HV BATTERY REMOVAL


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

    A01GWKI

  3. REMOVE DECK BOARD ASSEMBLY (w/o Spare Tire)

    A01GZ3P

  4. 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. REMOVE BATTERY SERVICE HOLE COVER LH


    1. A01GZIME02
      Text in Illustration
      *A for Standard
      *B for Ottoman
      *1 Fastening Tape

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

  6. 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. DISCONNECT AUXILIARY BATTERY TERMINAL

    Note

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

    Tech Tips

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

  8. 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.

      Tech Tips

      Tape the screwdriver tip before use.

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

    A01GZC0

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

      Tech Tips

      Tape the screwdriver tip before use.

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

  10. REMOVE SERVICE PLUG COVER

    A01H102

    1. Remove the 4 bolts and service plug cover.

  11. REMOVE SERVICE PLUG GRIP

    A01GZ4DE03

    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.

      Tech Tips

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

  12. 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. 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. REMOVE MOTOR CABLE COVER RH (for LHD)


    1. A01H000

      Remove the 2 clips and motor cable cover RH.

  15. REMOVE MOTOR CABLE COVER LH (for RHD)


    1. A01H1LZ

      Remove the 2 clips and motor cable cover LH.

  16. REMOVE INVERTER COVER ASSEMBLY RH (for LHD)


    1. A01GW7A

      Remove the 2 clips and inverter cover assembly RH.

  17. REMOVE INVERTER COVER ASSEMBLY LH (for RHD)


    1. A01GZOK

      Remove the 2 clips and inverter cover assembly LH.

  18. 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. 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. 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

      Tech Tips

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

  21. 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

      Tech Tips

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

  22. 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.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  23. 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.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  24. 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. 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. INSTALL MOTOR CABLE COVER RH (for LHD)


    1. A01H000

      Install the motor cable cover RH with the 2 clips.

  27. INSTALL MOTOR CABLE COVER LH (for RHD)


    1. A01H1LZ

      Install the motor cable cover LH with the 2 clips.

  28. 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. 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. REMOVE REAR SEAT ASSEMBLY (for Fixed Seat Type)

    Click here

  31. REMOVE REAR SEAT ASSEMBLY (for Power Seat)

    Click here

  32. REMOVE REAR SEAT ASSEMBLY (for Ottoman)

    Click here

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

    Click here

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

    Click here

  35. REMOVE NO. 1 CENTER FLOOR TO BRACE EXTENSION

    A01GX0N

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

  36. REMOVE NO. 2 CENTER FLOOR TO BRACE EXTENSION

    A01GXBN

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

  37. REMOVE REAR SEAT CONSOLE BOX LOWER BRACKET

    A01GWFW

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

  38. REMOVE HOLE PLUG

    A01GXLC

    1. Remove the 2 hole plugs.

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

    A01GYC0E03
    Text in Illustration
    *1 Battery Cover Lock Striker
    *2 Service Plug Grip

    CAUTION:

    Be sure to wear insulated gloves.


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

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

  40. DISCONNECT FRAME WIRE

    A01GZLT

    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. REMOVE BATTERY ROOM VENTILATION HOSE


    1. A01H0LR

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

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

  43. REMOVE TOOL BOX (w/o Spare Tire)


    1. A01H04I

      Remove the 2 clips and tool box.

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

    A01GXHH

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

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

  46. DISCONNECT HV BATTERY

    A01GWN1

    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.

      Tech Tips

      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
      Text in Illustration
      *a Cabin Side
      *b Luggage Compartment Side

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

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

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

      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. 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. REMOVE HV BATTERY

    A01H0G1E01
    Text in Illustration
    *a Part A
    *b Vehicle Rear

    CAUTION:

    Be sure to wear insulated gloves.


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

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

    A01H0JL

    CAUTION:

    Be sure to wear insulated gloves.


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

  50. REMOVE BATTERY COOLING BLOWER ASSEMBLY (for Upper Side)

    A01GYCO

    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. REMOVE NO. 4 HYBRID BATTERY INTAKE DUCT

    A01H01T

    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. REMOVE NO. 1 HYBRID BATTERY SHIELD SUB-ASSEMBLY

    A01H1AC

    CAUTION:

    Be sure to wear insulated gloves.


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

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

    A01GYH4

    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. REMOVE BATTERY COOLING BLOWER ASSEMBLY (for Lower Side)

    A01GX7W

    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. REMOVE NO. 1 HYBRID BATTERY INTAKE DUCT

    A01H0VB

    CAUTION:

    Be sure to wear insulated gloves.


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

  56. REMOVE REAR HYBRID BATTERY WITH LABEL SHIELD

    A01GW6G

    CAUTION:

    Be sure to wear insulated gloves.


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

  57. REMOVE NO. 4 HYBRID BATTERY SHIELD PANEL

    A01H02W

    CAUTION:

    Be sure to wear insulated gloves.


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

  58. REMOVE NO. 8 HYBRID VEHICLE BATTERY SHIELD SUB-ASSEMBLY

    A01GZAJ

    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. REMOVE CONVERTER COOLING EXHAUST DUCT

    A01GWAZ

    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. REMOVE CONVERTER WIRE BRACKET

    A01GXE0

    CAUTION:

    Be sure to wear insulated gloves.


    1. Detach the clamp.

    2. Remove the 2 nuts and converter wire bracket.

  61. REMOVE CONVERTER COOLING BLOWER

    A01H0VP

    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. REMOVE HV CONVERTER POWER SUPPLY WIRE

    A01GZFM

    CAUTION:

    Be sure to wear insulated gloves.


    1. Detach the clamp.

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

  63. REMOVE CONVERTER COOLING BLOWER BRACKET

    A01GZA6

    CAUTION:

    Be sure to wear insulated gloves.


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

  64. REMOVE NO. 2 HYBRID VEHICLE CONVERTER SIGNAL WIRE

    A01H0Y3

    CAUTION:

    Be sure to wear insulated gloves.


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

  65. REMOVE HV CONVERTER

    A01H1EH

    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. REMOVE NO. 3 HYBRID BATTERY INTAKE DUCT

    A01GZ9C

    CAUTION:

    Be sure to wear insulated gloves.


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

  67. REMOVE POWER STEERING CONVERTER WIRE

    A01H0RF

    CAUTION:

    Be sure to wear insulated gloves.


    1. Disconnect the connector.

    2. Remove the nut and power steering converter wire.

  68. REMOVE NO. 4 HYBRID VEHICLE BATTERY SHIELD REINFORCEMENT

    A01H0CK

    CAUTION:

    Be sure to wear insulated gloves.


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

  69. REMOVE HYBRID BATTERY TERMINAL BLOCK

    A01H0TE

    CAUTION:

    Be sure to wear insulated gloves.


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

  70. REMOVE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

    A01GYWU

    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. REMOVE BATTERY SMART UNIT

    A01GY2O

    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. REMOVE NO. 2 HYBRID BATTERY PACK WIRE

    A01H1KE

    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.