HV BATTERY REMOVAL


  1. PRECAUTION

    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 for this DTC first.

  3. REMOVE REAR FLOOR MAT


    1. A003TLX

      Remove the rear floor mat.

  4. REMOVE REAR DECK FLOOR BOX


    1. A003TAA

      Remove the rear deck floor box.

  5. REMOVE BATTERY BOX COVER


    1. A003UZD

      Disengage the 3 guides and remove the battery box cover.

  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.

      A003U1R

      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. A003UIY

      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. A003TFR

      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. A003RRSE01
      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 PACKAGE TRAY TRIM PANEL ASSEMBLY


    1. A003SY6

      Disengage the 2 suspenders.

    2. Disengage the 2 pins and remove the package tray trim panel assembly.

  12. REMOVE DECK BOARD SUB-ASSEMBLY


    1. A003SXQ

      Disengage the 3 claws and 3 clips, and remove the deck board sub-assembly.

  13. REMOVE NO. 6 BATTERY CARRIER PANEL


    1. A003THNE01
      Text in Illustration
      *1 Double-sided Tape

      Remove the No. 6 battery carrier panel as shown in the illustration.

  14. REMOVE REAR NO. 1 FLOOR BOARD


    1. A003SLI

      Remove the bolt.

    2. Disengage the 2 claws, 2 clips and 3 guides, and remove the rear No. 1 floor board.

  15. REMOVE REAR SEAT ASSEMBLY LH

    Click here

  16. REMOVE REAR SEAT ASSEMBLY RH

    Click here

  17. REMOVE REAR DOOR SCUFF PLATE RH

    Tech Tips

    Use the same procedure described for the LH side Click here.

  18. REMOVE REAR SEATBACK HINGE SUB-ASSEMBLY (for LH Side)


    1. A003U0G

      Remove the bolt and rear seatback hinge sub-assembly.

  19. REMOVE REAR SEATBACK HINGE SUB-ASSEMBLY (for RH Side)

    Tech Tips

    Use the same procedure described for the LH side.

  20. REMOVE REAR SEAT SIDE GARNISH RH


    1. A003S7L

      Disengage the 6 claws and 2 clips, and remove the rear seat side garnish RH.

  21. REMOVE REAR FLOOR BOARD SPACER


    1. A003U03

      Remove the 2 clips and rear floor board spacer.

  22. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT


    1. A003UG0

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

  23. REMOVE HYBRID BATTERY COVER SHEET


    1. A003RPL

      Remove the 2 hybrid battery cover sheet.

  24. REMOVE UPPER HYBRID BATTERY COVER SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. A003U1OE02
      Text in Illustration
      *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. Remove the 4 nuts and upper hybrid battery cover sub-assembly.

  25. REMOVE NO. 1 HYBRID BATTERY INTAKE DUCT


    1. A003RSF

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

  26. REMOVE BATTERY COOLING BLOWER ASSEMBLY

    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. A003U79

      Disconnect the 3 wire harness clamps.

    2. A003RJZ

      Disconnect the battery cooling blower assembly connector and clamp.

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

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


    1. A003SXC

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

  28. REMOVE REAR CENTER SEAT BACK HINGE SUB-ASSEMBLY


    1. A003SST

      Remove the 2 bolts and rear center seat back hinge sub-assembly.

  29. REMOVE CROSS ANCHOR BRACKET SUB-ASSEMBLY LH


    1. A003T47

      Remove the 2 bolts and cross anchor bracket sub-assembly LH.

  30. REMOVE CROSS ANCHOR BRACKET SUB-ASSEMBLY RH


    1. A003SEQ

      Remove the 2 bolts and cross anchor bracket sub-assembly RH.

    2. Disconnect the wire harness protector clamp.

  31. REMOVE FRAME WIRE

    CAUTION:


    • Wear insulating gloves.

    • Insulate the removed terminals with insulating tape.


    1. A003T59

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

    2. Disconnect the clamp and frame wire.

  32. REMOVE HV BATTERY ASSEMBLY

    CAUTION:

    Wear insulating gloves.


    1. A003SX6

      Disconnect the connector and electrical key oscillator clamp.

    2. A003U74

      Remove the 4 bolts shown in the illustration.

    3. Remove the HV battery.

      Note


      • To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.

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

      • While lowering the HV battery from the vehicle, do not allow it to contact the vehicle.

      • When moving the hybrid battery assembly, make sure to use an engine lifter.

      Tech Tips

      Attach tape to the feet and edges of the battery to protect tools and the vehicle body.

  33. REMOVE HYBRID BATTERY JUNCTION BLOCK

    CAUTION:

    Wear insulating gloves.


    1. A003SD9

      Disconnect the 2 connectors from the hybrid battery junction block.

    2. A003TOX

      Disconnect the 2 connectors from the hybrid battery junction block.

    3. A003UX4

      Remove the 3 nuts and hybrid battery junction block.

  34. REMOVE BATTERY SMART UNIT

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. A003TF5

      Disconnect the 3 connectors.

    2. Remove the 2 bolts and battery smart unit.

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

    CAUTION:

    Wear insulating gloves.


    1. A003U2M

      Disconnect the connector.

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

    3. A003TTHE02
      Text in Illustration
      *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.

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

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

    CAUTION:

    Wear insulating gloves.


    1. A003TDD

      Disconnect the 3 wire harness clamps.

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

    3. A003RV6

      Disengage the 2 claws and remove the HV battery thermistor.

  37. REMOVE NO. 1 HYBRID BATTERY COVER INTAKE DUCT


    1. A003UPH

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

  38. REMOVE UPPER HYBRID BATTERY COVER SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.

    Tech Tips

    Perform this procedure only when removal and installation of any parts under the upper hybrid battery cover sub-assembly is necessary.


    1. A003U4P

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

  39. REMOVE NO. 1 HYBRID BATTERY PACKING

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.

    Tech Tips


    • Perform this procedure only when replacement of the No. 1 hybrid battery packing is necessary.

    • If a new No. 1 hybrid battery packing is installed to the new HV battery, reusing the used No. 1 hybrid battery packing is not necessary.


    1. A003SQU

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

  40. REMOVE NO. 2 HYBRID BATTERY PACK WIRE


    1. A003S6X

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