- Safety and preparation
- Wear safety glasses, chemical-resistant gloves and old clothes. Car batteries contain sulfuric acid and can spit sparks; eye and hand protection prevent burns and cuts.
- Work in a well-ventilated, non-smoking area away from open flames. Batteries can emit hydrogen gas.
- Park on level ground, engage parking brake, turn ignition and all accessories off and remove keys.
- Have a wheel chock or block to prevent vehicle movement if needed.

- Tools you need (detailed descriptions and how to use each)
- Ratchet handle and socket set (common sizes: 10 mm, 12 mm, 13 mm; Hilux commonly uses 10–13 mm nuts)
- Description: a hand tool with removable sockets that fit over nuts/bolts.
- How to use: pick the socket that fits snugly on the battery clamp or hold-down nut, attach to ratchet, turn counterclockwise to loosen, clockwise to tighten. Use short, steady strokes to avoid slipping.
- Combination wrench set (open-end + box-end wrenches, same sizes as sockets)
- Description: hand wrenches for nuts where a ratchet won’t fit.
- How to use: slide box or open end over nut, pull to loosen/tighten. Use the box end for better grip on rounded nuts.
- Battery terminal puller (optional but recommended if terminals are stuck)
- Description: a clamp-style puller that presses the terminal off the battery post evenly.
- How to use: fit the puller over the terminal, turn the center bolt to press the terminal straight off the post. Prevents damage to terminal/clamp.
- Wire brush / battery terminal cleaner
- Description: round brushes sized for battery posts and a wire-bristle brush for clamps.
- How to use: after removing terminals, brush battery posts and inside of clamps to remove corrosion. Rotate brush while applying light pressure.
- Baking soda and water solution + small brush or rag
- Description: baking soda neutralizes acid; water rinses.
- How to use: mix a tablespoon baking soda in a cup of water, apply to corroded areas, brush gently, then wipe and dry. Avoid electrical connectors until dry.
- Terminal protector spray or petroleum jelly
- Description: protective coating that prevents corrosion after installation.
- How to use: coat clean terminals/clamps lightly after installation.
- Multimeter (digital)
- Description: measures voltage and verifies battery charge/state.
- How to use: set to DC volts (20V range), place red lead to positive post, black lead to negative post. ~12.6–12.8 V = fully charged; ~12.0 V = low; <11.8 V = discharged.
- Battery lift strap or two-person lift
- Description: strap or hand-carrying method for safely lifting heavy batteries (15–25 kg typical).
- How to use: loop strap under battery and lift with your legs or lift with a helper to avoid dropping and minimize back strain.
- Torque wrench (optional, good practice)
- Description: wrench that tightens nuts to a set torque.
- How to use: set to recommended torque for clamp nuts (snug, usually low torque; if no spec, tighten until secure but not crushing terminals).
- Memory saver (optional)
- Description: plug-in device that keeps ECU power to retain radio presets, ECU adaptations, clock.
- How to use: connect to OBD port or 12V accessory socket before disconnecting battery; follow device instructions.
- Protective apron and absorbent rags (recommended)
- Description: keep clothes and work area clean and safe from acid spills.
- How to use: lay rags under battery tray to catch drips, wear apron to protect clothing.

- Step-by-step procedure (concise direct actions)
- Confirm replacement battery specs first: match physical size, terminal orientation (left/right), voltage (12V), and CCA (cold-cranking amps) at least equal to OEM. If your Hilux uses AGM or start/stop, buy the correct battery type.
- Use multimeter to check the existing battery voltage before removal to know its state.
- Put on gloves and eye protection. If using memory saver, connect it now.
- Locate the battery (usually under the hood on Hilux; some models may have it in the wheel well or under a cover). Remove any plastic covers using a screwdriver or trim tool.
- Disconnect negative terminal first (black, negative sign)
- Use the socket or wrench to loosen the nut on the negative clamp.
- Wiggle the clamp and pull upward. If stuck, use terminal puller or gently twist with pliers. Always remove negative first to reduce short risk.
- Disconnect positive terminal second (red, positive sign)
- Loosen nut and remove clamp. Keep clamps away from any metal parts (tuck with insulated material).
- Remove battery hold-down/clamp
- Use appropriate socket/wrench to remove the hold-down bolt(s). Keep hardware for reinstallation unless damaged.
- Lift battery out carefully using a lift strap or two people. Keep battery upright to avoid spilling.
- Inspect battery tray, clamps and cable ends
- Clean tray and surrounding area. Remove corrosion with baking soda solution then rinse with water and dry.
- Inspect cable insulation and copper strands. If frayed or heavily corroded, replace the cable or terminal ends (see replacement parts below).
- Clean terminals and posts
- Use the wire brush to clean posts and inside of clamps until shiny. Dry thoroughly.
- Install new battery
- Place new battery in tray with the correct orientation (terminals on correct sides).
- Refit hold-down/clamp and tighten securely (do not over-tighten or deform battery case).
- Connect positive terminal first
- Slide positive clamp onto positive post and tighten nut until clamp is snug. Do not over-tighten.
- Connect negative terminal second
- Attach clamp and tighten snugly.
- Apply terminal protector or a light coat of petroleum jelly to terminals and clamps.
- Start engine to verify correct installation. Check dash warning lights. Verify accessories and clock/radio settings; if using a memory saver, disconnect it now.
- Use multimeter to confirm system voltage with engine off (~12.6 V) and with engine running (~13.8–14.6 V indicating charging).

- When extra tools are required and why
- Terminal puller: required if terminals are seized to avoid damaging clamps or posts.
- Torque wrench: required if you want to tighten nuts to a specific torque and avoid crushing terminals or loose connections.
- Battery charger or load tester: required if you want to verify old battery capacity before replacing or to charge a low-but-salvageable battery.
- Cable crimper and replacement terminals: required if cable ends are corroded/frayed and need replacement; clean crimps give reliable connections.
- Replacement negative battery sensor/BMS (if fitted): required if the vehicle has an intelligent battery sensor on the negative cable and it is damaged or the ECU reports sensor faults. Some Hilux models use a sensor that must be re-installed correctly.

- Parts that commonly need replacement and why
- Battery (obvious if old/weak/fails CCA or won’t hold charge)
- What to buy: 12V battery matching OEM dimensions and terminal layout, CCA at least OEM spec. If your Hilux uses AGM or Enhanced Flooded Battery (EFB), buy the correct type.
- Why: worn cells reduce cranking ability and reliability; replacement restores starting and charging performance.
- Battery hold-down clamp or bracket
- Why: if bent, corroded or missing; a secure hold prevents battery movement and connector stress.
- Battery cable ends or entire battery cables
- Why: corrosion or frayed wires reduce conductivity, cause starting and charging issues; replacing ensures low-resistance connection.
- Battery tray or insulating pad
- Why: corroded or damaged tray can trap acid and degrade new battery; replace if heavily rusted.
- Intelligent Battery Sensor / Battery Monitoring Sensor (BMS/IBS)
- Why: some vehicles track battery condition. A faulty sensor causes charging errors or ECU faults and may need replacement by part number for your model year.
- Fusible links or main fuses (rare)
- Why: if short occurred or cables were forced and blew a main fuse; replace with correct amp rating only.

- Testing and verification after replacement
- Multimeter check: battery off ~12.6 V, engine running ~13.8–14.6 V.
- Load-test or have shop test new battery if in doubt.
- Check for dash warning lights, ABS/airbag or charging system warnings; if present, confirm connectors and sensors are connected; clearance may require scan tool to reset codes.
- Verify that radio presets, clock and window auto-functions work (reset if needed).

- Battery disposal and environmental notes
- Return old battery to the retailer or a recycling center; most places accept used lead-acid batteries and may give a core credit.
- Never throw a battery in general waste. Acid and lead are hazardous.

- Quick troubleshooting pointers
- If vehicle won’t crank after install: check terminal tightness, battery orientation, main fuses and battery ground connection.
- If charging light stays on: check alternator belt, alternator connections, BMS sensor and fuses.

- Short checklist to buy before starting
- Correct replacement battery (match size, terminal side, CCA, type)
- Socket/ratchet set (10–13 mm), combination wrenches
- Wire brush/terminal cleaner, baking soda, rags
- Terminal protector or petroleum jelly
- Multimeter
- Terminal puller, gloves, eye protection
- Optional: memory saver, torque wrench, cable-repair kit

- Final notes (practical tips)
- Always disconnect negative first, connect negative last.
- Lift with your legs or use two people — batteries are heavy.
- If unsure about battery type (AGM vs conventional) or presence of battery sensor, match the OEM battery specification in the owner’s manual or purchase through a reputable parts supplier for your specific Hilux year/model.

No questions.
rteeqp73

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