HV BATTERY REMOVAL

PROCEDURE


  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)

    Click here

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

    Click here

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

    Click here

  5. REMOVE BATTERY SERVICE HOLE COVER LH

    Click here

  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)

    Click here

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

    Click here

  10. REMOVE SERVICE PLUG COVER

    Click here

  11. REMOVE SERVICE PLUG GRIP

    Click here

  12. REMOVE COWL TOP VENTILATOR LOUVER RH (for LHD)

    Click here

  13. REMOVE COWL TOP VENTILATOR LOUVER LH (for RHD)

    Click here

  14. REMOVE MOTOR CABLE COVER RH (for LHD)

    Click here

  15. REMOVE MOTOR CABLE COVER LH (for RHD)

    Click here

  16. REMOVE INVERTER COVER ASSEMBLY RH (for LHD)

    Click here

  17. REMOVE INVERTER COVER ASSEMBLY LH (for RHD)

    Click here

  18. REMOVE CONNECTOR COVER ASSEMBLY (for LHD)

    Click here

  19. REMOVE CONNECTOR COVER ASSEMBLY (for RHD)

    Click here

  20. CHECK TERMINAL VOLTAGE (for LHD)

    Click here

  21. CHECK TERMINAL VOLTAGE (for RHD)

    Click here

  22. INSTALL CONNECTOR COVER ASSEMBLY (for LHD)

    Click here

  23. INSTALL CONNECTOR COVER ASSEMBLY (for RHD)

    Click here

  24. INSTALL INVERTER COVER ASSEMBLY RH (for LHD)

    Click here

  25. INSTALL INVERTER COVER ASSEMBLY LH (for RHD)

    Click here

  26. INSTALL MOTOR CABLE COVER RH (for LHD)

    Click here

  27. INSTALL MOTOR CABLE COVER LH (for RHD)

    Click here

  28. INSTALL COWL TOP VENTILATOR LOUVER RH (for LHD)

    Click here

  29. INSTALL COWL TOP VENTILATOR LOUVER LH (for RHD)

    Click here

  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

    A000YUN

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

  36. REMOVE NO. 2 CENTER FLOOR TO BRACE EXTENSION

    A000ZZL

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

  37. REMOVE REAR SEAT CONSOLE BOX LOWER BRACKET

    A000ZEC

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

  38. REMOVE HOLE PLUG

    A000WPL

    1. Remove the 2 hole plugs.

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

    A000VM8E03
    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

    A000VEI

    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. A000W9O

      Remove the battery shield contact from the HV battery.

  41. REMOVE BATTERY ROOM VENTILATION HOSE


    1. A000ZO9

      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)

    Click here

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

    A000W44

    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

    A000TI7

    CAUTION:

    Be sure to wear insulated gloves.


    1. Remove the 2 nuts.

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

    3. A001004

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

    4. A00103P

      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. A000U0E

      Disconnect the 2 connectors and detach the clamp.

    7. A000ZBY

      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. A000WG4

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

    10. A000VVH

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

    11. A000Y8KE02
      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. A00102Q

      w/ Active Stabilizer Suspension System:

      Disconnect the 2 connectors.

    13. A000XON

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

    14. A000ZFN

      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. A000WP4E01
      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

    Click here

  48. REMOVE HV BATTERY

    A000WNRE02
    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

    A000UH4

    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)

    Click here

  51. REMOVE NO. 4 HYBRID BATTERY INTAKE DUCT

    Click here

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

    A000YMQ

    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

    A000X1T

    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)

    Click here

  55. REMOVE NO. 1 HYBRID BATTERY INTAKE DUCT

    A000XCA

    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

    A000U0P

    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

    A000XMS

    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

    A000YYM

    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

    Click here

  60. REMOVE CONVERTER WIRE BRACKET

    Click here

  61. REMOVE CONVERTER COOLING BLOWER

    Click here

  62. REMOVE HV CONVERTER POWER SUPPLY WIRE

    Click here

  63. REMOVE CONVERTER COOLING BLOWER BRACKET

    Click here

  64. REMOVE NO. 2 HYBRID VEHICLE CONVERTER SIGNAL WIRE

    Click here

  65. REMOVE HV CONVERTER

    Click here

  66. REMOVE NO. 3 HYBRID BATTERY INTAKE DUCT

    A000Y71

    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

    A000YFX

    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

    A000VU3

    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

    Click here

  70. REMOVE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

    A000ZHP

    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

    Click here

  72. REMOVE NO. 2 HYBRID BATTERY PACK WIRE

    A000ZBK

    CAUTION:

    Be sure to wear insulated gloves.


    1. Detach the 2 clamps and disconnect the connector.

    2. A000Y2A

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