HV BATTERY STACK 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 sub-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 TB1 - 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. PERFORM UTILITY

    Tech Tips

    Make sure to perform "Normal Battery Stack Average Voltage Calculation" before removing a hybrid vehicle supply stack sub-assembly to be able to appropriately adjust the voltage of the replacement stack Click here.

  5. REMOVE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

    Click here

  6. REMOVE BATTERY SMART UNIT

    CAUTION:

    Wear insulated gloves.


    1. A0043FD

      Disconnect the 3 connectors.

    2. A004089

      Disconnect the 4 connectors.

      Note

      Insulate the removed connectors with insulating tape.

    3. A0042QS

      Remove the 2 nuts and battery smart unit.

  7. REMOVE NO. 1 HYBRID BATTERY INTAKE DUCT


    1. A00410G

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

  8. REMOVE NO. 2 HYBRID BATTERY INTAKE DUCT


    1. A00446V

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

  9. REMOVE NO. 4 HYBRID BATTERY INTAKE DUCT

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. A0041G3

      Disconnect the 2 intake air temperature sensors and 3 clamps.

      Note

      When disengaging each intake air temperature sensor, pull out the clamp while squeezing.

    2. Disconnect the 2 clips and remove the No. 4 hybrid battery intake duct.

  10. REMOVE NO. 3 HYBRID BATTERY INTAKE DUCT

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. A00443T

      Disconnect the 2 intake air temperature sensors and 4 clamps.

      Note

      When disengaging each intake air temperature sensor, pull out the clamp while squeezing.

    2. Disconnect the 2 clips and remove the No. 3 hybrid battery intake duct .

  11. REMOVE NO. 2 HYBRID VEHICLE BATTERY HOSE

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. A0041YF

      Disconnect the 2 clips and remove the No. 2 hybrid vehicle battery hose.

  12. REMOVE NO. 1 HYBRID VEHICLE BATTERY HOSE

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. A0042XV

      Disconnect the 8 clips and remove the No. 1 hybrid vehicle battery hose.

  13. REMOVE NO. 1 HYBRID VEHICLE SUPPLY STACK SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. A0043NS

      Using an insulated tool, remove the nut and disconnect the No. 1 hybrid vehicle battery pack cable.

      Note

      Insulate the disconnected terminal with insulating tape.

    2. A00426S

      Using an insulated tool, remove the nut and disconnect the No. 3 hybrid vehicle battery pack cable.

      Note

      Insulate the disconnected terminal with insulating tape.

    3. A0043N4

      Disengage the 4 claws and remove the No. 5 hybrid battery intake duct.

    4. A00434X

      Disengage the 8 claws and remove the No. 1 hybrid battery exhaust duct and No. 2 hybrid battery exhaust duct.

    5. A00413F

      Remove the 3 bolts and No. 1 hybrid vehicle battery shield reinforcement.

    6. A0042XP

      Remove the 3 bolts and No. 2 hybrid vehicle battery shield reinforcement.

    7. A0042EC

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

      Note

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

  14. REMOVE NO. 2 HYBRID VEHICLE SUPPLY STACK SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. A004041

      Using an insulated tool, remove the nut and disconnect the electric vehicle battery plug assembly.

      Note

      Insulate the disconnected terminal with insulating tape.

    2. A0040RP

      Using an insulated tool, remove the nut and disconnect the No. 3 hybrid vehicle battery pack cable.

      Note

      Insulate the disconnected terminal with insulating tape.

    3. A00434X

      Disengage the 8 claws and remove the No. 1 hybrid battery exhaust duct and No. 2 hybrid battery exhaust duct.

    4. A003ZWQ

      Disengage the 8 claws and remove the No. 5 hybrid battery exhaust duct and No. 6 hybrid battery exhaust duct.

    5. A0041ZB

      Remove the 6 bolts and 2 No. 2 hybrid vehicle battery shield reinforcements.

    6. A00433J

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

      Note

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

  15. REMOVE NO. 3 HYBRID VEHICLE SUPPLY STACK SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. A0040ZY

      Using an insulated tool, remove the 2 bolts and electric vehicle fuse.

    2. A004041

      Using an insulated tool, remove the nut and disconnect the electric vehicle battery plug assembly.

      Note

      Insulate the disconnected terminal with insulating tape.

    3. A0040VIE01

      Disconnect the connector.

    4. Remove the 3 nuts, electric vehicle battery plug assembly and No. 1 hybrid vehicle battery rear shield bracket.

    5. A0043ED

      Using an insulated tool, remove the nut and No. 6 hybrid vehicle battery terminal.

    6. Disengage the 2 claws and remove the hybrid battery terminal block.

    7. A0043FZ

      Using an insulated tool, remove the nut and disconnect the No. 3 hybrid vehicle battery pack cable.

      Note

      Insulate the disconnected terminal with insulating tape.

    8. A003ZWQ

      Disengage the 8 claws and remove the No. 1 hybrid battery exhaust duct and No. 2 hybrid battery exhaust duct.

    9. A003ZWU

      Disengage the 8 claws and remove the No. 5 hybrid battery exhaust duct and No. 6 hybrid battery exhaust duct.

    10. A00402E

      Remove the 6 bolts and 2 No. 2 hybrid vehicle battery shield reinforcements.

    11. A0041KP

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

      Note

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

  16. REMOVE NO. 4 HYBRID VEHICLE SUPPLY STACK SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. A0040JW

      Using an insulated tool, remove the nut and disconnect the No. 2 hybrid vehicle battery pack cable.

      Note

      Insulate the disconnected terminal with insulating tape.

    2. A0043B3

      Using an insulated tool, remove the nut and disconnect the No. 3 hybrid vehicle battery pack cable.

      Note

      Insulate the disconnected terminal with insulating tape.

    3. A00412E

      Disengage the 4 claws and remove the No. 5 hybrid battery intake duct.

    4. A003ZWU

      Disengage the 8 claws and remove the No. 1 hybrid battery exhaust duct and No. 2 hybrid battery exhaust duct.

    5. A004361

      Remove the 3 bolts and No. 1 hybrid vehicle battery shield reinforcement.

    6. A00436G

      Remove the 3 bolts and No. 2 hybrid vehicle battery shield reinforcement.

    7. A004394

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

      Note

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

  17. PERFORM RECOVERY INSPECTION


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