HV BATTERY STACK 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 supply stack sub-assembly 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)

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

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Initialize back door lock Power door lock control system

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  • Replacement of No. 1 HV supply stack sub-assembly

  • Replacement of No. 2 HV supply stack sub-assembly

  • Replacement of No. 3 HV supply stack sub-assembly

  • Replacement of No. 4 HV supply stack sub-assembly

  • Replacement of No. 5 HV supply stack sub-assembly

  1. Battery diagnosis

  2. Battery status info update

 HV battery status information cannot be updated

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  • Replacement of battery ECU assembly

  • Replacement of HV battery junction block assembly

 Current sensor offset learning DTCs are stored

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

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*1: When performing learning using the GTS.
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CAUTION:


  • B006HTF

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

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  • B006HUP

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

  • The hybrid system has high-voltage circuits. Accidents, such as electric shock, or electric leaks may result if the hybrid system is not operated in a correct manner. Make sure to follow the correct procedure.

  • When disposing of an HV battery or HV supply stack sub-assembly, make sure to return them through an authorized collection agent who is capable of handling them safely.

  • Before returning an HV battery, make sure to perform a recovery inspection.

  • Before returning an HV supply stack sub-assembly, make sure to perform a recovery inspection.

  • Make a note of the output DTCs as some of them may be necessary for "Recovery Inspection" of the HV battery and HV supply stack sub-assemblies.

Note

When replacing the HV supply stack sub-assembly, it is necessary to check, adjust and equalize the SOC of the HV battery. Otherwise, the engine may run longer than normal, resulting in a decrease in fuel efficiency.

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.

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  2. READ VALUE USING GTS


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / HV Battery / Data List / Hybrid Battery Temperature 1 to 15.


      Powertrain > HV Battery > Data List
      Tester Display
      Hybrid Battery Temperature 1
      Hybrid Battery Temperature 2
      Hybrid Battery Temperature 3
      Hybrid Battery Temperature 4
      Hybrid Battery Temperature 5
      Hybrid Battery Temperature 6
      Hybrid Battery Temperature 7
      Hybrid Battery Temperature 8
      Hybrid Battery Temperature 9
      Hybrid Battery Temperature 10
      Hybrid Battery Temperature 11
      Hybrid Battery Temperature 12
      Hybrid Battery Temperature 13
      Hybrid Battery Temperature 14
      Hybrid Battery Temperature 15

    4. Read the Data List.

      Note

      If any of the temperatures listed in "Hybrid Battery Temperature 1 to 15" are 50°C or more, leave the vehicle until the temperature drops to less than 50°C.

  3. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY

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  4. REMOVE BATTERY ECU ASSEMBLY

    Click here

  5. REMOVE HYBRID BATTERY TERMINAL BLOCK

    Click here

  6. REMOVE HV BATTERY HEATER RELAY

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  7. DISCONNECT WIRE HARNESS

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B006IGQ

      Disengage the 3 clamps.

    2. B006J3N

      Disconnect the connector.

    3. Disengage the 6 clamps.

    4. B006I53

      Disconnect the connector.

    5. Disengage the 3 clamps.

    6. Remove the nut.

    7. B006IKO

      Remove the 2 nuts and service plug bracket.

    8. B006IUKN01

      Open the wire harness protector.

    9. Disengage the 6 clamps (B).

    10. Disengage the clamp (A) and remove the wire harness protector.

    11. B006HVB

      Remove the 2 nuts and fuse box bracket.

    12. B006I5H

      Disengage the 4 clamps.

  8. REMOVE NO. 1 BATTERY FRAME

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B006I0T

      Remove the 3 nuts and No. 1 battery frame.

  9. REMOVE NO. 2 BATTERY FRAME

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B006J3S

      Remove the 2 nuts and No. 2 battery frame.

  10. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B006HJG

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

  11. REMOVE NO. 4 HYBRID BATTERY INTAKE DUCT

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B006HHX

      Remove the 5 clips and 5 No. 4 hybrid battery intake ducts from the HV battery.

  12. REMOVE NO. 1 HV BATTERY HOSE

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B006I90

      Remove the 10 clips.

    2. Disengage 10 claws to remove the No. 1 HV battery hose.

  13. REMOVE NO. 1 HYBRID BATTERY PACK WIRE

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.

    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. B006IMZ

      Disconnect the 2 connectors.

    2. B006HYB

      Disconnect the 7 connectors.

    3. B006IVM

      Disengage the 6 clamps.

    4. B006IUP

      Remove the 3 bolts and No. 1 hybrid battery pack wire from the HV battery.

  14. REMOVE NO. 1 HV BATTERY PROTECTOR

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B006HPP

      Remove the bolt and No. 1 HV battery protector from the HV battery.

  15. REMOVE NO. 7 HYBRID BATTERY INTAKE DUCT

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B006IH5

      Disengage the 2 claws of 2 hybrid battery thermistors (sensor portion) and disconnect the hybrid battery thermistor from the No. 7 hybrid battery intake duct.

    2. Disengage each claw to remove the 5 No. 7 hybrid battery intake ducts.

  16. REMOVE NO. 1 HV BATTERY SHIELD REINFORCEMENT

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B006IWH

      Remove the 16 bolts and 4 No. 1 HV battery shield reinforcements.

  17. REMOVE NO. 1 HV SUPPLY STACK SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B006IGZ

      Remove the 4 nuts and No. 1 HV supply stack sub-assembly.

  18. REMOVE NO. 2 HV SUPPLY STACK SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B006IZZ

      Remove the 4 nuts and No. 2 HV supply stack sub-assembly.

  19. REMOVE NO. 3 HV SUPPLY STACK SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B006ILZ

      Remove the 4 nuts and No. 3 HV supply stack sub-assembly.

  20. REMOVE NO. 4 HV SUPPLY STACK SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B006IL3

      Remove the 4 nuts and No. 4 HV supply stack sub-assembly.

  21. REMOVE NO. 5 HV SUPPLY STACK SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B006IZM

      Remove the 4 nuts and No. 5 HV supply stack sub-assembly.

  22. PERFORM RECOVERY INSPECTION


    1. Before returning the HV supply stack sub-assembly, make sure to perform a recovery inspection.

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