HV BATTERY STACK REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during HV battery stack removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedure Effect/Inoperative when not Performed Link

  • Battery ECU assembly

  • HV battery junction block assembly

 Perform current sensor offset learning DTCs are stored

Click here

Hybrid battery terminal block Perform high voltage fuse accumulated load history reset DTCs are output

Click here


  • No. 1 HV supply stack sub-assembly

  • No. 2 HV supply stack sub-assembly

  • Prediagnostic battery charge

  • Battery diagnosis

  • Battery status info update

 Warning light illumination
Disconnect cable from negative auxiliary battery terminal Memorize steering angle neutral point LKA/LDA system (for Mono camera type)

for Stereo Camera type: Click here

for Mono Camera type: Click here

Lane control system (for Stereo camera type)
Parking support brake system*
Pre-collision system (for Mono camera type)
Pre-collision system (for Stereo camera type)
Adaptive high beam system

    Lighting system (EXT)

  • Cornering lights
Variable gear ratio steering system

Click here

Parking assist monitor system

Click here

Panoramic view monitor system

Click here

Initialize rear door sunshade system Rear door sunshade system

Click here

Initialize power trunk lid system Power trunk lid system

Click here

HV battery

  • Prediagnostic battery charge

  • Battery diagnosis

  • Battery status info update

 Warning light illumination

Click here

DRS ECU (rear steering control ECU) Perform neutral position memorization and motor rotation angle sensor calibration

  • Dynamic rear steering system

  • Steering wheel off-center

  • DTCs are output

Click here


    for LHD:

  • No.1 seat reclining adjuster assembly RH (Including removal and installation)


    for RHD:

  • No.1 seat reclining adjuster assembly LH (Including removal and installation)

 Initialize position control ECU Rear power seat control system

Click here

*: When performing learning using the GTS.
Click here Click here

CAUTION:


  • B004YIH

    Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.

    Click here

  • B004STG

    To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.

  • The hybrid system has high-voltage circuits. Accidents, such as electric shock, or electric leaks may result if the hybrid system is not operated in a correct manner. Make sure to follow the correct procedure.

  • When disposing of an HV battery assembly or hybrid vehicle supply stack sub-assembly, make sure to return them through an authorized collection agent who is capable of handling them safely.

  • Before returning an HV battery assembly, make sure to perform a recovery inspection.

  • Before returning an HV supply stack sub-assembly, make sure to perform a recovery inspection.

  • Make a note of the output DTCs as some of them may be necessary for "Recovery Inspection" of the HV battery assembly and HV supply stack sub-assemblies.

Note

When replacing the No. 1 hybrid vehicle supply stack sub-assembly or No. 2 hybrid vehicle supply stack sub-assembly, it is necessary to check, adjust and equalize the SOC of the HV battery. Otherwise, the engine may run longer than normal, resulting in a decrease in fuel efficiency.

Click here

PROCEDURE


  1. READ VALUE USING TECHSTREAM


    1. Connect the Techstream to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / HV Battery / Data List / Hybrid Battery Temperature 1 to 6.


      Powertrain > HV Battery > Data List
      Tester Display
      Hybrid Battery Temperature 1
      Hybrid Battery Temperature 2
      Hybrid Battery Temperature 3
      Hybrid Battery Temperature 4
      Hybrid Battery Temperature 5
      Hybrid Battery Temperature 6

    4. Read the Data List.

      Note

      If any of the temperatures listed in "Hybrid Battery Temperature 1 to 6" are 50°C or more, leave the vehicle until the temperature drops to less than 50°C.

  2. PRECAUTION

    Click here

  3. REMOVE HV BATTERY ASSEMBLY

    Click here

  4. REMOVE UPPER HV BATTERY COVER PANEL

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004UNU

      Remove the 8 nuts and upper HV battery cover panel.

  5. REMOVE NO. 2 HYBRID BATTERY SHIELD SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004UDQ

      Detach the 2 clamps.

    2. Remove the 4 bolts, 2 nuts and No. 2 hybrid battery shield sub-assembly.

  6. REMOVE NO. 1 HYBRID BATTERY SHIELD SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004R84

      Remove the 4 bolts, 2 nuts and No. 1 hybrid battery shield sub-assembly.

  7. REMOVE HYBRID BATTERY TERMINAL BLOCK

    Click here

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

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004Y4N

      Remove the 4 bolts, 4 nuts and upper No. 1 hybrid battery cover sub-assembly.

  9. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004SJ9

      Detach the guide and remove the No. 1 hybrid battery exhaust duct.

  10. REMOVE BATTERY VOLTAGE SENSOR (for Upper Side)

    Click here

  11. REMOVE BATTERY ECU ASSEMBLY

    Click here

  12. REMOVE NO. 7 HV BATTERY SHIELD SUB-ASSEMBLY (for Upper Side)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004R4E

      Disconnect the connector.

    2. Detach the 9 clamps.

    3. Remove the 2 nuts, No. 7 HV battery shield sub-assembly and wire harness clamp bracket.

  13. REMOVE NO. 1 HV SUPPLY STACK SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004TMI

      Disconnect the 2 connectors.

      Note

      Insulate the disconnected connectors with insulating tape.

    2. Detach the 6 clamps.

    3. Remove the nut.

    4. B004XZS

      Remove the 4 nuts and No. 1 HV supply stack sub-assembly.

  14. REMOVE NO. 8 HYBRID BATTERY INTAKE DUCT

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004Y66

      Remove the No. 8 hybrid battery intake duct.

  15. REMOVE WIRE HARNESS CLAMP BRACKET

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004TY9

      Detach the 8 clamps.

    2. Remove the 4 nuts and wire harness clamp bracket.

  16. REMOVE BATTERY COOLING BLOWER ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004UDP

      Remove the 2 bolts and nut.

    2. Disconnect the 2 fittings on the No. 6 hybrid battery intake duct and remove the battery cooling blower assembly.

  17. REMOVE NO. 6 HYBRID BATTERY INTAKE DUCT

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004UKL

      Detach the 2 clamps.

    2. Disconnect the HV battery intake air temperature sensor.

    3. Remove the No. 6 hybrid battery intake duct.

  18. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004SLL

      Disconnect the 3 connectors.

      Note

      Insulate the disconnected connectors with insulating tape.

    2. Remove the 4 nuts and HV battery junction block assembly.

      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.

  19. REMOVE UPPER HV BATTERY CARRIER SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004RO4

      Remove the 7 bolts, 6 nuts and upper HV battery carrier sub-assembly.

  20. REMOVE BATTERY VOLTAGE SENSOR (for Lower Side)

    Click here

  21. REMOVE NO. 7 HV BATTERY SHIELD SUB-ASSEMBLY (for Lower Side)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004VEF

      Disconnect the connector.

    2. Detach the 7 clamps.

    3. Remove the 2 nuts, No. 7 HV battery shield sub-assembly and wire harness clamp bracket.

  22. REMOVE NO. 2 HV BATTERY PACK WIRE

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004YKJ

      Detach the clamp and remove the No. 2 HV battery pack wire.

  23. REMOVE NO. 2 HV SUPPLY STACK SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004X64

      Detach the clamp.

    2. Remove the 4 nuts and No. 2 HV supply stack sub-assembly.

  24. REMOVE NO. 9 HYBRID BATTERY INTAKE DUCT

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004Y7P

      Remove the No. 9 hybrid battery intake duct.

  25. PERFORM RECOVERY INSPECTION


    1. Before returning the HV supply stack sub-assembly, make sure to perform a recovery inspection.

      Click here