HV BATTERY REMOVAL


  1. PRECAUTION

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  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 SERVICE PLUG GRIP

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  4. REMOVE INVERTER COVER ASSEMBLY LH (w/ Cover)


    1. A003WP0

      Remove the 2 clips

    2. Disengage the claw and remove the inverter cover assembly LH.

  5. REMOVE INVERTER COVER

    CAUTION:

    Wear insulating gloves.


    1. A003WQ2

      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 insulating gloves.

    Note

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


    1. A003W23

      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 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. A003XT9E01
      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 }

  8. INSTALL INVERTER COVER ASSEMBLY LH (w/ Cover)


    1. Engage the claw and install the inverter cover assembly LH.

    2. Install the 2 clips.

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


    1. Remove the tonneau cover assembly.

  10. REMOVE REAR NO. 4 FLOOR BOARD (w/o Woofer)


    1. Remove the rear No. 4 floor board.

  11. REMOVE REAR NO. 4 FLOOR BOARD (w/ Woofer)


    1. A003WPK

      Disengage the 2 clips and 3 guides, and remove the rear No. 4 floor board.

  12. REMOVE DECK FLOOR BOX LH (w/o Woofer)


    1. A003WLJ

      Remove the clip.

    2. Disengage the 6 guides and remove the deck floor box LH.

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


    1. A003X65

      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. A003YRO

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

  15. REMOVE REAR NO. 1 FLOOR BOARD


    1. A003ZU1

      Remove the bolt.

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

  16. REMOVE REAR SEAT ASSEMBLY

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  17. REMOVE REAR DOOR SCUFF PLATE LH


    1. A003ZA0

      Disengage the 4 claws, 2 guides and 2 clips, and remove the rear door scuff plate LH.

  18. REMOVE REAR DOOR SCUFF PLATE RH

    Tech Tips

    Use the same procedure as for the LH side.

  19. REMOVE REAR SEAT SIDE GARNISH LH


    1. A003WIU

      Remove the clip.

    2. Disengage the 6 claws and remove the rear seat side garnish LH.

  20. REMOVE REAR SEAT SIDE GARNISH RH

    Tech Tips

    Use the same procedure as for the LH side.

  21. REMOVE HV BATTERY SHIELD SHEET

    A003X3I

    Remove the hybrid vehicle battery shield sheet.

  22. REMOVE HYBRID BATTERY COVER SHEET


    1. A003V1X

      Remove the hybrid battery cover sheet.

  23. REMOVE REAR FLOOR BOARD SPACER


    1. A003YK4

      Remove the 2 clips and rear floor board spacer.

  24. REMOVE NO. 1 HYBRID BATTERY INTAKE DUCT


    1. A003V2I

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

  25. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT


    1. A003VGS

      Remove the clip and No. 1 hybrid battery exhaust 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. A003W0D

      Disconnect the 2 wire harness clamps.

    2. A003W4U

      Disconnect the battery cooling blower assembly connector and clamp.

    3. A003XZX

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

  27. REMOVE UPPER HYBRID BATTERY COVER SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. A003XRPE01
      Text in Illustration
      *a Turn
      *b Projection

      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.

  28. REMOVE FRAME WIRE

    CAUTION:


    • Wear insulated gloves.

    • Insulate the removed terminals with insulating tape.


    1. A003W24

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

    2. Disconnect the clamp and frame wire.

  29. REMOVE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves.

    Note

    Insulate the disconnected terminals with insulating tape.


    1. A003WX6

      Disconnect the 2 connectors from the hybrid battery junction block assembly.

    2. A003YII

      Disconnect the 2 connectors from the hybrid battery junction block assembly.

    3. A003ZR3

      Remove the 3 nuts and hybrid battery junction block assembly.

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


    1. A003XZB

      Disconnect the 2 wire harness clamps.

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

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


    1. A003XEL

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

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


    1. A003Y1S

      Disconnect the wire harness protector clamp.

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

  33. REMOVE REAR CENTER SEAT BACK HINGE SUB-ASSEMBLY


    1. A003ZU2

      Remove the 2 bolts and center seat hinge subassembly.

  34. REMOVE HV BATTERY

    CAUTION:

    Wear insulating gloves.

    Note

    Since the HV battery is very heavy, 2 people are needed to remove the HV battery. When removing the HV battery, do not damage the parts around it.


    1. A003VSDE01
      Text in Illustration
      *1 No. 2 hybrid vehicle battery carrier sheet
      *2 No. 3 hybrid vehicle battery carrier sheet
      *3 Hybrid vehicle battery lower cover plate

      Remove the No. 2 hybrid vehicle battery carrier sheet.

    2. Remove the No. 3 hybrid vehicle battery carrier sheet.

    3. Remove the hybrid vehicle battery lower cover plate.

    4. A003YVS

      Disconnect the connector and electrical key oscillator clamp.

    5. A003XWY

      Remove the 4 bolts shown in the illustration.

    6. 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 HV battery, 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.

  35. REMOVE BATTERY SMART UNIT

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. A003Z2J

      Disconnect the 3 connectors.

    2. Remove the 2 bolts and battery smart unit.

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

    CAUTION:

    Wear insulating gloves.


    1. A003WRW

      Disconnect the connector.

    2. Remove the bolt and electric vehicle battery plug assembly as shown in the illustration.

    3. A003V6WE01
      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, to release the lock.

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

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

    CAUTION:

    Wear insulating gloves.


    1. A003ZMV

      Disconnect the 3 wire harness clamps.

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

    3. A003YXN

      Disengage the 2 claws and remove the HV battery thermistor.

  38. REMOVE NO. 1 HYBRID BATTERY COVER INTAKE DUCT


    1. A003Z7L

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

  39. 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. A003Z6D

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

  40. 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. A003VCF

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

  41. REMOVE NO. 2 HYBRID BATTERY PACK WIRE


    1. A003XC3

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