HV BATTERY REMOVAL

PROCEDURE


  1. PRECAUTION

    Click here

  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 TB 0 to 5.

    4. Read the Data List.

      Note

      If any of the temperatures listed in "Temp of Batt TB 0 to 5" are 50°C or more, leave the vehicle until the temperature drops to less than 50°C.

  3. 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 removing or installing internal battery components. If this DTC is output, perform troubleshooting for this DTC first.

  4. REMOVE SERVICE PLUG GRIP

    Click here

  5. REMOVE INVERTER COVER

    Click here

  6. CHECK TERMINAL VOLTAGE

    Click here

  7. INSTALL INVERTER COVER

    Click here

  8. REMOVE FRONT SEAT ASSEMBLY RH


  9. REMOVE CENTER FLOOR CARPET COVER LH

    Click here

  10. REMOVE CENTER FLOOR CARPET COVER RH

    Click here

  11. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY

    Click here

  12. REMOVE FRONT NO. 2 CONSOLE BOX INSERT

    Click here

  13. REMOVE CONSOLE BOX ASSEMBLY

    Click here

  14. REMOVE NO. 1 HYBRID BATTERY SHIELD SUB-ASSEMBLY

    CAUTION:

    Wear insulated gloves.

    Note


    • When handling the HV battery, disconnect the high voltage connector of the battery smart unit to prevent the hybrid battery cell voltage from dropping.

    • Insulate the removed connectors with insulating tape.


    1. B005YN3

      Disconnect the 3 clamps.

    2. B005Z97

      Remove the 4 bolts and No. 1 hybrid battery shield sub-assembly.

    3. B005YVD

      Disconnect the 4 connectors from the battery smart unit.

      Note

      Insulate the removed connectors with insulating tape.

  15. DISCONNECT FRAME WIRE

    CAUTION:

    Wear insulated gloves.

    Note

    Insulate the removed terminals with insulating tape.


    1. B005XHW

      Using an insulated tool, remove the 3 nuts and disconnect the frame wire from the hybrid battery junction block assembly.

    2. B005XGOE01
      Text in Illustration
      *a Front of Vehicle

      Install the frame wire as shown in the illustration.

  16. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT


    1. B005XTW

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

  17. REMOVE NO. 4 HYBRID BATTERY INTAKE DUCT


    1. B005YU7

      Remove the 2 clips and No. 4 hybrid battery intake duct.

  18. REMOVE HV BATTERY

    CAUTION:

    Wear insulated gloves.

    Note


    • Insulate the removed connectors and terminals with insulating tape.

    • Since the HV battery is very heavy, 2 people are needed to remove the HV battery.

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

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


    1. B005ZQJ

      Disconnect the 2 connectors.

    2. Disconnect the floor carpet from the HV battery.

    3. Remove the 6 bolts.

      B005YZE
    4. B005ZIQE01
      Text in Illustration
      *1 Guide Pin

      Remove the HV battery.

      Tech Tips

      Be sure to place the HV battery on the attachment to prevent the guide pins from being damaged.

  19. REMOVE NO. 2 HYBRID VEHICLE BATTERY COVER PANEL LH

    CAUTION:

    Wear insulated gloves.

    Note

    Insulate the removed connectors with insulating tape.


    1. B005ZD4

      Disconnect the connector.

    2. B005XPT

      Remove the 4 bolts and No. 2 hybrid vehicle battery LH cover panel.

  20. REMOVE BATTERY SMART UNIT

    Click here

  21. REMOVE NO. 2 HYBRID BATTERY SHIELD SUB-ASSEMBLY

    CAUTION:

    Wear insulated gloves.

    Note

    Insulate the removed connectors with insulating tape.


    1. B005XKR

      Disconnect the connector and clamp.

    2. B005Z9O

      Disconnect the clamp.

    3. B005ZFN

      Disconnect the connector.

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

    5. B005YWV

      Remove the 4 bolts and No. 2 hybrid battery shield sub-assembly.

  22. REMOVE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

    Click here

  23. REMOVE NO. 2 HYBRID BATTERY PACK WIRE

    CAUTION:

    Wear insulated gloves.


    1. B005ZLQ

      Disconnect the 2 clamps and remove the No. 2 hybrid battery pack wire.

  24. PERFORM HV BATTERY RECOVERY INSPECTION


    1. Before returning the HV battery, make sure to perform a recovery inspection Click here