Click here

HV BATTERY REMOVAL

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Click here Click here
  1. Click here

    READ OUTPUT DTC


    1. Check for DTCs (Click here).

      Note:

      Confirm that P0AA6 (Hybrid Battery Voltage System Isolation Fault) is not output before performing removal or installation work on the internal parts of the battery. If the DTC is output, perform troubleshooting procedures first.

  2. Click here

    REMOVE LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY (w/ Spare Tire)

  3. Click here

    REMOVE DECK BOARD ASSEMBLY (w/o Spare Tire)

  4. Click here

    REMOVE DECK TRIM SIDE BOARD LH (w/o Spare Tire)


    1. A01GXQQ

      Detach the 2 clips and remove the deck trim side board LH.

  5. Click here

    REMOVE BATTERY SERVICE HOLE COVER LH


    1. A01GZIME02

      Detach the clip, fastening tape and remove the battery service hole cover LH.

      Table 1. Text in Illustration
      *A for Standard
      *B for Ottoman
      *1 Fastening Tape
  6. Click here

    PRECAUTION

    Note:

    After turning the power switch off, waiting time may be required before disconnecting the cable from the auxiliary battery negative (-) terminal. Therefore, make sure to read the disconnecting the cable from the auxiliary battery negative (-) terminal notices before proceeding with work (Click here).

  7. Click here

    DISCONNECT AUXILIARY BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).

    Tip:

    Both cables should be disconnected to prevent the AMD terminal from shorting to ground.

  8. Click here

    REMOVE REAR SEAT LOWER CONSOLE BOX COVER (for 4-Passenger with Ottoman)


    1. A01GYU2

      Using a screwdriver, detach the 4 claws, then detach the 2 hooks and remove the rear seat lower console box cover.

      Tip:

      Tape the screwdriver tip before use.

  9. Click here

    REMOVE ARMREST DOOR CAP (except 4-Passenger with Ottoman)


    1. Using a thin-bladed screwdriver, detach the 6 claws.

      Tip:

      Tape the screwdriver tip before use.

    2. Detach the 2 hooks and remove the armrest door cap.

  10. Click here

    REMOVE SERVICE PLUG COVER


    1. Remove the 4 bolts and service plug cover.

  11. Click here

    REMOVE SERVICE PLUG GRIP

    CAUTION:

    • Remove the service plug grip to interrupt a high voltage circuit at the time of the check.

    • Keep the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.

    • All the high voltage wiring connectors are orange colored.


    1. Wear insulated gloves. Slide the service plug grip upward, turn the lever downward, and then remove the service plug grip.

      CAUTION:

      After disconnecting the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals.

      Note:

      Never turn the power switch on (READY) with the service plug grip removed as malfunctions may occur.

      Tip:

      Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

  12. Click here

    REMOVE COWL TOP VENTILATOR LOUVER RH (for LHD)


    1. A01GXQ9

      Remove the 4 clips and hood to cowl top seal.

    2. Remove the 6 clips and cowl top ventilator louver RH.

  13. Click here

    REMOVE COWL TOP VENTILATOR LOUVER LH (for RHD)


    1. A01GZEK

      Remove the 4 clips and hood to cowl top seal.

    2. Remove the 6 clips and cowl top ventilator louver LH.

  14. Click here

    REMOVE MOTOR CABLE COVER RH (for LHD)


    1. A01H000

      Remove the 2 clips and motor cable cover RH.

  15. Click here

    REMOVE MOTOR CABLE COVER LH (for RHD)


    1. A01H1LZ

      Remove the 2 clips and motor cable cover LH.

  16. Click here

    REMOVE INVERTER COVER ASSEMBLY RH (for LHD)


    1. A01GW7A

      Remove the 2 clips and inverter cover assembly RH.

  17. Click here

    REMOVE INVERTER COVER ASSEMBLY LH (for RHD)


    1. A01GZOK

      Remove the 2 clips and inverter cover assembly LH.

  18. Click here

    REMOVE CONNECTOR COVER ASSEMBLY (for LHD)

    CAUTION:

    Wear insulating gloves.


    1. A01GXYO

      Using an insulated tool, remove the 2 bolts and connector cover assembly.

      Note:

      • Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter.

      • Do not touch the high voltage connectors or terminals for 10 minutes after the service plug grip is removed.

  19. Click here

    REMOVE CONNECTOR COVER ASSEMBLY (for RHD)

    CAUTION:

    Wear insulating gloves.


    1. A01GX3O

      Using an insulated tool, remove the 2 bolts and connector cover assembly.

      Note:

      • Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter.

      • Do not touch the high voltage connectors or terminals for 10 minutes after the service plug grip is removed.

  20. Click here

    CHECK TERMINAL VOLTAGE (for LHD)

    CAUTION:

    Wear insulating gloves.


    1. A01H1SR

      Using the voltmeter, measure the voltage between the terminals of the 2 phase connectors.

      Standard voltage
      0 V
      Tip:

      Use measuring range of DC 750 V or more on the voltmeter.

  21. Click here

    CHECK TERMINAL VOLTAGE (for RHD)

    CAUTION:

    Wear insulating gloves.


    1. A01GX6G

      Using the voltmeter, measure the voltage between the terminals of the 2 phase connectors.

      Standard voltage
      0 V
      Tip:

      Use measuring range of DC 750 V or more on the voltmeter.

  22. Click here

    INSTALL CONNECTOR COVER ASSEMBLY (for LHD)

    CAUTION:

    Wear insulating gloves.


    1. A01GXYO

      Using an insulated tool, install the connector cover assembly with the 2 bolts.

      8.0 N*m 82 kgf*cm 71 in.*lbf
  23. Click here

    INSTALL CONNECTOR COVER ASSEMBLY (for RHD)

    CAUTION:

    Wear insulating gloves.


    1. A01GX3O

      Using an insulated tool, install the connector cover assembly with the 2 bolts.

      8.0 N*m 82 kgf*cm 71 in.*lbf
  24. Click here

    INSTALL INVERTER COVER ASSEMBLY RH (for LHD)


    1. A01GW7A

      Align the locating hole of the inverter cover assembly RH with the locating pin of the inverter with converter assembly. Set the inverter cover assembly RH to the inverter with converter assembly.

    2. Press the positions where the clips are to secure the inverter cover assembly RH to the inverter with converter assembly.

  25. Click here

    INSTALL INVERTER COVER ASSEMBLY LH (for RHD)


    1. A01GWCS

      Align the locating hole of the inverter cover assembly LH with the locating pin of the inverter with converter assembly. Set the inverter cover assembly LH to the inverter with converter assembly.

    2. Press the positions where the clips are to secure the inverter cover assembly LH to the inverter with converter assembly.

  26. Click here

    INSTALL MOTOR CABLE COVER RH (for LHD)


    1. A01H000

      Install the motor cable cover RH with the 2 clips.

  27. Click here

    INSTALL MOTOR CABLE COVER LH (for RHD)


    1. A01H1LZ

      Install the motor cable cover LH with the 2 clips.

  28. Click here

    INSTALL COWL TOP VENTILATOR LOUVER RH (for LHD)


    1. A01GXQ9

      Install the hood to cowl top seal with the 4 clips.

    2. Install the cowl top ventilator louver RH with the 6 clips.

  29. Click here

    INSTALL COWL TOP VENTILATOR LOUVER LH (for RHD)


    1. A01GZEK

      Install the hood to cowl top seal with the 4 clips.

    2. Install the cowl top ventilator louver LH with the 6 clips.

  30. Click here

    REMOVE REAR SEAT ASSEMBLY (for Fixed Seat Type)

    (Click here)

  31. Click here

    REMOVE REAR SEAT ASSEMBLY (for Power Seat)

    (Click here)

  32. Click here

    REMOVE REAR SEAT ASSEMBLY (for Ottoman)

    (Click here)

  33. Click here

    REMOVE REAR COOLER UNIT (w/ Rear Air Conditioning System)

    (Click here)

  34. Click here

    REMOVE REAR COOLER UNIT (w/o Rear Air Conditioning System)

    (Click here)

  35. Click here

    REMOVE NO. 1 CENTER FLOOR TO BRACE EXTENSION


    1. Remove the 3 clips and No. 1 center floor to brace extension.

  36. Click here

    REMOVE NO. 2 CENTER FLOOR TO BRACE EXTENSION


    1. Remove the 3 clips and No. 2 center floor to brace extension.

  37. Click here

    REMOVE REAR SEAT CONSOLE BOX LOWER BRACKET


    1. Remove the 6 bolts and rear seat console box lower bracket.

  38. Click here

    REMOVE HOLE PLUG


    1. Remove the 2 hole plugs.

  39. Click here

    REMOVE NO. 2 HYBRID BATTERY SHIELD SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


    1. Using the service plug grip, release the battery cover lock striker.

      Table 2. Text in Illustration
      *1 Battery Cover Lock Striker
      *2 Service Plug Grip

    2. Remove the 2 nuts and disconnect the No. 2 HV battery shield sub-assembly from the HV battery.

  40. Click here

    DISCONNECT FRAME WIRE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Remove the 2 nuts and disconnect the frame wire from the HV battery.

      Note:

      Insulate the terminals of the removed high voltage wire with insulating tape.

    2. A01H0IH

      Remove the battery shield contact from the HV battery.

  41. Click here

    REMOVE BATTERY ROOM VENTILATION HOSE


    1. A01H0LR

      Remove the grommet and battery room ventilation hose from the floor.

  42. Click here

    REMOVE LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY (w/o Spare Tire)

  43. Click here

    REMOVE TOOL BOX (w/o Spare Tire)


    1. A01H04I

      Remove the 2 clips and tool box.

  44. Click here

    REMOVE SPARE WHEEL GUARD SUB-ASSEMBLY (w/ Spare Tire)


    1. Remove the 2 clips and spare wheel guard sub-assembly.

  45. Click here

    REMOVE SPARE WHEEL GUARD SUB-ASSEMBLY (w/o Spare Tire)

  46. Click here

    DISCONNECT HV BATTERY

    CAUTION:

    Be sure to wear insulated gloves.


    1. Remove the 2 nuts.

    2. Detach the claw and remove the wire harness protector.

    3. A01H1R9

      Detach the 3 claws and remove the upper relay block cover.

    4. A01GXJF

      Detach the 2 claws and disconnect the connector.

    5. Remove the 3 nuts and disconnect the No. 4 luggage room wire and hybrid vehicle converter power supply wire from the fusible link block assembly.

      Note:

      Insulate the terminals of the removed wire with insulating tape to prevent a short to body ground.

    6. A01H0N6

      Disconnect the 2 connectors and detach the clamp.

    7. A01H0U3

      Remove the 3 nuts, and then detach the 2 clamps with the fusible link block assembly raised.

    8. Disconnect the 3 connectors.

      Tip:

      After performing the step above, temporarily install the fusible link block assembly with the 3 nuts so that the HV battery can be removed easily.

    9. A01GZBK

      Remove the 2 nuts, detach the 4 clamps and disconnect the No. 4 luggage room wire.

    10. A01GX9L

      Detach the clamp and disconnect the No. 2 hybrid battery pack wire connector.

    11. A01GZE1E02

      Remove the 2 nuts and disconnect the air conditioning tube assembly from the HV battery.

      Table 3. Text in Illustration
      *a Cabin Side
      *b Luggage Compartment Side
    12. A01H0DM

      w/ Active Stabilizer Suspension System:

      Disconnect the 2 connectors.

    13. A01GYLE

      Remove the 3 bolts for the front part of the HV battery from the cabin side.

    14. A01GZ3K

      Remove the 4 nuts, 2 bolts and 2 HV battery brackets.

    15. w/ Spare Tire:

      Remove the bolt that holds the spare tire in place, move the spare tire and set the No. 4 luggage room wire and vehicle wire harness into the gap left by the spare tire.

    16. w/o Spare Tire:

      Place the No. 4 luggage room wire and vehicle wire harness in the bottom of the luggage compartment and install the tool box and deck board assembly.

      Note:

      Be careful not to damage the No. 4 luggage room wire or vehicle wire harness.

    17. Install the luggage compartment floor mat upside down.

    18. Prepare a piece of cardboard that is at least 780 mm (2.56 ft.) long and 540 mm (1.77 ft.) wide.

    19. Lift the HV battery alternating between the left and right sides and place it on the piece of cardboard.

    20. A01GZKSE01

      Pull out the HV battery and piece of cardboard together from the rear of the vehicle.

      Table 4. Text in Illustration
      *1 Cardboard
      *a 780 mm (2.56 ft.)
      *b 540 mm (1.77 ft.)
      Note:

      • When pulling out the HV battery assembly, 2 people are needed. One should work from the luggage compartment side and the other from the cabin side.

      • When pulling out the HV battery assembly, do not allow the wire harnesses and the HV battery assembly case to interfere with the vehicle body.

  47. Click here

    REMOVE POWER STEERING CONVERTER ASSEMBLY

    CAUTION:

    Perform work using insulated gloves and insulated tools.


    1. A01H0XS

      Remove the 2 nuts and power steering ECU bracket.

    2. A01H0PW

      Disconnect the 5 connectors.

    3. A01GX6P

      Remove the 4 nuts and power steering converter assembly.

  48. Click here

    REMOVE HV BATTERY

    CAUTION:

    Be sure to wear insulated gloves.


    1. Using a rope or equivalent, remove the HV battery from the vehicle.

      Table 5. Text in Illustration
      *a Part A
      *b Vehicle Rear
      Note:

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

      • In order to prevent the hydrogen hose from being damaged, make sure the rope does not extend toward the rear of the vehicle past the part labeled A when lifting the HV battery.

  49. Click here

    REMOVE NO. 6 HYBRID VEHICLE BATTERY SHIELD SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


    1. Remove the 3 nuts, 3 bolts and No. 6 hybrid vehicle battery shield sub-assembly.

  50. Click here

    REMOVE BATTERY COOLING BLOWER ASSEMBLY (for Upper Side)

    CAUTION:

    Be sure to wear insulating gloves.


    1. Disconnect the connector.

    2. Remove the nut, 2 bolts and battery cooling blower assembly (for upper side).

  51. Click here

    REMOVE NO. 4 HYBRID BATTERY INTAKE DUCT

    CAUTION:

    Be sure to wear insulating gloves.


    1. Detach the 2 claws and remove the No. 4 hybrid battery intake duct from the battery cooling blower assembly (for upper side).

  52. Click here

    REMOVE NO. 1 HYBRID BATTERY SHIELD SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


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

  53. Click here

    REMOVE NO. 4 HYBRID VEHICLE BATTERY CARRIER BRACKET SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


    1. Remove the No. 1 hybrid battery packing.

    2. Remove the 4 nuts, 3 bolts and No. 4 hybrid vehicle battery carrier bracket sub-assembly.

  54. Click here

    REMOVE BATTERY COOLING BLOWER ASSEMBLY (for Lower Side)

    CAUTION:

    Be sure to wear insulating gloves.


    1. Detach the clamp and disconnect the connector.

    2. Remove the nut and 2 bolts.

    3. Detach the 2 claws and remove the battery cooling blower assembly (for lower side).

  55. Click here

    REMOVE NO. 1 HYBRID BATTERY INTAKE DUCT

    CAUTION:

    Be sure to wear insulated gloves.


    1. Remove the 3 clips and No. 1 hybrid battery intake duct.

  56. Click here

    REMOVE REAR HYBRID BATTERY WITH LABEL SHIELD

    CAUTION:

    Be sure to wear insulated gloves.


    1. Remove the 2 nuts, 3 bolts and rear hybrid battery with label shield.

  57. Click here

    REMOVE NO. 4 HYBRID BATTERY SHIELD PANEL

    CAUTION:

    Be sure to wear insulated gloves.


    1. Remove the 6 nuts, bolt and No. 4 hybrid battery shield panel.

  58. Click here

    REMOVE NO. 8 HYBRID VEHICLE BATTERY SHIELD SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


    1. Detach the clamp.

    2. Remove the 5 nuts, bolt and No. 8 hybrid vehicle battery shield sub-assembly as shown in the illustration.

  59. Click here

    REMOVE CONVERTER COOLING EXHAUST DUCT

    CAUTION:

    Be sure to wear insulated gloves.


    1. Remove the clip.

    2. Detach the clamp and 2 claws and remove the converter cooling exhaust duct.

  60. Click here

    REMOVE CONVERTER WIRE BRACKET

    CAUTION:

    Be sure to wear insulated gloves.


    1. Detach the clamp.

    2. Remove the 2 nuts and converter wire bracket.

  61. Click here

    REMOVE CONVERTER COOLING BLOWER

    CAUTION:

    Be sure to wear insulated gloves.


    1. Detach the clamp and disconnect the connector.

    2. Remove the 2 nuts and bolt.

    3. Detach the 2 claws and remove the converter cooling blower.

  62. Click here

    REMOVE HV CONVERTER POWER SUPPLY WIRE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Detach the clamp.

    2. Remove the nut and hybrid vehicle converter power supply wire.

  63. Click here

    REMOVE CONVERTER COOLING BLOWER BRACKET

    CAUTION:

    Be sure to wear insulated gloves.


    1. Detach the 2 clamps and remove the converter cooling blower bracket.

  64. Click here

    REMOVE NO. 2 HYBRID VEHICLE CONVERTER SIGNAL WIRE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Disconnect the connector and remove the No. 2 hybrid vehicle converter signal wire.

  65. Click here

    REMOVE HV CONVERTER

    CAUTION:

    Be sure to wear insulated gloves.


    1. Disconnect the 3 connectors.

    2. Detach the 4 clamps.

    3. Remove the 4 nuts and hybrid vehicle converter.

  66. Click here

    REMOVE NO. 3 HYBRID BATTERY INTAKE DUCT

    CAUTION:

    Be sure to wear insulated gloves.


    1. Disconnect the intake air temperature sensor and remove the No. 3 hybrid battery intake duct.

  67. Click here

    REMOVE POWER STEERING CONVERTER WIRE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Disconnect the connector.

    2. Remove the nut and power steering converter wire.

  68. Click here

    REMOVE NO. 4 HYBRID VEHICLE BATTERY SHIELD REINFORCEMENT

    CAUTION:

    Be sure to wear insulated gloves.


    1. Remove the 2 nuts and No. 4 hybrid vehicle shield reinforcement.

  69. Click here

    REMOVE HYBRID BATTERY TERMINAL BLOCK

    CAUTION:

    Be sure to wear insulated gloves.


    1. Remove the 3 nuts, bolt and hybrid battery terminal block.

  70. Click here

    REMOVE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.


    1. Disconnect the 4 connectors.

    2. Remove the 3 nuts and hybrid battery junction block assembly.

      Note:

      Insulate the connectors of the removed high voltage wires with insulating tape.

  71. Click here

    REMOVE BATTERY SMART UNIT

    CAUTION:

    Be sure to wear insulated gloves.


    1. Disconnect the 3 connectors from the battery smart unit.

    2. Remove the nut and battery smart unit.

      Note:

      Insulate the connectors of the removed high voltage wires with insulating tape.

  72. Click here

    REMOVE NO. 2 HYBRID BATTERY PACK WIRE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Detach the 2 clamps and disconnect the connector.

    2. A01H23H

      Detach the 3 clamps and remove the No. 2 hybrid battery pack wire.