HV BATTERY REMOVAL


  1. PRECAUTION

    CAUTION:


    • 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 Click here.

    • When disposing of HV batteries and hybrid vehicle supply stack assemblies, make sure to return them through an authorized collection agent who is capable of handling them safely.

    • Before returning the HV battery, make sure to perform a recovery inspection Click here.

    • Before returning the hybrid vehicle supply stack sub-assembly, make sure to perform a recovery inspection Click here.

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

  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 / Hybrid Control / Data List / Temp of Batt TB 1 - 12.

    4. Read the Data List.

      Note

      If any of the temperatures listed in "Temp of Batt TB1 - 12" are 50°C or more, leave the vehicle until the temperature drops to less than 50°C.

  3. CHECK FOR DTCS


    1. Check for DTCs Click here

      Note

      Confirm that DTC P0AA6 (Hybrid Battery Voltage System Isolation Fault) is not output before doing removal or installation work inside the battery. If this DTC is output, perform troubleshooting for this DTC first.

  4. REMOVE SERVICE PLUG GRIP

    Click here

  5. REMOVE INVERTER COVER

    CAUTION:

    Wear insulated gloves.


    1. A00446H

      Remove the 9 bolts and inverter cover.

      Note

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

  6. CHECK TERMINAL VOLTAGE

    CAUTION:

    Wear insulated gloves.

    Note

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


    1. A0041DD

      Using a voltmeter, measure the voltage between the terminals of the 2 phase connectors.

      Standard voltage
      0 V

      Tech Tips

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

  7. INSTALL INVERTER COVER

    CAUTION:

    Wear insulated gloves.


    1. A0042LKE01
      Text in Illustration
      *1 Interlock

      Install the inverter cover with the 9 bolts to the inverter with converter assembly.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

      Note


      • Make sure that the interlock is fully engaged.

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

  8. REMOVE REAR NO. 2 FLOOR BOARD


    1. A00449U

      Using a clip remover, remove the 2 clips.

    2. Disengage the 3 fasteners and remove the rear No. 2 floor board.

  9. REMOVE REAR NO. 4 FLOOR BOARD SUB-ASSEMBLY


    1. Remove the rear No.4 floor board sub-assembly.

  10. REMOVE DECK FLOOR BOX LH

    Tech Tips

    Use the same procedure as for the RH side Click here.

  11. REMOVE TONNEAU COVER ASSEMBLY


    1. Remove the tonneau cover assembly.

  12. REMOVE REAR NO. 2 FLOOR BOARD SUB-ASSEMBLY


    1. A0043P1

      Disengage the claw and 2 clips, and remove the rear No. 2 floor board sub-assembly.

  13. REMOVE REAR NO. 1 FLOOR BOARD SUB-ASSEMBLY


    1. A004109

      Disengage the claw and 3 clips, and remove the rear No. 1 floor board sub-assembly.

  14. REMOVE REAR NO. 1 FLOOR BOARD


    1. Fold the rear seatback assembly LH forward.

    2. A0042PSE01
      Text in Illustration
      *1 Fastener

      Disengage the fastener.

    3. Fold the rear seatback assembly LH forward.

    4. A0040XLE01
      Text in Illustration
      *1 Fastener

      Disengage the fastener.

    5. A0043PV

      Using a clip remover, remove the clip.

    6. Disengage the 3 fasteners and remove the rear No. 1 floor board.

  15. REMOVE DECK TRIM SERVICE HOLE COVER


    1. A0040WX

      Disengage the 4 claws.

    2. Disengage the 4 guides and remove the deck trim service hole cover.

  16. REMOVE REAR DECK TRIM COVER


    1. A0043JF

      Disengage the 4 claws and remove the rear deck trim cover.

  17. REMOVE REAR DOOR SCUFF PLATE LH


    1. A0040QT

      Disengage the 7 claws and remove the rear door scuff plate LH.

  18. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH


    1. A0042YY

      Remove the rear door opening trim weatherstrip LH.

  19. REMOVE REAR DOOR SCUFF PLATE RH

    Tech Tips

    Use the same procedure described for the LH side.

  20. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH

    Tech Tips

    Use the same procedure described for the LH side.

  21. REMOVE REAR SEAT CUSHION ASSEMBLY


    1. A0041DUE01
      Text in Illustration
      *1 Front Hook
      *2 Rear Hook

      Disengage the front hook of the rear seat cushion assembly from the vehicle body as shown in the illustration.

      Standard Measurement
      Dimension Measurement
      a 100 mm (3.94 in.) or less

      Note

      Follow the instructions below carefully as the cushion frame can be deformed easily.


      1. Choose a front hook to disengage first. Place your hands near the front hook as shown in the illustration. Then lift the seat cushion to disengage the front hook.

      2. Repeat the above procedure for the other hook.

    2. Disengage the 2 rear hooks of the rear seat cushion assembly from the rear seatback assembly.

    3. Remove the rear seat cushion assembly.

      Note

      Be careful not to damage the vehicle body.

  22. REMOVE REAR SIDE SEATBACK ASSEMBLY LH


    1. A0042ZC

      Remove the bolt.

    2. A0043ARE01
      Text in Illustration
      *1 Fastener

      Disengage the fastener.

    3. A0042MX

      Disengage the 2 guides and remove the rear side seatback assembly LH as shown in the illustration.

  23. REMOVE REAR SIDE SEATBACK ASSEMBLY RH


    1. A0041NL

      Remove the bolt.

    2. A0041DQE01
      Text in Illustration
      *1 Fastener

      Disengage the fastener.

    3. A0041ZJ

      Disengage the 2 guides and remove the rear side seatback assembly RH as shown in the illustration.

  24. REMOVE LUGGAGE HOLD BELT STRIKER ASSEMBLY (for LH Side)


    1. A0042TO

      Remove the 2 bolts.

    2. Disengage each guide and remove the 2 luggage hold belt striker assemblies.

  25. REMOVE TONNEAU COVER HOLDER CAP (for LH Side)


    1. A0043ZDE01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, disengage the claw and remove the tonneau cover holder cap.

      Tech Tips

      Tape the screwdriver tip before use.

  26. REMOVE LUGGAGE HOLD BELT STRIKER ASSEMBLY (for RH Side)

    Tech Tips

    Use the same procedure described for the LH side.

  27. REMOVE TONNEAU COVER HOLDER CAP (for RH Side)

    Tech Tips

    Use the same procedure described for the LH side.

  28. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH


    1. Remove the screw.

      A0041IQ

    2. Disengage the 7 claws and 2 clips.

    3. Disconnect the connector and remove the deck trim side panel assembly LH.

  29. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH


    1. Remove the screw.

      A0040C2

    2. Disengage the 7 claws and 2 clips, and remove the deck trim side panel assembly RH.

  30. REMOVE BATTERY COOLING BLOWER ASSEMBLY (for RH Side)

    Note


    • Be sure not to touch the fan part of the battery cooling blower assembly.

    • Do not lift the battery cooling blower assembly using the wire harness.


    1. A0044AD

      Disconnect the connector and clamp from the battery cooling blower assembly.

    2. Remove the 3 nuts and battery cooling blower assembly (for RH side).

  31. REMOVE BATTERY COOLING BLOWER ASSEMBLY (for LH Side)

    Note


    • Be sure not to touch the fan part of the battery cooling blower assembly.

    • Do not lift the battery cooling blower assembly using the wire harness.


    1. A0042D1

      Disconnect the connector and clamp from the battery cooling blower assembly.

    2. Remove the 3 nuts and battery cooling blower assembly (for LH side).

  32. REMOVE HYBRID BATTERY HOSE ASSEMBLY


    1. A0042GS

      Disconnect the clip.

    2. Disengage the claw.

    3. Disconnect the grommet and remove the hybrid battery hose assembly.

  33. REMOVE NO. 4 HYBRID VEHICLE BATTERY CARRIER BRACKET


    1. A0041TP

      Remove the bolt and No. 4 hybrid vehicle battery carrier bracket.

  34. REMOVE NO. 2 HYBRID VEHICLE BATTERY SHIELD PANEL

    CAUTION:

    Wear insulated gloves.


    1. A00445NE01
      Text in Illustration
      *1 Battery Cover Lock Striker
      *2 Button
      *a Projection
      *b Turn

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

      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. A0042Z5

      Remove the 3 nuts and No. 2 hybrid vehicle battery shield panel.

  35. REMOVE NO. 1 HYBRID VEHICLE BATTERY SHIELD PANEL

    CAUTION:

    Wear insulated gloves.


    1. A00415T

      Disengage the 2 claws and remove the 3 clamps and electrical key oscillator.

    2. A0040AS

      Disconnect the connector and clamp.

    3. Remove the 7 nuts and No. 1 hybrid vehicle battery shield panel.

  36. DISCONNECT EV CHARGER WIRE

    CAUTION:

    Wear insulated gloves.


    1. A004014

      Disconnect the connector.

      Note

      Insulate the disconnected connector with insulating tape.

    2. Remove the nut and disconnect the electric vehicle charger wire.

  37. DISCONNECT FRAME WIRE

    CAUTION:

    Wear insulated gloves.


    1. A0041UN

      Using an insulated tool, remove the 2 nuts.

    2. Disconnect the shield wire ground and frame wire.

      Note

      Insulate the disconnected terminal with insulating tape.

  38. REMOVE NO. 1 HYBRID BATTERY INTAKE DUCT


    1. A00410G

      Remove the clip and No. 1 hybrid battery intake duct.

  39. REMOVE NO. 2 HYBRID BATTERY INTAKE DUCT


    1. A00446V

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

  40. REMOVE HV BATTERY

    CAUTION:

    Wear insulated gloves.

    Note


    • Insulate the removed connectors and terminals with insulating tape.

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


    1. Remove the 2 bolts from each upper back door damper stay bracket.

      Tech Tips

      Have an assistant support the back door.

    2. Rotate each upper back door damper stay bracket upside-down as shown in the illustration and install them with the 2 bolts.

      A0040ND

      Tech Tips

      Make sure to provide enough clearance so that the vehicle body will not be damaged during removal/installation of the HV battery.

    3. A00414J

      Disconnect the clamp.

    4. A004483

      Disconnect the connector and 2 clamps.

    5. A0041AY

      Disconnect the 4 clamps.

    6. A0040MV

      Remove the 2 bolts.

    7. A0042Q3

      Install the 2 engine hangers (12281-28010) with the 2 bolts as shown in the illustration.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }
    8. A00433O

      Remove the 8 bolts and 2 nuts.

    9. A0041YUE01
      Text in Illustration
      *1 Hook

      Set the hooks and straps as shown in the illustration.

    10. Using a suitable adaptor such as straps, remove the HV battery.

      CAUTION:

      To prevent any accidents and injuries due to the weight of the HV battery, follow all specified procedures and be careful to balance the HV battery when removing or installing it.

      Note

      Make sure that the HV battery does not interfere with the vehicle body during removal or installation.

  41. REMOVE ELECTRIC VEHICLE CHARGER ASSEMBLY

    CAUTION:

    Wear insulated gloves.


    1. A00430D

      Disconnect the 2 connectors.

    2. A00412RE01
      Text in Illustration
      *a Green-colored Lock

      Disconnect the clamp.

    3. Using a screwdriver, slide the 2 green-colored locks of the 2 connectors in the direction indicated by the arrow in the illustration to release them and disconnect the 2 connectors.

      Note

      Insulate the removed connectors and terminals and connector with insulating tape.

    4. A00408P

      Disconnect the 2 clamps.

    5. A004141

      Remove the 4 bolts and electric vehicle charger assembly.

    6. A0040FK

      Remove the 4 bolts and 2 electric vehicle charger brackets.

  42. REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY RH


    1. A00428W

      Disconnect the clamp.

    2. Remove the 2 bolts and child restraint seat anchor bracket sub-assembly RH.

  43. REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB-ASSEMBLY LH


    1. A0040Y8

      Remove the 2 bolts and child restraint seat anchor bracket sub-assembly LH.

  44. REMOVE NO. 2 HYBRID VEHICLE BATTERY MOUNT BRACKET


    1. A0040BP

      Disconnect the 4 clamps.

    2. A00449D

      Remove the 2 bolts and No. 2 hybrid vehicle battery mount bracket.

  45. REMOVE NO. 1 HYBRID VEHICLE BATTERY MOUNT BRACKET


    1. A0041P2

      Remove the 2 bolts and No. 1 hybrid vehicle battery mount bracket.

  46. PERFORM RECOVERY INSPECTION


    1. Before returning the HV battery, make sure to perform a recovery inspection Click here.