HV BATTERY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:


  • When disposing of an HV battery, make sure to return it through an authorized collection agent who is capable of handling it safely. If the HV battery is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.

  • Accidents such as electric shock may result if the HV battery is disposed of improperly or abandoned. Therefore, make sure to return all HV batteries through an authorized collection agent.

  • After removing the HV battery, keep it away from water. Exposure to water may cause the HV battery to produce heat, resulting in a fire.

PROCEDURE


  1. PRECAUTION

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  2. CHECK FOR DTC


    1. Check for DTC.

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      Note

      Confirm that P0AA6 (Hybrid Battery Voltage System Isolation Fault) is not output before removing or installing the HV battery. If this DTC is output, perform troubleshooting for this DTC first.

  3. REMOVE SERVICE PLUG GRIP

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  4. REMOVE CONNECTOR COVER ASSEMBLY

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  5. CHECK TERMINAL VOLTAGE

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  6. INSTALL CONNECTOR COVER ASSEMBLY

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  7. REMOVE FRONT LUGGAGE COMPARTMENT TRIM COVER

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  8. REMOVE REAR LUGGAGE COMPARTMENT TRIM COVER

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  9. REMOVE REAR SEAT ASSEMBLY

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  10. REMOVE REAR SEAT SUB FLOOR PANEL

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  11. REMOVE NO. 1 ROOM PARTITION COVER

    Tech Tips

    Use the same procedure as for the No. 2 room partition cover.

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  12. REMOVE NO. 2 ROOM PARTITION COVER

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  13. REMOVE NO. 1 LUGGAGE COMPARTMENT LAMP ASSEMBLY

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  14. REMOVE FRONT UPPER LUGGAGE COMPARTMENT TRIM COVER

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  15. REMOVE ROPE HOOK ASSEMBLY (for LH Side)

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  16. REMOVE LUGGAGE COMPARTMENT TRIM COVER LH (for LH Side)

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  17. REMOVE ROPE HOOK ASSEMBLY (for RH Side)

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  18. REMOVE LUGGAGE COMPARTMENT TRIM COVER RH (for RH Side)

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  19. REMOVE REAR NO. 1 FLOOR CROSSMEMBER BRACE RH


    1. B004F8P

      Remove the 2 bolts, 2 nuts and rear No. 1 floor crossmember brace RH.

  20. REMOVE REAR NO. 1 FLOOR CROSSMEMBER BRACE LH

    B004EM7

    1. Disengage the clamp.

    2. Remove the 2 bolts, 2 nuts and rear No. 1 floor crossmember brace LH.

  21. REMOVE NO. 4 HV BATTERY SHIELD PANEL

    CAUTION:

    Wear insulated gloves.


    1. B004GIUC02
      *1 Service Plug Grip
      *2 Battery Cover Lock Striker
      *a Projection
      *b Button
      *c Turn

      Using the service plug grip, remove the battery cover lock striker from the No. 4 HV battery shield panel.

      Tech Tips

      Insert the projection of the service plug grip and turn the button of the battery cover lock striker counterclockwise to release the lock.

    2. B004E5S

      Remove the 4 nuts and No. 4 HV battery shield panel.

  22. DISCONNECT FRAME WIRE

    CAUTION:

    Wear insulated gloves.


    1. B004GNY

      Remove the earth terminal from the upper No. 1 hybrid battery cover sub-assembly.

    2. B004FXC

      Disengage the 2 clamps.

    3. Disconnect the 2 frame wire connectors from the hybrid battery terminal block.

      Note

      Insulate the disconnected connectors with insulating tape.

  23. SEPARATE NO. 3 HYBRID BATTERY INTAKE DUCT

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  24. REMOVE NO. 4 HYBRID BATTERY INTAKE DUCT

    CAUTION:

    Wear insulated gloves.


    1. B004FIK

      Remove the 2 clips and No. 4 hybrid battery intake duct with No. 3 hybrid battery intake duct from the HV battery.

  25. REMOVE NO. 3 HYBRID BATTERY INTAKE DUCT


    1. B004GTG

      Remove the No. 3 hybrid battery intake duct from the No. 4 hybrid battery intake duct.

  26. REMOVE NO. 1 FLOOR UNDER COVER ASSEMBLY


    1. B004GRKN02

      Remove the 4 clips (A).

    2. Disengage the 6 clips (B) to remove the No. 1 floor under cover assembly.

  27. REMOVE HV BATTERY

    CAUTION:

    Wear insulated gloves.


    1. B004EX9

      Remove the 2 grommets.

    2. Remove the 2 battery drain plugs as indicated by the arrows, in the order shown in the illustration.

      B004EOUC02
      *a Push the battery drain plug toward the front of the vehicle. *b While pushing the battery drain plug, disengage the rear claw.
      *c Remove the battery drain plug. - -

      Note


      • If a claw or the waterproofing rubber is damaged, replace the battery drain plug with a new one.

      • If the drain valve is clogged, replace the battery drain plug with a new one.

      B004E7NC01
      *a Claw
      *b Waterproofing Rubber
      *c Drain Valve
    3. B004GSP

      Remove the 4 bolts.

    4. B004GLL

      Disconnect the HV battery connector.

    5. B004E87

      Remove the 2 bolts.

    6. B004FQTC01
      *a Areas to be Held

      Hold the areas shown in the illustration and remove the HV battery.

      Note


      • To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.

      • Use cardboard or other similar material to protect the HV battery and vehicle body from damage.

      • Since the HV battery is very heavy, 2 people are needed to remove the HV battery. When removing the HV battery, do not damage the parts around it.

      • When removing the HV battery from the vehicle, do not allow it to contact the vehicle.

      • When removing/installing/moving the HV battery, make sure not to tilt it more than 80°.

      • When moving the HV battery, make sure to use an engine lifter.

      Tech Tips

      Attach tape to the feet and edges of the HV battery to protect tools and the vehicle body.

    7. B004GN1C01
      *a Attachment

      Place the HV battery on attachments.

    8. B004FXEC01
      *1 Front Hybrid Battery Guide (Yellow)
      *2 Rear Hybrid Battery Guide (White)

      Remove the front hybrid battery guide and rear hybrid battery guide from the HV battery.

  28. REMOVE UPPER NO. 1 HYBRID BATTERY COVER SUB-ASSEMBLY

    CAUTION:

    Wear insulated gloves.


    1. B004E8I

      Remove the 13 nuts and upper No. 1 hybrid battery cover sub-assembly from the HV battery.

  29. REMOVE BATTERY VOLTAGE SENSOR

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  30. REMOVE UPPER NO. 5 HV BATTERY CARRIER BRACKET

    CAUTION:

    Wear insulated gloves.


    1. B004FZQ

      Remove the 4 nuts and upper No. 5 HV battery carrier bracket from the HV battery.

  31. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY

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  32. REMOVE UPPER NO. 6 HV BATTERY CARRIER BRACKET

    CAUTION:

    Wear insulated gloves.


    1. B004G0G

      Remove the 4 nuts and upper No. 6 HV battery carrier bracket from the HV battery.

  33. REMOVE UPPER NO. 3 HV BATTERY CARRIER BRACKET

    CAUTION:

    Wear insulated gloves.


    1. B004GPU

      Disconnect the EV battery plug connector.

    2. Remove the bolt and EV battery plug from the upper No. 3 HV battery carrier bracket as shown in the illustration.

    3. B004E5T

      Remove the 2 nuts and upper No. 3 HV battery carrier bracket from the HV battery.