot Dorman products dot com or call eight six six nine three three two nine one one this video is for general information purposes only Dorman products incorporated makes no representations or warranties oral or written expressed or implied regarding the information contained in this video you are responsible for consulting and complying with all state and federal laws please consult with an ASC certified automotive professional before any automotive repairs the entire risk as to the results and the performance of the information contained in this video is assumed by the viewer and in no event shall Dorman products incorporated or its customers be liable for any consequential incidental special or direct damages suffered in the course of using the information in this video