OEM hybrid battery swap - how to swap electronics

ChrisFix have a good one in YouTube.. Did you check that? He was changing the cells, but the electronics parts should be visible?

How many miles on the original one?

Here in Dallas area, there is a company comes to home and replace it with OEM battery for $2200 and they give 5 year warranty also.

 

Wiring harness and bus bars come already installed on a new OEM pack... You just unbolt the relays and sensors and ecu from the old pack chassis and botl it to new pack chasis and plug everything in. Usually takes me 2.25 hours from start to finish.

As for holding voltage after orange safety plug is out, it's wise to be cautious when you're new to it, but once that circuit is broken by removing orange plug its safe to handle. To confirm, measure this voltage with a multi tester on the battery side of the relays.

 

There were a couple of long wires that were included and had to be installed, trying to remember... I think it was the ones that go to the safety latch. Had to buy a very low value torque wrench to put those couple of nuts on.

I suggest the OP take careful pictures of the electronics area from every possible angle for reference. Also of the top of the pack, as the rubber tube thing needs to be moved as well. Then take careful notes on how the wires are routed into and through the electronics area. It wasn't that complicated, just move everything from one pack to the other and put it all back together the way it was in the first. But having noted where all the wires go first is important.

I would also suggest getting a set of JIS bits ahead of time and use them to open the ECU and inspect the inside for corrosion, which will be at the wiring connectors. I didn't have any JIS bits at the time and the Philips head bits and screwdrivers did not fit right, so I gave up rather than risk stripping the screw heads.