HV BATTERY REMOVAL


  1. PRECAUTION

    Tech Tips

    Click here.

  2. READ OUTPUT DTC


    1. Check for DTCs Click here.

      Note

      Check for DTCs and confirm that P0AA6 (High voltage insulation is unusual) is not output before doing removal or installation inside the battery. If the DTC is output, perform troubleshooting first.

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  4. REMOVE BATTERY SERVICE HOLE COVER


    1. A01NG1N

      Disengage the 2 clips and 2 guides, and remove the battery service hole cover.

      Tech Tips

      Because these are 2-piece clips, one side will remain in the bracket when they are being removed.

  5. REMOVE SERVICE PLUG GRIP

    CAUTION:


    • Remove the service plug grip to interrupt a high voltage circuit at the time of the check.

    • Keep the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.

    • All the high voltage wiring connectors are orange colored.


    1. A01NGQ8

      Wear insulated gloves. Remove the service plug grip after sliding the lever of the service plug grip.

      CAUTION:


      • Keep the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.

      • After disconnecting the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals.

      Tech Tips

      Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

  6. REMOVE ENGINE ROOM SIDE COVER LH


    1. A01NFNX

      Remove the 4 clips and engine room side cover LH.

  7. REMOVE ENGINE ROOM SIDE COVER


    1. A01NGSF

      Remove the 4 clips and engine room side cover.

  8. REMOVE COOL AIR INTAKE DUCT SEAL


    1. A01NCUN

      Remove the 6 clips and cool air intake duct seal.

  9. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY


    1. A01NG9A

      Remove the 3 clamps and Disconnect the water hose from the intake air resonator sub-assembly.

    2. Remove the 2 bolts and intake air resonator sub-assembly from the inverter with converter assembly.

  10. REMOVE INLET NO. 2 AIR CLEANER


    1. A01ND8W

      Remove the 2 bolts and inlet No. 2 air cleaner.

  11. REMOVE INVERTER TERMINAL COVER

    CAUTION:

    Wear insulating gloves.


    1. A01NEKJ

      Remove the 11 bolts and inverter terminal cover.

      Note

      Make sure to pull the inverter cover straight up, as a connector is connected to the bottom of the cover.

  12. CHECK TERMINAL VOLTAGE

    CAUTION:

    Wear insulating gloves.

    Note


    • Insulate the removed terminals with insulating tape.

    • Do not allow any foreign objects or water to enter the inverter with converter assembly.


    1. A01NDRD

      Using a voltmeter, measure the voltage between the 2 terminals.

      Standard voltage
      0 V

      Tech Tips

      Use a measuring range of DC 750 V or more on the voltmeter.

  13. INSTALL INVERTER TERMINAL COVER


    1. A01NEKJ

      Temporarily install the inverter cover with the 11 bolts to prevent any foreign objects or water from entering the inverter with converter assembly.

  14. INSTALL INLET NO. 2 AIR CLEANER


    1. A01ND8W

      Install the inlet No. 2 air cleaner with the 2 bolts.

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

  15. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY


    1. A01NG9A

      Install the intake air resonator sub-assembly with the 2 bolts.

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

    2. Connect the 3 water hose clamps to the intake air resonator sub-assembly.

  16. INSTALL COOL AIR INTAKE DUCT SEAL


    1. A01NCUN

      Install the cool air intake duct seal with the 6 clips.

  17. INSTALL ENGINE ROOM SIDE COVER


    1. A01NGSF

      Install the engine room side cover with the 4 clips.

  18. INSTALL ENGINE ROOM SIDE COVER LH


    1. A01NFNX

      Install the engine room side cover with the 4 clips.

  19. REMOVE REAR NO. 1 SEAT ASSEMBLY (for LH Side)

    Tech Tips

    Click here.

  20. REMOVE REAR NO. 1 SEAT ASSEMBLY (for RH Side)

    Tech Tips

    Click here.

  21. REMOVE REAR DOOR SCUFF PLATE LH


    1. A01NEW9

      Disengage the 6 claws, 3 clips and guide, and remove the rear door scuff plate LH.

  22. REMOVE REAR DOOR SCUFF PLATE RH

    Tech Tips

    Perform the same procedure as for the LH side.

  23. REMOVE REAR SEAT SIDE COVER LH


    1. A01NFWF

      Remove the 2 clips.

    2. Disengage the 2 claws and 3 clips, and remove the rear seat side cover LH.

      Tech Tips

      A part of the clip remains on the vehicle side.

  24. REMOVE REAR SEAT SIDE COVER RH

    Tech Tips

    Perform the same procedure as for the LH side.

  25. REMOVE AIR INTAKE COVER


    1. Remove the air intake cover LH.


      1. A01NH4EE02
        Text in Illustration
        *1 Protective Tape

        Release the claw by using a screwdriver with the tip taped, and remove its 2 hole covers.

      2. A01NDIZ

        Remove the 2 screws, then release the 2 claws and remove the air intake cover LH.

    2. Remove the air intake cover CTR.


      1. A01NGKPE01
        Text in Illustration
        *1 Protective Tape

        Release the claw by using a screwdriver with the tip taped, and remove its 2 hole covers.

      2. A01NG8X

        Remove the 2 screws, then release the 2 claws and remove the center air intake cover.

    3. Remove the air intake cover RH.


      1. A01NG83E04
        Text in Illustration
        *1 Protective Tape

        Release the claw by using a screwdriver with its tip taped, and remove the 2 hole covers.

      2. A01NGWJE01

        Remove the 2 screws, then release the 2 claws and remove the air intake cover RH.

  26. SEPARATE FRONT FLOOR CARPET ASSEMBLY


    1. Turn back the front floor carpet assembly.

  27. REMOVE BATTERY CARRIER BRACKET


    1. A01NH9N

      Remove the 2 bolts and battery carrier bracket.

  28. REMOVE BATTERY CARRIER DUCT


    1. A01NGX1

      Remove the 2 bolts and battery carrier duct LH.

    2. A01NF6O

      Remove the 2 bolts and battery carrier duct CTR.

    3. A01NF54

      Remove the 2 bolts and battery carrier duct RH.

  29. REMOVE NO. 1 BATTERY COVER LID

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. A01NGSWE01

      Using the service plug grip, remove the No. 1 battery cover lid.

      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 2 bolts and battery service hole cover.

  30. REMOVE BATTERY COVER SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. A01NDIU

      Remove the bolt and No. 3 wire frame from the battery cover sub-assembly.

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

      A01NFQLE01

      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.

    3. A01NELK

      Disconnect the connector and clamp shown in the illustration.

    4. A01ND58

      Separate the 2 claws and clamp, and remove the indoor electrical key oscillator.

    5. Remove the 25 bolts, 6 nuts and battery cover.

  31. REMOVE BATTERY SMART UNIT

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.

    Note

    Insulate the removed terminals with insulating tape.


    1. A01NDT2

      Disconnect the 3 connectors.

    2. Remove the 2 nuts and battery smart unit.

  32. REMOVE HV BATTERY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.

    Note


    • Make sure to bundle the wire harness with insulation tape to prevent it from getting caught when removing components.

    • Insulate the removed terminals with insulating tape.

    Tech Tips

    Exchange the lower hybrid battery carrier panel as a set when liquids collect at the lower hybrid battery carrier panel and powder sticks.


    1. Remove the HV battery module LH.


      1. A01NET3

        Remove the battery room ventilation hose between the HV battery module LH and center HV battery module.

      2. A01NHZS

        Disconnect the connector and clamp of the battery thermo sensor.

      3. A01NG7K

        Remove the nut and main battery cable from the HV battery module LH.

        Note


        • Insulate the tool with insulating tape.

        • Do not use a universal joint. Using a universal joint may cause the socket extension to drop and create a short circuit.

      4. Disconnect the connector.

      5. A01NCLY

        Remove the nut, then disconnect the EV battery plug from the HV battery module LH.

        Note


        • Insulate the tool with insulating tape.

        • Do not use a universal joint. Using a universal joint may cause the socket extension to drop and create a short circuit.

      6. A01ND66

        Remove the carry belts from the center HV battery module and install them to the HV battery module LH.

        Note

        Insert the ends of the carry belts into the installation holes. Pull the carry belts upward to securely install them.

      7. A01NEZ5

        Remove the HV battery module LH.

      8. Remove the carry belts from the HV battery module LH.

    2. Remove the center HV battery module.


      1. A01NHPN

        Disconnect the connector and clamp.

      2. Separate the 2 wire harness clamps.

      3. A01NH1A

        Disconnect the 2 connectors and clamp.

      4. A01NGZK

        Disconnect the connector.

      5. A01NDIN

        Disconnect the connector and clamp.

      6. A01NDP6

        Remove the battery room ventilation hose between the center HV battery module and HV battery module RH.

      7. Install the carry belts to the center HV battery module.

        Note

        Insert the ends of the carry belts into the installation holes. Pull the carry belts upward to securely install them.

      8. A01NH1R

        Remove the center HV battery module.

      9. Remove the carry belts from the center HV battery module.

    3. Remove the HV battery module RH.


      1. A01NGFI

        Disconnect the connector.

      2. A01NCQ8

        Remove the nut and the No. 2 HV battery pack cable.

        Note


        • Insulate the tool with insulating tape.

        • Do not use a universal joint. Using a universal joint may cause the socket extension to drop and create a short circuit.

      3. A01NFDJ

        Remove the battery room ventilation hose.

      4. Install the carry belts to the HV battery module RH.

        Note

        Insert the ends of the carry belts into the installation holes. Pull the carry belts upward to securely install them.

      5. A01NDZL

        Remove the HV battery module RH.

      6. Remove the carry belts from the HV battery module RH.

  33. REMOVE NO. 2 HV BATTERY PACK CABLE

    Tech Tips

    Exchange the lower hybrid battery carrier panel as a set when liquids collect at the lower hybrid battery carrier panel and powder sticks.


    1. A01NERL

      Remove the nut and the No. 2 HV battery pack cable.

  34. REMOVE BATTERY COOLING BLOWER ASSEMBLY

    Tech Tips

    Exchange the lower hybrid battery carrier panel as a set when liquids collect at the lower hybrid battery carrier panel and powder sticks.


    1. A01NGGJ

      Disconnect each battery cooling blower assembly connector and 3 clamps.

    2. A01NF7C

      Remove the 9 nuts and 3 battery cooling blower assemblies.

  35. REMOVE ELECTRIC VEHICLE BATTERY PLUG ASSEMBLY

    Tech Tips

    Exchange the lower hybrid battery carrier panel as a set when liquids collect at the lower hybrid battery carrier panel and powder sticks.


    1. A01NCRD

      Disconnect the connector and clamp.

    2. A01NCLZ

      Remove the bolt and EV battery plug.

  36. REMOVE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

    Tech Tips

    Exchange the lower hybrid battery carrier panel as a set when liquids collect at the lower hybrid battery carrier panel and powder sticks.


    1. A01NGOS

      Remove the 2 nuts, then disconnect the No. 3 wire frame from the hybrid battery junction block assembly.

    2. A01ND5A

      Disconnect the 2 main battery cable connectors from the hybrid battery junction block assembly.

    3. A01NGCH

      Remove the 3 nuts and hybrid battery junction block assembly.

  37. REMOVE HYBRID BATTERY CARRIER PANEL

    Tech Tips

    Exchange the lower hybrid battery carrier panel as a set when liquids collect at the lower hybrid battery carrier panel and powder sticks.


    1. Remove the hybrid battery carrier panel from the vehicle.

  38. REMOVE NO. 2 BATTERY PACKING

    Tech Tips

    Exchange the lower hybrid battery carrier panel as a set when liquids collect at the lower hybrid battery carrier panel and powder sticks.


    1. A01NHH6

      Remove the No. 2 battery packing from the lower hybrid battery carrier panel.

  39. REMOVE HYBRID BATTERY PACK WIRE


    1. A01NHT2

      Disconnect the 3 clamps, then remove the battery pack wire from the lower hybrid battery carrier panel.

    2. A01NG37

      Remove the battery pack wire from the lower hybrid battery carrier panel.

      Tech Tips

      Remove the foam pad by pushing it in the direction shown in the illustration.

    3. A01NHFY

      Remove the 4 clamps from hybrid battery carrier panel.