HV BATTERY REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during HV battery removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure Necessary Procedures Effect/Inoperative Function when Necessary Procedure not Performed Link
Auxiliary battery terminal is disconnected/reconnected Memorize steering angle neutral point Lane departure alert system (w/ Steering Control)

Click here

Intelligent clearance sonar system*1
Simple intelligent parking assist system*1
Pre-crash safety system
Parking assist monitor system

Click here

Initialize back door lock Power door lock control system

Click here

Replacement of HV battery Battery status info update HV battery status information cannot be updated

Click here

Replacement of hybrid battery terminal block Perform high voltage fuse accumulated load history reset DTCs are stored

Click here

*1: When performing learning using the GTS.
Click here Click here

CAUTION:


  • B004PF2

    Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.

    Click here

  • B004Q03

    To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.

Tech Tips

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

PROCEDURE


  1. PRECAUTION

    Note


    • After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

      Click here

    • When the cable is disconnected from the negative (-) auxiliary battery terminal, some systems need to be initialized after the cable is reconnected.

      Click here

    • If the HV battery has been struck or dropped, replace it.

    • When connecting a connector to the HV battery, confirm that the connector is securely connected through the following:

      - Push the connector until a click sound is heard.

      - Visually check and confirm that the connector is securely connected by pulling on it.

    • Make sure to insulate the high-voltage connectors and terminals of the HV battery with insulating tape after removing it.

      If the HV battery stored without insulating the connectors and terminals, electric shock or fire may result.

    • When performing repairs around the HV battery, such as using a tap, do not allow metal shavings to enter the HV battery.

    • Do not touch any high voltage wire harnesses, connectors or parts with bare hands.

    • B004P8Q

      Hold the areas shown in the illustration and lift the HV battery.

    • Do not allow foreign matter, such as grease or oil, to adhere to the bolts or nuts of the HV battery.

    • B004PK7C03
      *a Opening

      Do not put your hands into the openings of the HV battery.

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

    • Do not climb on top of or stand on the HV battery.

    • Do not allow any foreign matter or water to enter the HV battery.

    • If any bolts, nuts or clips are dropped into the HV battery, make sure to remove them.

  2. REMOVE SERVICE PLUG GRIP

    Click here

  3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  4. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)

    Click here

  5. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

    Click here

  6. REMOVE WATER GUARD PLATE LH

    Click here

  7. REMOVE COWL BODY MOUNTING REINFORCEMENT LH

    Click here

  8. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

    Click here

  9. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

    Click here

  10. DISCONNECT ENGINE WIRE

    Click here

  11. REMOVE CONNECTOR COVER ASSEMBLY

    Click here

  12. CHECK TERMINAL VOLTAGE

    Click here

  13. INSTALL CONNECTOR COVER ASSEMBLY

    CAUTION:

    Wear insulated gloves.


    1. B004QC8C04
      *a Bolt (A)
      *b Bolt (B)

      Using a T25 "TORX" socket wrench, install the connector cover assembly to the inverter with converter assembly with the bolt (A).

      Torque:
      4.5 N*m  { 46 kgf*cm, 40 in.*lbf }

      Note

      Do not touch the waterproof seal of the connector cover assembly.

    2. Install the bolt (B).

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

  14. CONNECT ENGINE WIRE

    Click here

  15. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

    Click here

  16. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

    Click here

  17. INSTALL COWL BODY MOUNTING REINFORCEMENT LH

    Click here

  18. INSTALL WATER GUARD PLATE LH

    Click here

  19. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)

    Click here

  20. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

    Click here

  21. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  22. REMOVE REAR SEAT CUSHION ASSEMBLY

    Click here

  23. REMOVE REAR SEAT CUSHION LOCK HOOK

    Click here

  24. REMOVE REAR DOOR SCUFF PLATE LH

    Click here

  25. REMOVE REAR UNDER SIDE COVER LH

    Click here

  26. REMOVE REAR DOOR SCUFF PLATE RH

    Tech Tips

    Use the same procedure as for the LH side.

    Click here

  27. REMOVE REAR UNDER SIDE COVER RH

    Tech Tips

    Use the same procedure as for the LH side.

    Click here

  28. REMOVE REAR UNDER COVER


    1. B004QCS

      Disengage the 2 clips.

    2. Disengage the 2 guides to remove the rear under cover from the rear seat cushion leg sub-assembly.

  29. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY


    1. B004P1E

      Remove the 6 bolts and rear seat cushion leg sub-assembly.

  30. REMOVE BATTERY COOLING BLOWER ASSEMBLY

    Click here

  31. REMOVE NO. 1 HV BATTERY COVER PANEL RH

    CAUTION:

    Wear insulated gloves.


    1. B004QTNC02
      *1 Service Plug Grip
      *2 Battery Cover Lock Striker
      *a Projection
      *b Turn
      *c Button

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

      Tech Tips

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

    2. Remove the 3 bolts, 2 nuts and No. 1 HV battery cover panel RH from the HV battery.

  32. DISCONNECT HV FLOOR UNDER WIRE

    CAUTION:

    Wear insulated gloves.

    Note

    Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.


    1. B004OPZC02
      *a Shield Ground

      Disconnect the 2 HV battery junction block assembly connectors.

    2. Disconnect the shield ground from the HV battery.

  33. DISCONNECT FLOOR WIRE

    CAUTION:

    Wear insulated gloves.


    1. B004PXY

      Disengage the clamp.

    2. Disconnect the electric vehicle battery plug assembly connector.

    3. Disconnect the HV battery junction block assembly connector.

  34. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT


    1. B004OQ6

      Remove the clip.

    2. Disengage the claw to remove the No. 1 hybrid battery exhaust duct from the HV battery.

  35. DISCONNECT FLOOR WIRE

    CAUTION:

    Wear insulated gloves.


    1. B004OXE

      Disengage the clamp.

    2. Disconnect the battery voltage sensor connector.

  36. REMOVE HV BATTERY

    CAUTION:

    Wear insulated gloves.


    1. B004PBR

      Remove the 5 bolts and HV battery from the vehicle.

      Note


      • Do not allow foreign matter, such as grease or oil, to adhere to the bolts of the HV battery.

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

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

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

      • When removing the HV battery from the vehicle, do not allow it to contact the vehicle.

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

      • Insulate the disconnected terminals or connectors with insulating tape.

      • If the HV battery has been struck or dropped, replace it.

  37. REMOVE UPPER NO. 1 HYBRID BATTERY COVER SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B004QGJ

      Remove the 6 bolts, 5 nuts and upper No. 1 hybrid battery cover sub-assembly from the HV battery.

  38. REMOVE NO. 1 HV BATTERY SHIELD PANEL

    Click here

  39. REMOVE BATTERY VOLTAGE SENSOR

    Click here

  40. REMOVE HYBRID BATTERY TERMINAL BLOCK

    Click here

  41. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY

    Click here

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

    Click here

  43. REMOVE NO. 1 HYBRID BATTERY INTAKE DUCT

    Click here