BATTERY SMART UNIT REMOVAL

  1. PRECAUTION

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  2. REMOVE SERVICE PLUG GRIP

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  3. REMOVE CONNECTOR COVER ASSEMBLY

    CAUTION:

    • Do not touch the high voltage connectors and terminals for 10 minutes after the service plug grip is removed.

    • Wear insulated gloves.

    Note

    Do not start the hybrid system with the service plug grip removed because it may cause a malfunction.

    1. Remove the 2 bolts and connector cover assembly.

      A011YJW

      Note

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

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

  4. CHECK TERMINAL VOLTAGE

    CAUTION:

    Wear insulated gloves.

    Note

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

    1. Using a voltmeter, measure the voltage between the terminals of the 2 phase connectors.

      A011VIF
      Standard voltage
      0 V

      Tech Tips

      Use a measuring range of DC 750 V or more on the voltmeter.

  5. INSTALL CONNECTOR COVER ASSEMBLY

    CAUTION:

    Wear insulated 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. Install the connector cover assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  6. REMOVE REAR SEAT CUSHION ASSEMBLY

    1. Disengage the hook of the seat cushion from the vehicle body as shown in the illustration.

      Note

      Follow the instructions below carefully as the cushion frame can be deformed easily.

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

        A011VLJE01
        Standard Measurement
        a 100 mm (3.94 in.) or less

      2. Repeat the step above for the other hook.

    2. Remove the rear seat cushion assembly.

  7. REMOVE REAR SEAT CUSHION LOCK HOOK

    1. Disengage the claw and remove the rear seat cushion lock hook.

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      Note

      Rear seat cushion lock hooks must not be reused.

      Tech Tips

      Use the same procedure for the RH side and the LH side.

  8. SEPARATE REAR SEATBACK ASSEMBLY

    1. Fold down the rear seatback assembly RH.

    2. Using a moulding remover, disengage the claw and guide, and remove the No. 2 room partition cover.

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    3. Disconnect the rear seat outer belt from the rear seat center shoulder belt guide.

    4. Pull the cable in the direction shown in the illustration to release the rear seatback lock and then fold the rear seatback assembly LH forward.

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  9. REMOVE REAR SIDE SEATBACK ASSEMBLY LH

    1. Disconnect the rear seat outer belt from the rear seat shoulder belt guide LH.

    2. Disconnect the connector.

    3. Remove the 2 bolts.

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    4. Disengage the hook and remove the rear side seatback assembly LH.

  10. REMOVE NO. 1 HYBRID BATTERY INTAKE DUCT

    1. Remove the 3 clips and No. 1 hybrid battery intake duct.

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  11. REMOVE NO. 2 HYBRID VEHICLE BATTERY UPPER COVER BRACKET

    1. Remove the 2 nuts and No. 2 hybrid vehicle battery upper cover bracket.

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  12. SEPARATE NO. 2 HYBRID BATTERY INTAKE DUCT

    1. Remove the clip.

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    2. Disengage the 2 claws and separate the No. 2 hybrid battery intake duct.

  13. 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. Disconnect the connector from the battery cooling blower assembly.

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    2. Remove the 3 nuts and battery cooling blower assembly.

  14. REMOVE BATTERY SMART UNIT

    CAUTION:

    Wear insulated gloves.

    1. Using the service plug grip, remove the battery cover lock striker.

      A011WTOE01
      Text in Illustration
      *1 Service Plug Grip
      *2 Battery Cover Lock Striker
      *3 Button
      *a Turn
      *b Projection

      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. Disconnect the 2 connectors.

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    3. Remove the 2 bolts, nut and No. 2 hybrid vehicle battery shield panel.

    4. Disconnect the 3 wire harness clamps.

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    5. Disconnect the connector.

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      Note

      Insulate the removed terminals with insulating tape.

    6. Remove the bolt.

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    7. Remove the battery smart unit together with the No. 2 hybrid vehicle battery shield panel toward the rear of the vehicle.

      A011YT5E01
      Text in Illustration
      *1 Battery Smart Unit
      *2 No. 2 Hybrid Vehicle Battery Shield Panel

      Tech Tips

      When removing the battery smart unit and No. 2 hybrid vehicle battery shield panel from the vehicle, they can only be removed together.