HV BATTERY STACK INSTALLATION

PROCEDURE


  1. INSTALL NO. 9 HYBRID BATTERY INTAKE DUCT

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004AV1

      Install the No. 9 hybrid battery intake duct.

  2. INSTALL NO. 2 HV SUPPLY STACK SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004CRW

      Install the HV supply stack sub-assembly No. 2 with the 4 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    2. Attach the clamp.

  3. INSTALL NO. 2 HV BATTERY PACK WIRE

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004CJ3

      Attach the clamp and install the No. 2 HV battery pack wire.

  4. INSTALL NO. 7 HV BATTERY SHIELD SUB-ASSEMBLY (for Lower Side)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004BTP

      Install the No. 7 HV battery shield sub-assembly and wire harness clamp bracket with the 2 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    2. Attach the 7 clamps.

    3. Connect the connector.

      Note

      Make sure that the connector is connected securely.

  5. INSTALL BATTERY VOLTAGE SENSOR (for Lower Side)

    Click here

  6. INSTALL UPPER HV BATTERY CARRIER SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B000T7LN01

      Install the upper HV battery carrier sub-assembly.

    2. While pressing the upper HV battery carrier sub-assembly downwards, tighten the 7 bolts and 6 nuts in the order shown in the illustration.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

      Note

      After installing, check that the upper HV battery carrier sub-assembly is properly installed.

      Tech Tips


      • An elastic body for resonance countermeasures with the No. 2 HV supply stack sub-assembly exists in the center of the No. 7 HV battery shield sub-assembly and generates a reactive force by being squashed by the upper HV battery carrier sub-assembly.

      • Install the upper HV battery carrier sub-assembly while pressing downwards with 475 to 517 N (48 to 53 kgf, 106.8 to 116.2 lbf).

  7. INSTALL HV BATTERY JUNCTION BLOCK ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004AD4

      Install the HV battery junction block assembly with the 4 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

      Note


      • Do not drop the HV battery junction block assembly, strike it with tools or subject it to impact.

      • If the HV battery junction block assembly is subjected to an impact, replace it with a new one.

    2. Connect the 3 connectors.

      Note

      Make sure that the connector is connected securely.

  8. INSTALL NO. 6 HYBRID BATTERY INTAKE DUCT

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004B29

      Install the No. 6 hybrid battery intake duct.

    2. Connect the HV battery intake air temperature sensor.

    3. Attach the 2 clamps.

  9. INSTALL BATTERY COOLING BLOWER ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004BUJ

      Connect the 2 fittings on the No. 6 hybrid battery intake duct and install the battery cooling blower assembly.

    2. Install the 2 bolts and nut.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  10. INSTALL WIRE HARNESS CLAMP BRACKET

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004C7F

      Install the wire harness clamp bracket with the 4 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    2. Attach the 8 clamps.

  11. INSTALL NO. 8 HYBRID BATTERY INTAKE DUCT

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004CQP

      Install the No. 8 hybrid battery intake duct.

  12. INSTALL NO. 1 HV SUPPLY STACK SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004CFM

      Install the No. 1 HV supply stack sub-assembly with the 4 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    2. B004BGX

      Install the nut.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    3. Attach the 6 clamps.

    4. Connect the 2 connectors.

      Note

      Make sure that the connector is connected securely.

  13. INSTALL NO. 7 HV BATTERY SHIELD SUB-ASSEMBLY (for Upper Side)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004AQY

      Install the No. 7 HV battery shield sub-assembly and wire harness clamp bracket with the 2 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    2. Attach the 9 clamps.

    3. Connect the connector.

      Note

      Make sure that the connector is connected securely.

  14. INSTALL BATTERY ECU ASSEMBLY

    Click here

  15. INSTALL BATTERY VOLTAGE SENSOR (for Upper Side)

    Click here

  16. INSTALL NO. 1 HYBRID BATTERY EXHAUST DUCT

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004CIG

      Attach the guide and install the No. 1 hybrid battery exhaust duct.

  17. INSTALL UPPER NO. 1 HYBRID BATTERY COVER SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B000RWXN01

      Install the upper No. 1 hybrid battery cover sub-assembly.

    2. While pressing the upper No. 1 hybrid battery cover sub-assembly downwards, tighten the 4 bolts and 4 nuts in the order shown in the illustration.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

      Note

      After installing, check that the upper No. 1 hybrid battery cover sub-assembly is properly installed.

      Tech Tips


      • An elastic body for resonance countermeasures with the No. 1 HV supply stack sub-assembly exists in the center of the No. 7 HV battery shield sub-assembly and generates a reactive force by being squashed by the upper No. 1 hybrid battery cover sub-assembly.

      • Install the upper No. 1 hybrid battery cover sub-assembly while pressing downwards with 426 N (43 kgf, 95.8 lbf) or more.

  18. INSTALL HYBRID BATTERY TERMINAL BLOCK

    Click here

  19. INSTALL NO. 1 HYBRID BATTERY SHIELD SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004B7J

      Install the No. 1 hybrid battery shield sub-assembly with the 4 bolts and 2 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  20. INSTALL NO. 2 HYBRID BATTERY SHIELD SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004BUS

      Install the No. 2 hybrid battery shield sub-assembly with the 4 bolts and 2 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    2. Attach the 2 clamps.

  21. INSTALL UPPER HV BATTERY COVER PANEL

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004B31

      Install the upper HV battery cover panel with the 8 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  22. INSTALL HV BATTERY ASSEMBLY

    Click here

  23. PERFORM UTILITY

    Note


    • Perform "Battery Status Info Update" after replacing a malfunctioning HV supply stack sub-assembly.

      Click here

    • Perform "Prediagnostic Battery Charge" after replacing a malfunctioning HV supply stack sub-assembly.

      Click here

    • Perform "Battery Diagnosis" after replacing a malfunctioning HV supply stack sub-assembly.

      Click here