HV BATTERY REMOVAL


  1. PRECAUTION

    Click here

  2. CHECK FOR DTCS


    1. Check for DTCs Click here.

      Note

      Confirm that P0AA6 (Hybrid Battery Voltage System Isolation Fault) is not output before doing removal or installation work 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

    CAUTION:


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

    • Wear insulated gloves.

    Note

    Do not start the hybrid system with the service plug grip removed because it may cause a malfunction.


    1. A01HTFV

      Remove the 2 bolts and connector cover assembly.

      Note


      • Make sure to pull the connector cover assembly straight up, as a connector is connected to the bottom of the cover.

      • Do not allow any foreign matter or water to enter the inverter with converter assembly.

  5. CHECK TERMINAL VOLTAGE

    CAUTION:

    Wear insulated gloves.

    Note

    Do not allow any foreign matter or water to enter the inverter with converter assembly.


    1. A01HSVH

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

      Standard voltage
      0 V

      Tech Tips

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

  6. INSTALL CONNECTOR COVER ASSEMBLY

    CAUTION:

    Wear insulated gloves.

    Note


    • Make sure that the interlock is fully engaged.

    • Do not allow any foreign matter or water to enter the inverter with converter assembly.


    1. Install the connector cover assembly with the 2 bolts.

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

  7. REMOVE AUXILIARY BATTERY


    1. A01HVXB

      Open the auxiliary battery terminal cap.

    2. Loosen the nut, and disconnect the positive (+) auxiliary battery cable.

    3. Disconnect the auxiliary battery hose.

    4. Loosen the nut, and remove the bolt.

    5. Remove the auxiliary battery clamp.

    6. Remove the auxiliary battery.

  8. REMOVE REAR FLOOR FINISH PLATE


    1. A01HUSM

      Remove the 5 clips.

    2. A01HU2Q

      Disengage the 4 clips and remove the rear floor finish plate.

  9. REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM HOOK


    1. A01HV3FE01
      Text in Illustration
      *1 Pin

      Push the 2 pins and remove the 2 No. 1 luggage compartment trim hooks.

  10. REMOVE LUGGAGE COMPARTMENT INNER TRIM COVER LH


    1. A01HW3NE01
      Text in Illustration
      *1 Clip <A>
      *2 Clip <B>

      Remove the clip <A>.

    2. Remove the 2 clips <B>.

    3. Disengage the fastener and remove the luggage compartment inner trim cover LH.

  11. REMOVE LUGGAGE COMPARTMENT INNER TRIM COVER RH


    1. A01HUJME01
      Text in Illustration
      *1 Clip <A>
      *2 Clip <B>

      Remove the clip <A>.

    2. Remove the 2 clips <B>.

    3. Disengage the fastener and remove the luggage compartment inner trim cover RH.

  12. REMOVE REAR SEAT CUSHION ASSEMBLY


    1. Disengage the hook of the seat cushion from the vehicle body as shown in the illustration.

      Note

      Follow the instructions below carefully as the cushion frame can be deformed easily.


      1. A01HU3FE01

        Choose a hook to disengage first. Place your hands near the hook as shown in the illustration. Then lift the seat cushion to disengage the hook.

        Standard Measurement
        a 100 mm (3.94 in.) or less

      2. Repeat the step above for the other hook.

    2. Remove the rear seat cushion assembly.

  13. REMOVE REAR SEAT CUSHION LOCK HOOK


    1. A01HVMY

      Disengage the claw and remove the rear seat cushion lock hook.

      Note

      Rear seat cushion lock hooks must not be reused.

      Tech Tips

      Use the same procedure for the RH side and the LH side.

  14. REMOVE REAR SEATBACK ASSEMBLY RH


    1. Fold down the rear seatback assembly RH.

    2. A01HTTPE01
      Text in Illustration
      *1 Fastener

      Disengage the 3 fasteners as shown in the illustration.

    3. A01HUYA

      Remove the 2 bolts and rear seatback assembly RH.

      Note

      Be careful not to damage the vehicle body.

  15. REMOVE NO. 2 ROOM PARTITION COVER


    1. A01HTNJ

      Using a moulding remover, disengage the claw and guide, and remove the No. 2 room partition cover.

  16. REMOVE REAR SEATBACK ASSEMBLY LH


    1. Disconnect the rear seat inner with center belt assembly LH from the rear seat center shoulder belt guide.

    2. A01HSGM

      Pull the cable in the direction shown in the illustration to release the rear seatback lock and then fold the rear seatback assembly LH forward.

    3. A01HU1HE01
      Text in Illustration
      *1 Fastener

      Disengage the 2 fasteners as shown in the illustration.

    4. A01HUZH

      Remove the 2 bolts and rear seatback assembly LH.

      Note

      Be careful not to damage the vehicle body.

  17. REMOVE REAR SIDE SEATBACK ASSEMBLY LH


    1. Disconnect the rear seat outer belt from the rear seat shoulder belt guide LH.

    2. Disconnect the connector.

    3. A01HT1N

      Remove the 2 bolts.

    4. Disengage the hook and remove the rear side seatback assembly LH.

  18. REMOVE REAR SIDE SEATBACK ASSEMBLY RH


    1. Disconnect the rear seat outer belt from the rear seat shoulder belt guide RH.

    2. Disconnect the connector.

    3. A01HVKC

      Remove the 2 bolts.

    4. Disengage the hook and remove the rear side seatback assembly RH.

  19. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH


    1. Disconnect the rear door opening trim weatherstrip LH.

  20. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH


    1. Disconnect the rear door opening trim weatherstrip RH.

  21. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for LH Side)


    1. A01HSBP

      Remove the bolt and disconnect the floor anchor of the rear seat outer belt assembly.

  22. DISCONNECT REAR SEAT OUTER BELT ASSEMBLY (for RH Side)


    1. A01HV4A

      Remove the bolt and disconnect the floor anchor of the rear seat outer belt assembly.

  23. REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH


    1. A01HUQC

      Remove the 2 nuts and child restraint seat anchor bracket sub-assembly LH.

  24. DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH


    1. A01HT53

      Remove the bolt and disconnect the floor anchor of the rear seat inner with center belt assembly LH.

  25. REMOVE ROOF SIDE INNER GARNISH LH


    1. A01HSG3

      Disengage the 5 clips.

    2. Disengage the guide and remove the roof side inner garnish LH.

  26. REMOVE ROOF SIDE INNER GARNISH RH

    Tech Tips

    Use the same procedure as for the LH side.

  27. REMOVE CENTER STOP LIGHT SET


    1. A01HT8VE01

      Slide the center stop light set in the order and directions shown by the arrows in the illustration while pushing it towards the rear of the vehicle to disengage the 4 claws.

    2. A01HW3S

      Turn the center stop light set 180 degrees as shown by the arrow in the illustration.

      Tech Tips

      This makes it easier to disconnect the connector.

    3. Disconnect the connector and remove the center stop light set.

  28. REMOVE CHILD RESTRAINT SEAT TETHER ANCHOR COVER


    1. A01HTYT

      Using a moulding remover, disengage the 2 claws and 2 guides to remove the child restraint seat tether anchor cover.

      Tech Tips

      Use the same procedure for the other 2 child restraint seat tether anchor covers.

  29. REMOVE REAR SEAT SHOULDER BELT COVER


    1. A01HTG4

      Using a moulding remover, disengage the 2 claws and 4 guides and remove the rear seat shoulder belt cover.

      Tech Tips

      Use the same procedure for the other 2 rear seat shoulder belt covers.

  30. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY


    1. A01HSUSE01
      Text in Illustration
      *1 Protective Tape

      Using pliers, disengage the 3 clips from inside the luggage compartment as shown in the illustration.

      Tech Tips

      Tape the tip of the pliers before use.

    2. Disengage the 5 guides.

    3. Pass the 3 rear seat belt floor anchors through the package tray trim panel assembly then remove the package tray trim panel assembly.

  31. REMOVE NO. 1 ROOM PARTITION BOARD


    1. A01HTSA

      Using a clip remover, remove the 4 clips.

    2. Disengage the 5 clips and remove the No. 1 room partition board.

  32. REMOVE NO. 1 HYBRID BATTERY INTAKE DUCT


    1. A01HTNN

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

  33. REMOVE NO. 4 HYBRID BATTERY SHIELD PANEL

    CAUTION:

    Wear insulated gloves.


    1. A01HSMOE01
      Text in Illustration
      *1 Service Plug Grip
      *2 Battery Cover Lock Striker
      *3 Button
      *a Projection
      *b Turn

      Using the service plug grip, remove the battery cover lock striker.

      Tech Tips

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

    2. A01HVNP

      Remove the bolt, 2 nuts and No. 4 hybrid battery shield panel.

  34. DISCONNECT NO. 4 FLOOR WIRE

    CAUTION:

    Wear insulated gloves.

    Note

    Insulate the disconnected connectors with insulating tape.


    1. A01HTN6

      Disconnect the 2 connectors shown in the illustration.

    2. Disconnect the shielded wire ground and No. 4 floor wire.

  35. DISCONNECT LOW VOLTAGE CONNECTOR


    1. A01HVUZ

      Disconnect the connector and clamp.

    2. A01HTKR

      Disconnect the 2 connectors.

  36. REMOVE HV BATTERY

    CAUTION:

    Wear insulated gloves.


    1. A01HSL7

      Remove the 6 bolts from the HV battery.

    2. A01HSF9

      Install the spare wheel cover assembly upside down.

    3. A01HTEJE01
      Text in Illustration
      *1 Cardboard
      *a Hold up
      *b Insert
      *c HV battery bolt attachment position

      Cut and shape a piece of cardboard so that it fits the area between the HV battery bolt attachment positions, and then insert it as shown in the illustration.

    4. Using a tire lever to hold up the HV battery, insert the cardboard until it cannot be inserted any further.

      Note

      Secure the No. 4 floor wire with electrical tape to prevent it from getting caught when moving the battery or other parts.

      Tech Tips

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

    5. A01HTX3E01
      Text in Illustration
      *1 Cardboard
      *a Pull

      Pull the cardboard and HV battery together to the middle of the luggage compartment.

      Note

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

    6. A01HU7M

      Remove the 2 nuts and No. 2 hybrid vehicle battery upper cover bracket.

    7. A01HSWT

      Remove the clip.

    8. Disengage the 2 claws and remove the No. 2 hybrid battery intake duct.

    9. A01HVLF

      Disconnect the connector from the battery cooling blower assembly.

    10. Remove the 3 nuts and battery cooling blower assembly.

      Note


      • Be sure not to touch the fan part of the battery cooling blower assembly.

      • Do not lift the battery cooling blower assembly using the wire harness.

    11. A01HSHA

      Remove the 2 clips.

    12. A01HTC7E01
      Text in Illustration
      *a Turn 180°
      *b Pull

      Turn the cardboard and HV battery 180° together.

    13. Pull the HV battery together with the cardboard toward the rear of the vehicle.

    14. A01HSOM

      Using a suitable adaptor such as a rope, remove the HV battery while tilting it.

      Note

      While lowering the HV battery from the vehicle, do not allow it to contact the vehicle.

  37. REMOVE NO. 2 HYBRID VEHICLE BATTERY SHIELD PANEL

    CAUTION:

    Wear insulated gloves.


    1. A01HU52E01
      Text in Illustration
      *1 Service Plug Grip
      *2 Battery Cover Lock Striker
      *3 Button
      *a Turn
      *b Projection

      Using the service plug grip, remove the battery cover lock striker.

      Tech Tips

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

    2. A01HTAV

      Disconnect the connector.

    3. Remove the 2 bolts, nut and No. 2 hybrid vehicle battery shield panel.

    4. A01HV9P

      Disconnect the 3 wire harness clamps.

  38. REMOVE BATTERY SMART UNIT


    1. A01HSRR

      Disconnect the connector.

      Note

      Insulate the removed connector with insulating tape.

    2. Remove the bolt and battery smart unit.

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

    CAUTION:

    Wear insulated gloves.


    1. A01HSOB

      Remove the bolt, 3 nuts and No. 1 hybrid battery shield sub-assembly.

  40. REMOVE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

    CAUTION:

    Wear insulated gloves.

    Note

    Insulate the disconnected terminals with insulating tape.


    1. A01HULE

      Disengage the claw and disconnect the terminal cover.

    2. A01HUE9

      Using an insulated tool, remove the 2 bolts.

    3. A01HSRA

      Disconnect the connector shown in the illustration.

    4. A01HSXT

      Remove the 3 bolts and hybrid battery junction block assembly.

  41. SEPARATE NO. 2 HYBRID BATTERY PACK WIRE

    CAUTION:

    Wear insulated gloves.


    1. A01HTJ9

      Disconnect the connector and 5 clamps, and remove the No. 2 hybrid battery pack wire.

  42. REMOVE NO. 1 HYBRID VEHICLE BATTERY CARRIER BRACKET SUB-ASSEMBLY


    1. A01HVB2

      Remove the 2 bolts and No. 1 hybrid vehicle battery carrier bracket sub-assembly.

  43. REMOVE NO. 2 HYBRID VEHICLE BATTERY CARRIER BRACKET SUB-ASSEMBLY


    1. A01HT1D

      Remove the 2 bolts and No. 2 hybrid vehicle battery carrier bracket sub-assembly.