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

  3. REMOVE REAR NO. 2 FLOOR BOARD


    1. A01JB5ZE01

      Disengage the 2 guides <A> as shown in the illustration.

    2. Disengage the 3 guides <B> and remove the rear No. 2 floor board.

  4. REMOVE REAR DECK FLOOR BOX


    1. Remove the rear deck floor box.

  5. REMOVE REAR NO. 3 FLOOR BOARD


    1. A01JC33

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

  6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  7. REMOVE SERVICE PLUG GRIP

    CAUTION:


    • Wear insulating gloves.

    • Remove the service plug grip to interrupt the high voltage circuit at the time of inspection or repair.

    • 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 colored in orange.


    1. Wear insulating gloves and remove the service plug grip after sliding up the lever of the service plug grip as shown in the illustration.

      A01JATW

      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 removing the service plug grip, do not touch the high voltage connectors or terminals for 10 minutes.

      Tech Tips

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

  8. REMOVE INVERTER TERMINAL COVER

    CAUTION:

    Wear insulating gloves.


    1. A01J95T

      Remove the 9 bolts and inverter terminal cover.

      Note

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

  9. CHECK TERMINAL VOLTAGE

    CAUTION:

    Wear insulating gloves.

    Note

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


    1. A01J8W4

      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.

  10. INSTALL INVERTER TERMINAL COVER

    CAUTION:

    Wear insulating gloves.

    Note


    • Make sure that the interlock is fully engaged.

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


    1. A01JCVEE01
      Text in Illustration
      *1 Interlock

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

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

  11. REMOVE TONNEAU COVER ASSEMBLY (w/ Tonneau Cover)


    1. Remove the tonneau cover assembly.

  12. REMOVE REAR SEAT CUSHION ASSEMBLY


    1. A01JC67E01
      Text in Illustration
      *1 100 mm (3.94 in.) or less
      *2 Hook
      *3 Guide

      Disengage the 2 front hooks of the seat cushion from the vehicle body as shown in the illustration.

      Note

      Follow the instructions below carefully as the cushion frame deforms easily.


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

      2. Repeat the above procedure for the other hook.

    2. Disengage the 2 guides of the seat cushion from the seatback.

    3. Remove the rear seat cushion assembly.

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


    1. A01J8Q1

      Disengage the 2 claws and 2 clips, and remove the rear No. 1 floor board sub-assembly.

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


    1. A01JCFP

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

  15. REMOVE REAR NO. 1 FLOOR BOARD


    1. A01JBVX

      Remove the bolt.

    2. Disengage the 2 claws and 2 clips, and remove the rear No. 1 floor board.

  16. REMOVE REAR DOOR SCUFF PLATE LH


    1. A01JA7L

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

  17. REMOVE REAR DOOR SCUFF PLATE RH

    Tech Tips

    Use the same procedure described for the LH side.

  18. REMOVE REAR SIDE SEAT BACK ASSEMBLY LH


    1. A01J9D6

      Remove the bolt.

    2. A01J9I5

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

  19. REMOVE REAR SIDE SEAT BACK ASSEMBLY RH


    1. A01JCTM

      Remove the bolt.

    2. A01JB67

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

  20. REMOVE REAR NO. 4 FLOOR BOARD


    1. A01JB13

      Disengage the guide and remove the rear No. 4 floor board.

  21. REMOVE DECK FLOOR BOX LH


    1. A01J9G6

      Remove the clip.

    2. Disengage the 2 guides and remove the deck floor box LH.

  22. REMOVE DECK TRIM SERVICE HOLE COVER


    1. A01JD05

      Disengage the 2 claws and 3 guides, and remove the deck trim service hole cover.

  23. REMOVE REAR DECK TRIM COVER


    1. A01JCDX

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

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


    1. A01JAKN

      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. A01JBMIE01
      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 DECK TRIM SIDE PANEL ASSEMBLY LH


    1. Remove the screw.

    2. Disengage the 7 claws and 2 clips.

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

      A01J8UZ

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

    Tech Tips

    Use the same procedure described for the LH side.

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

    Tech Tips

    Use the same procedure described for the LH side.

  29. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH


    1. Remove the screw.

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

      A01JCY2

  30. REMOVE REAR FLOOR BOARD SPACER


    1. A01JA4L

      Remove the 2 clips and rear floor board spacer.

  31. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT


    1. A01J8X8

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

  32. REMOVE UPPER HYBRID BATTERY COVER SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. A01JB3CE01

      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. Remove the 4 nuts and upper hybrid battery cover sub-assembly.

  33. REMOVE NO. 1 HYBRID BATTERY INTAKE DUCT


    1. A01J9LJ

      Remove the 2 clips and No. 1 hybrid battery intake duct.

  34. REMOVE BATTERY COOLING BLOWER ASSEMBLY

    Note


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

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


    1. A01JB2I

      Disconnect the 3 wire harness clamps.

    2. A01JBO7

      Disconnect the battery cooling blower assembly connector and clamp.

    3. Remove the 2 bolts, nut and battery cooling blower assembly.

  35. REMOVE NO. 7 HYBRID VEHICLE BATTERY UPPER CARRIER BRACKET


    1. A01J9XJ

      Disconnect the wire harness clamp.

    2. Remove the bolt and No. 7 hybrid battery upper carrier bracket.

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


    1. A01JB81

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

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


    1. A01JAMP

      Disconnect the wire harness protector clamp.

    2. A01JD9C

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

  38. REMOVE FRAME WIRE

    CAUTION:


    • Wear insulating gloves.

    • Insulate the removed terminals with insulating tape.


    1. A01JC0Y

      Remove the 2 nuts, then disconnect the frame wire from the hybrid battery junction block assembly.

    2. Disconnect the clamp and frame wire.

  39. REMOVE HV BATTERY ASSEMBLY

    CAUTION:

    Wear insulating gloves.


    1. A01JD7Z

      Disconnect the connector and electrical key oscillator clamp.

    2. A01JBRA

      Remove the 4 bolts shown in the illustration.

    3. Remove the HV battery.

  40. REMOVE HYBRID BATTERY JUNCTION BLOCK

    CAUTION:

    Wear insulating gloves.


    1. A01JC1W

      Disconnect the 2 connectors from the hybrid battery junction block.

    2. A01JA5F

      Disconnect the 2 connectors from the hybrid battery junction block.

    3. A01J8LF

      Remove the 3 nuts and hybrid battery junction block.

  41. REMOVE BATTERY SMART UNIT

    CAUTION:

    Wear insulating gloves.


    1. A01JA5A

      Disconnect the 3 connectors.

    2. Remove the 2 nuts and battery smart unit.

  42. REMOVE NO. 1 HYBRID VEHICLE BATTERY CARRIER BRACKET SUB-ASSEMBLY

    CAUTION:

    Wear insulating gloves.


    1. A01JCGS

      Disconnect the connector.

    2. Remove the bolt and EV battery plug as shown in the illustration.

    3. A01JAG1E01

      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.

    4. Remove the 3 nuts and No. 1 hybrid vehicle battery carrier bracket sub-assembly.

  43. REMOVE NO. 4 HYBRID VEHICLE BATTERY CARRIER BRACKET SUB-ASSEMBLY

    CAUTION:

    Wear insulating gloves.


    1. A01J8O1

      Disconnect the 3 wire harness clamps.

    2. Remove the 3 bolts and No. 4 hybrid vehicle battery carrier bracket sub-assembly.

    3. A01J9BE

      Disengage the 2 claws and remove the HV battery thermistor.

  44. REMOVE NO. 1 HYBRID BATTERY COVER INTAKE DUCT


    1. A01J9D2

      Remove the 2 clips and No. 1 hybrid battery cover intake duct.

  45. REMOVE UPPER HYBRID BATTERY COVER SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. A01J9EJ

      Remove the 3 bolts, 8 nuts and battery cover with the No. 1 hybrid battery shield sub-assembly.

  46. REMOVE NO. 1 HYBRID BATTERY PACKING

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. A01JAYD

      Remove the 2 clamps and No. 1 hybrid battery packing.

  47. REMOVE NO. 2 HYBRID BATTERY PACK WIRE


    1. A01JABK

      Disconnect the 2 clamps, then remove the No. 2 hybrid battery pack wire.