HV BATTERY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:


  • When disposing of an HV battery module, make sure to return it through an authorized collection agent who is capable of handling it safely. If the HV battery module is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.

  • Accidents such as electric shock may result if an HV battery module is disposed of improperly or abandoned. Therefore, make sure to return all HV battery modules through an authorized collection agent.

  • After removing an HV battery module, keep it away from water. Exposure to water may cause the HV battery module to produce heat, resulting in a fire.

PROCEDURE


  1. PRECAUTION

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  2. CHECK FOR DTC


    1. Check for DTCs.

      Click here

      Note

      Confirm that P0AA6 (Hybrid Battery Voltage System Isolation Fault) is not output before removing or installing an HV battery module. If this DTC is output, perform troubleshooting for this DTC first.

      Click here

  3. REMOVE SERVICE PLUG GRIP

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  4. DISCONNECT WIRE HARNESS

    Click here

  5. DISCONNECT INVERTER RESERVE TANK ASSEMBLY

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  6. REMOVE NO. 1 INVERTER RESERVE TANK BRACKET (for 2WD)

    Click here

  7. REMOVE CONNECTOR COVER ASSEMBLY

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  8. CHECK TERMINAL VOLTAGE

    Click here

  9. INSTALL CONNECTOR COVER ASSEMBLY

    Click here

  10. REMOVE REAR SEAT ASSEMBLY

    for Manual Seat: Click here

    for Power Seat: Click here

  11. REMOVE NO. 2 HYBRID BATTERY INTAKE DUCT


    1. B002K8F

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

  12. REMOVE NO. 1 HYBRID BATTERY INTAKE DUCT


    1. B002JHK

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

  13. REMOVE VOLTAGE INVERTER ASSEMBLY (w/ Voltage Inverter)

    Click here

  14. REMOVE NO. 2 HYBRID VEHICLE BATTERY SHIELD REINFORCEMENT

    Click here

  15. DISCONNECT POSITIVE AUXILIARY BATTERY TERMINAL


    1. B002IEAC01
      *A w/o Voltage Inverter
      *B w/ Voltage Inverter

      Remove the nut and disconnect the positive (+) auxiliary battery terminal.

      Note

      Insulate the terminals of the removed auxiliary battery terminal with insulating tape.

    2. w/o Voltage Inverter:

      Disconnect the 3 wire harness clamps and connector.

    3. w/ Voltage Inverter:

      Disconnect the 2 wire harness clamps and connector.

  16. REMOVE AUXILIARY BATTERY

    Click here

  17. DISCONNECT WIRE HARNESS

    CAUTION:

    Wear insulated gloves and use insulated tools.

    Note


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

    • Insulate the removed terminals and connector with insulating tape.

    • Insulate the removed connector with insulating tape.


    1. B002KQO

      for Power Seat:

      Disconnect the 3 clamps and No. 2 floor wire.

    2. B002IO3

      Disconnect the connector and wire harness clamps from the battery cooling blower assembly LH.

    3. Disconnect the connector and wire harness clamps from the battery cooling blower assembly RH.

    4. B002KA5

      Disconnect the 2 connectors and 6 wire harness clamps.

    5. B002HIXC01
      *a Ground Terminal

      Using an insulated tool, remove the 3 nuts, and disconnect the 2 No. 2 frame wires (high-voltage cables) and ground terminal.

  18. REMOVE HV BATTERY ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B002HUJ

      Remove the 4 clips and disconnect the floor carpet mat.

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

    3. B002I5OC02
      *a Bolt
      *b Ground Bolt
      *c Nut

      Remove the 6 bolts, 2 ground bolts, 2 nuts and HV battery assembly.

    4. Lift up the HV battery assembly, and pull out the 4 cables from the HV battery assembly towards the lower side.

      Note


      • Hold the areas shown in the illustration and lift up the HV battery assembly.

      • Since the HV battery assembly is very heavy, 4 people are needed to remove the HV battery assembly. When removing the HV battery assembly, do not damage the parts around it.

      B002J1KC01
      *a Areas to be Held

    5. Remove the HV battery assembly from the vehicle.

      Note


      • Since the HV battery assembly is very heavy, 4 people are needed to remove the HV battery assembly. When removing the HV battery assembly, do not damage the parts around it.

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

      • When removing/installing/moving the HV battery assembly, make sure not to tilt it more than 80°.

      Tech Tips

      When removing and installing the HV battery, do so from the back door opening.

    6. B002HGHC01
      *a Attachment

      Place the HV battery assembly on attachments.

  19. REMOVE NO. 3 HYBRID BATTERY EXHAUST DUCT


    1. Remove the No. 3 hybrid battery exhaust duct from the No. 1 hybrid battery exhaust duct.

  20. REMOVE NO. 4 HYBRID BATTERY EXHAUST DUCT


    1. Remove the No. 4 hybrid battery exhaust duct from the No. 2 hybrid battery exhaust duct.

  21. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY

    CAUTION:

    Wear insulated gloves and use insulated tools.


    1. B002KEQ

      Disconnect the 4 connectors.

      Note

      Insulate the removed connector with insulating tape.

    2. B002KOZ

      Remove the 3 nuts and hybrid battery junction block assembly.

  22. REMOVE LOWER NO. 2 HYBRID BATTERY CARRIER PATCH

    Click here

  23. REMOVE BATTERY VOLTAGE SENSOR

    Click here

  24. REMOVE NO. 2 HYBRID BATTERY PACK WIRE

    CAUTION:

    Wear insulated gloves.


    1. B002KBU

      Disconnect the 2 wire harness clamps and remove the No. 2 hybrid battery pack wire.

  25. REMOVE HYBRID BATTERY COVER SUB-ASSEMBLY LH

    CAUTION:

    Wear insulated gloves and use insulated tools.


    1. B002IOZC02
      *a Bolt
      *b Nut

      Remove the 4 bolts, 3 nuts and hybrid battery cover sub-assembly LH.

  26. REMOVE HYBRID BATTERY COVER SUB-ASSEMBLY RH

    CAUTION:

    Wear insulated gloves and use insulated tools.


    1. B002KKBC02
      *a Bolt
      *b Nut

      Remove the 4 bolts, 3 nuts and hybrid battery cover sub-assembly RH.

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

    CAUTION:

    Wear insulated gloves and use insulated tools.


    1. B002I0JC01
      *1 No. 1 Hybrid Vehicle Battery Carrier Bracket Sub-assembly LH Side
      *2 No. 1 Hybrid Vehicle Battery Carrier Bracket Sub-assembly RH Side

      Disconnect the wire harness clamp from the No. 1 hybrid vehicle battery carrier bracket sub-assembly LH side.

    2. Remove the 2 nuts and No. 1 hybrid vehicle battery carrier bracket sub-assembly LH side.

    3. Remove the 2 nuts and No. 1 hybrid vehicle battery carrier bracket sub-assembly RH side.

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

    CAUTION:

    Wear insulated gloves and use insulated tools.


    1. B002HQH

      Disconnect the 4 wire harness clamps.

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

  29. REMOVE NO. 2 HYBRID BATTERY COVER INTAKE DUCT

    CAUTION:

    Wear insulated gloves and use insulated tools.


    1. B002HXB

      Remove the No. 2 hybrid battery cover intake duct from the HV battery assembly.

    2. B002H4K

      Remove the 3 nuts and battery cooling blower assembly LH.

  30. REMOVE NO. 1 HYBRID BATTERY COVER INTAKE DUCT

    CAUTION:

    Wear insulated gloves and use insulated tools.


    1. B002JIU

      Disconnect the intake temperature sensor and wire harness clamp.

    2. B002IX8

      Remove the No. 1 hybrid battery cover intake duct from the HV battery assembly.

    3. B002JAL

      Remove the 3 nuts and battery cooling blower assembly RH.

  31. REMOVE NO. 2 HYBRID BATTERY EXHAUST DUCT

    CAUTION:

    Wear insulated gloves and use insulated tools.


    1. B002JQD

      Remove the clip and 3 nuts.

    2. B002IOTC01
      *1 Hybrid Battery End Plate
      B002HVY Raise Hybrid Battery Stack
      B002I10 Remove No. 2 Hybrid Battery Exhaust Duct

      Raise the hybrid battery stack vertically and remove the No. 2 hybrid battery exhaust duct.

      Note


      • Make sure to hold the hybrid battery stack by the hybrid battery end plates shown in the illustration.

      • Make sure to raise the hybrid battery stack as much as necessary for the removal of the No. 2 hybrid battery exhaust duct.

      • Make sure to hold the hybrid battery stack by the hybrid battery end plates shown in the illustration.

  32. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT

    CAUTION:

    Wear insulated gloves and use insulated tools.


    1. B002KVJ

      Remove the clip and 3 nuts.

    2. B002JMAC01
      *1 Hybrid Battery End Plate
      B002HVY Raise Hybrid Battery Stack
      B002I10 Remove No. 1 Hybrid Battery Exhaust Duct

      Raise the hybrid battery stack vertically and remove the No. 1 hybrid battery exhaust duct.

      Note


      • Make sure to hold the hybrid battery stack by the hybrid battery end plates shown in the illustration.

      • Make sure to raise the hybrid battery stack as much as necessary for the removal of the No. 1 hybrid battery exhaust duct.

      • Make sure to hold the hybrid battery stack by the hybrid battery end plates shown in the illustration.