HV BATTERY REMOVAL

PROCEDURE


  1. PRECAUTION

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  2. READ OUTPUT DTC


    1. Check for DTCs Click here.

      Note

      Check for DTCs and confirm that P0AA6 (Hybrid Battery Voltage System Isolation Fault) is not output before doing removal or installation inside the battery. If this DTC is output, perform troubleshooting for this DTC first.

  3. REMOVE SERVICE PLUG GRIP

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  4. REMOVE INVERTER COVER ASSEMBLY LH (w/ Cover)

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  5. REMOVE INVERTER COVER

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  6. CHECK TERMINAL VOLTAGE

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  7. INSTALL INVERTER COVER

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  8. INSTALL INVERTER COVER ASSEMBLY LH (w/ Cover)

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  9. REMOVE TONNEAU COVER ASSEMBLY (w/ Tonneau Cover)

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  10. REMOVE REAR NO. 4 FLOOR BOARD (w/o Woofer)

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  11. REMOVE REAR NO. 4 FLOOR BOARD (w/ Woofer)

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  12. REMOVE DECK FLOOR BOX LH (w/o Woofer)

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  13. REMOVE REAR NO. 1 FLOOR BOARD SUB-ASSEMBLY

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  14. REMOVE REAR NO. 2 FLOOR BOARD SUB-ASSEMBLY

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  15. REMOVE REAR NO. 1 FLOOR BOARD

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  16. REMOVE REAR SEAT ASSEMBLY

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  17. REMOVE REAR DOOR SCUFF PLATE LH

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  18. REMOVE REAR DOOR SCUFF PLATE RH

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  19. REMOVE REAR SEAT SIDE GARNISH LH

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  20. REMOVE REAR SEAT SIDE GARNISH RH

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  21. REMOVE HYBRID VEHICLE BATTERY SHIELD SHEET

    B001LWC

    Remove the hybrid vehicle battery shield sheet.

  22. REMOVE HYBRID BATTERY COVER SHEET


    1. B001N7C

      Remove the hybrid battery cover sheet.

  23. REMOVE REAR FLOOR BOARD SPACER


    1. B001KCR

      Remove the 2 clips and rear floor board spacer.

  24. REMOVE NO. 1 HYBRID BATTERY INTAKE DUCT


    1. B001KH7

      Remove the 2 clips and No. 1 hybrid battery intake duct.

  25. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT


    1. B001LE2

      Remove the clip and No. 1 hybrid battery exhaust duct.

  26. REMOVE BATTERY COOLING BLOWER ASSEMBLY

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  27. REMOVE UPPER HYBRID BATTERY COVER SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B001N90E04
      Text in Illustration
      *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. Remove the 4 nuts and upper hybrid battery cover sub-assembly.

  28. REMOVE FRAME WIRE

    CAUTION:


    • Wear insulated gloves.

    • Insulate the removed terminals with insulating tape.


    1. B001MQS

      Remove the 2 nuts, then disconnect the frame wire from the hybrid battery junction block.

    2. Disconnect the clamp and frame wire.

  29. REMOVE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

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  30. REMOVE NO. 7 HYBRID VEHICLE BATTERY UPPER CARRIER BRACKET


    1. B001L8M

      Disconnect the 2 wire harness clamps.

    2. Remove the bolt and No. 7 hybrid battery upper carrier bracket.

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


    1. B001KHU

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

  32. REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY RH


    1. B001NEE

      Disconnect the wire harness protector clamp.

    2. Remove the 2 bolts and child restraint seat anchor bracket sub-assembly RH.

  33. REMOVE REAR CENTER SEAT BACK HINGE SUB-ASSEMBLY


    1. B001KCQ

      Remove the 2 bolts and center seat hinge subassembly.

  34. REMOVE HV BATTERY

    CAUTION:

    Wear insulating gloves.

    Note

    Since the HV battery is very heavy, 2 people are needed to remove the HV battery. When removing the HV battery, do not damage the parts around it.


    1. B001MN4E03
      Text in Illustration
      *1 No. 2 hybrid vehicle battery carrier sheet
      *2 No. 3 hybrid vehicle battery carrier sheet
      *3 Hybrid vehicle battery lower cover plate

      Remove the No. 2 hybrid vehicle battery carrier sheet.

    2. Remove the No. 3 hybrid vehicle battery carrier sheet.

    3. Remove the hybrid vehicle battery lower cover plate.

    4. B001LND

      Disconnect the connector and electrical key oscillator clamp.

    5. B001KAW

      Remove the 4 bolts shown in the illustration.

    6. Remove the HV battery.

      Note


      • To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.

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

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

      • When moving the HV battery, make sure to use an engine lifter.

      Tech Tips

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

  35. REMOVE BATTERY SMART UNIT

    Click here

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

    CAUTION:

    Wear insulating gloves.


    1. B001M1Q

      Disconnect the connector.

    2. Remove the bolt and electric vehicle battery plug assembly as shown in the illustration.

    3. B001LKRE05
      Text in Illustration
      *a Projection
      *b Turn

      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, to release the lock.

    4. Remove the 3 nuts and No. 1 hybrid vehicle battery carrier bracket sub-assembly.

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

    CAUTION:

    Wear insulating gloves.


    1. B001MFL

      Disconnect the 3 wire harness clamps.

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

    3. B001MPN

      Disengage the 2 claws and remove the HV battery thermistor.

  38. REMOVE NO. 1 HYBRID BATTERY COVER INTAKE DUCT


    1. B001KRV

      Remove the 2 clips and No. 1 hybrid battery cover intake duct.

  39. REMOVE UPPER HYBRID BATTERY COVER SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B001N1Q

      Remove the 3 bolts, 8 nuts and upper hybrid battery cover sub-assembly with the No. 1 hybrid battery shield sub-assembly.

  40. REMOVE NO. 1 HYBRID BATTERY PACKING

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B001L9E

      Remove the 2 clamps and No. 1 hybrid battery packing.

  41. REMOVE NO. 2 HYBRID BATTERY PACK WIRE


    1. B001MUB

      Disconnect the 2 clamps, then remove the No. 2 hybrid battery pack wire.