2006 Prius Hybrid Battery Service Plug

i can't remember, but sometimes you have to push it a few times, or hold it in for so many seconds

 

When you're putting the plug back in is receptacle and the last step where you push it down to lock it in and engage the little two-pin locating plug that's actually on the plug that you had out the orange piece generally you need to slam it down pretty hard almost to the point where it hurts your finger so that that last connection is made well you can read about other people that had to do the same thing I don't know if it just needs a little bit of electrical grease or something but slamming it down seems to work the best I haven't broken one yet.

 

Doing the rear struts, well, you will be kind of "around" the battery, but I don't believe you're going to take any of its covers off, or see the ends of any orange cables. Under those circumstances, pulling the service plug would probably be the closest your mitts get to high voltage in the entire job. (And, in fact, if you look in the repair manual, Toyota does direct you to glove up before operating that plug.) The battery and orange cables just sitting there are not going to mess with you if you don't mess with them.

 

When you're putting the service plug back- 1)push the plug in, 2)swing the lever in, 3)slide the lever down

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+1 to ChapmanF's post. No need to remove the service plug, therefore no issues related to doing that.

Just forget about anything to do with the battery and just get on with replacing the struts.

No need to make this job more complicated than it needs to be.

 

Number #1 problem people have when working on a battery pack is not fully locking in place the Orange plug when they're done and then they freak out. So make sure you know that the plug is not locked into place after swinging the orange lever into place. It also has to slide down to lock it.

 

Also, if that lever is not fully slid into place, the car will give you a specific trouble code, P0A0D, that exactly means "say, I am not starting because you have left one of the safety interlocks open." So if you see that code, instead of freaking out, you go right back to that lever and click it.

Moral: those who have a decent scan tool and read trouble codes are able to remain calm where others might freak out.

 

Yes, but knowledgeable people who always remain calm are usually kinda dead inside...

 

While in there, you might want to clean up the HV battery fan.