HV BATTERY STACK INSTALLATION


  1. INSTALL NO. 4 HYBRID VEHICLE SUPPLY STACK SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.

    Note

    Before installing a new hybrid vehicle supply stack sub-assembly, the voltage should be adjusted to the appropriate value.


    1. Install the No. 4 hybrid vehicle supply stack sub-assembly with the 4 nuts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    2. Install the No. 2 hybrid vehicle battery shield reinforcement with the 3 bolts.

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

      Tech Tips

      Install the center bolt first.

    3. Install the No. 1 hybrid vehicle battery shield reinforcement with the 3 bolts.

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

      Tech Tips

      Install the center bolt first.

    4. Install the No. 1 hybrid battery exhaust duct and No. 2 hybrid battery exhaust duct with the 8 claws.

    5. Install the No. 5 hybrid battery intake duct with the 4 claws.

    6. Using an insulated tool, Install the No. 3 hybrid vehicle battery pack cable with a new bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Note


      • The terminal cover should be connected securely.

      • Make sure to connect the No. 3 hybrid vehicle battery pack cable securely. If the power switch is turned on (READY) without the No. 3 hybrid vehicle battery pack cable connected, the inner circuit of the battery smart unit will be damaged due to high voltage supplied through the battery block voltage detection circuit.

    7. Using an insulated tool, connect the No. 2 hybrid vehicle battery pack cable with a new bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Note

      The terminal cover should be connected securely.

  2. INSTALL NO. 3 HYBRID VEHICLE SUPPLY STACK SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.

    Note

    Before installing a new hybrid vehicle supply stack sub-assembly, the voltage should be adjusted to the appropriate value.


    1. Install the No. 3 hybrid vehicle supply stack sub-assembly with the 4 nuts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    2. Install the 2 No. 2 hybrid vehicle battery shield reinforcements with the 6 bolts.

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

      Tech Tips

      Install the center bolt first.

    3. Install the No. 1 hybrid battery exhaust duct and No. 2 hybrid battery exhaust duct with the 8 claws.

    4. Install the No. 5 hybrid battery exhaust duct and No. 6 hybrid battery exhaust duct with the 8 claws.

    5. Using an insulated tool, connect the No. 3 hybrid vehicle battery pack cable with a new bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Note


      • The terminal cover should be connected securely.

      • Make sure to connect the No. 3 hybrid vehicle battery pack cable securely. If the power switch is turned on (READY) without the No. 3 hybrid vehicle battery pack cable connected, the inner circuit of the battery smart unit will be damaged due to high voltage supplied through the battery block voltage detection circuit.

    6. Install the hybrid battery terminal block with the 2 claws.

    7. Using an insulated tool, install the No. 6 hybrid vehicle battery terminal with the nut.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Note

      The terminal cover should be connected securely.

    8. Install the electric vehicle battery plug assembly and No. 1 hybrid vehicle battery rear shield bracket with the 3 nuts.

      Torque:
      10 N*m  { 105 kgf*cm, 8 ft.*lbf }

    9. Connect the connector to the electric vehicle battery plug assembly.

    10. Using an insulated tool, connect the electric vehicle battery plug assembly with a new nut.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Note

      The terminal cover should be connected securely.

    11. Using an insulated tool, install the electric vehicle fuse with the 2 bolts.

      A0041I7E01
      Text in Illustration
      *A Type A *B Type B
      *a Number of horizontal lines: 1 *b Number of horizontal lines: 2
      Torque:
      Type A
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
      Type B
      6.2 N*m  { 63 kgf*cm, 55 in.*lbf }

      Tech Tips

      The type of the electric vehicle fuse (A or B) can be confirmed by the number of horizontal lines indicated on its label.

  3. INSTALL NO. 2 HYBRID VEHICLE SUPPLY STACK SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.

    Note

    Before installing a new hybrid vehicle supply stack sub-assembly, the voltage should be adjusted to the appropriate value.


    1. Install the No. 2 hybrid vehicle supply stack sub-assembly with the 4 nuts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    2. Install the 2 No. 2 hybrid vehicle battery shield reinforcements with the 6 bolts.

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

      Tech Tips

      Install the center bolt first.

    3. Install the No. 1 hybrid battery exhaust duct and No. 2 hybrid battery exhaust duct with the 8 claws.

    4. Install the No. 5 hybrid battery exhaust duct and No. 6 hybrid battery exhaust duct with the 8 claws.

    5. Using an insulated tool, connect the No. 3 hybrid vehicle battery pack cable with a new bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Note


      • The terminal cover should be connected securely.

      • Make sure to connect the No. 3 hybrid vehicle battery pack cable securely. If the power switch is turned on (READY) without the No. 3 hybrid vehicle battery pack cable connected, the inner circuit of the battery smart unit will be damaged due to high voltage supplied through the battery block voltage detection circuit.

    6. Using an insulated tool, connect the electric vehicle battery plug assembly with a new nut.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Note

      The terminal cover should be connected securely.

  4. INSTALL NO. 1 HYBRID VEHICLE SUPPLY STACK SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.

    Note

    Before installing a new hybrid vehicle supply stack sub-assembly, the voltage should be adjusted to the appropriate value.


    1. Install the No. 1 hybrid vehicle supply stack sub-assembly with the 4 nuts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    2. Install the No. 2 hybrid vehicle battery shield reinforcement with the 3 bolts.

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

      Tech Tips

      Install the center bolt first.

    3. Install the No. 1 hybrid vehicle battery shield reinforcement with the 3 bolts.

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

      Tech Tips

      Install the center bolt first.

    4. Install the No. 1 hybrid battery exhaust duct and No. 2 hybrid battery exhaust duct with the 8 claws.

    5. Install the No. 5 hybrid battery exhaust duct with the 4 claws.

    6. Using an insulated tool, connect the No. 3 hybrid vehicle battery pack cable with a new bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Note


      • The terminal cover should be connected securely.

      • Make sure to connect the No. 3 hybrid vehicle battery pack cable securely. If the power switch is turned on (READY) without the No. 3 hybrid vehicle battery pack cable connected, the inner circuit of the battery smart unit will be damaged due to high voltage supplied through the battery block voltage detection circuit.

    7. Using an insulated tool, connect the No. 1 hybrid vehicle battery pack cable with a new bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Note

      The terminal cover should be connected securely.

  5. INSTALL NO. 1 HYBRID VEHICLE BATTERY HOSE

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. Install the No. 1 hybrid vehicle battery hose with the 8 clips.

  6. INSTALL NO. 2 HYBRID VEHICLE BATTERY HOSE

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. Install the No. 2 hybrid vehicle battery hose with the 2 clips.

  7. INSTALL NO. 3 HYBRID BATTERY INTAKE DUCT


    1. Install the No. 3 hybrid battery intake duct with the 2 clips.

    2. Connect the 2 intake air temperature sensor and 4 clamps.

  8. INSTALL NO. 4 HYBRID BATTERY INTAKE DUCT


    1. Install the No. 4 hybrid battery intake duct with the 2 clips.

    2. Connect the 2 intake air temperature sensor and 3 clamps.

  9. INSTALL NO. 2 HYBRID BATTERY INTAKE DUCT


    1. Install the No. 2 hybrid battery intake duct with the clip.

  10. INSTALL NO. 1 HYBRID BATTERY INTAKE DUCT


    1. Install the No. 1 hybrid battery intake duct with the clip.

  11. INSTALL BATTERY SMART UNIT

    CAUTION:

    Wear insulated gloves.


    1. A0042QS
      A00405JE01

      Install the battery smart unit with the 2 nuts.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

      Note

      Check color of the label.

      Text in Illustration
      *a Black Label
    2. A0042UZ

      Be sure to connect the No. 3 hybrid vehicle battery pack cable to the correct terminals.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Note


      • The terminal cover should be connected securely.

      • Make sure to connect the No. 3 hybrid vehicle battery pack cable securely. If the power switch is turned on (READY) without the No. 3 hybrid vehicle battery pack cable connected, the inner circuit of the battery smart unit will be damaged due to high voltage supplied through the battery block voltage detection circuit.

    3. Connect the 4 connectors to the battery smart unit.

      Note

      Make sure that the connectors are connected securely.

    4. Connect the 3 connectors to the battery smart unit.

  12. INSTALL HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

    Click here

  13. PERFORM UTILITY

    Note

    Make sure to perform "Battery Status Info Update" if the hybrid vehicle supply stack sub-assembly or HV battery is replaced Click here.