HV BATTERY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

  • When disposing of an HV battery module, make sure to return it through an authorized collection agent who is capable of handling it safely. If the HV battery module is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.

  • Accidents such as electric shock may result if an HV battery module is disposed of improperly or abandoned. Therefore, make sure to return all HV battery modules through an authorized collection agent.

  • After removing an HV battery module, keep it away from water. Exposure to water may cause the HV battery module to produce heat, resulting in a fire.

PROCEDURE

  1. PRECAUTION

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  2. CHECK FOR DTC

    1. Check for DTCs.

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      Note:

      Confirm that P0AA6 (Hybrid Battery Voltage System Isolation Fault) is not output before removing or installing an HV battery module. If this DTC is output, perform troubleshooting for this DTC first.

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  3. REMOVE SERVICE PLUG GRIP

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  4. DISCONNECT WIRE HARNESS

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  5. DISCONNECT INVERTER RESERVE TANK ASSEMBLY

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  6. REMOVE NO. 1 INVERTER RESERVE TANK BRACKET (for 2WD)

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  7. REMOVE CONNECTOR COVER ASSEMBLY

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  8. CHECK TERMINAL VOLTAGE

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  9. INSTALL CONNECTOR COVER ASSEMBLY

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  10. REMOVE REAR SEAT ASSEMBLY

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  11. REMOVE REAR FLOOR FINISH PLATE (w/o Full Size Spare Tire)

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  12. REMOVE REAR DECK TRIM COVER (w/ Full Size Spare Tire)

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  13. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH

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  14. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH

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  15. REMOVE NO. 2 HYBRID BATTERY INTAKE DUCT

    1. C298376

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

  16. REMOVE NO. 1 EV BATTERY INTAKE DUCT

    1. C346011

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

  17. REMOVE NO. 2 HYBRID VEHICLE BATTERY SHIELD REINFORCEMENT

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  18. REMOVE AUXILIARY BATTERY

    1. C346102

      Remove the nut and disconnect the positive (+) auxiliary battery terminal.

      Note:

      Insulate the terminals of the removed auxiliary battery terminal with insulating tape.

    2. Disconnect the 6 wire harness clamps and connector.

    3. Remove the auxiliary battery.

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  19. DISCONNECT WIRE HARNESS

    CAUTION:

    Wear insulated gloves and use insulated tools.

    Note:

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

    • Insulate the removed terminals and connector with insulating tape.

    • Insulate the removed connector with insulating tape.

    1. C346103

      Disconnect the connector and wire harness clamps from the battery cooling blower assembly LH.

    2. Disconnect the connector and wire harness clamps from the battery cooling blower assembly RH.

    3. C298378

      Disconnect the 2 connectors and 6 wire harness clamps.

    4. C346104C01

      *a

      Ground Terminal

      Using an insulated tool, remove the 3 nuts, and disconnect the 2 No. 5 floor wires (high-voltage cables) and ground terminal.

  20. REMOVE HV BATTERY ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.

    1. C346100

      Remove the 4 clips and disconnect the front floor carpet assembly.

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

    3. C298381C02

      *a

      Bolt

      *b

      Ground Bolt

      *c

      Nut

      Remove the 6 bolts, 2 ground bolts, 2 nuts and HV battery assembly.

    4. Lift up the HV battery assembly, and pull out the 3 cables from the HV battery assembly towards the lower side.

      C298846C01

      *a

      Areas to be Held
      Note:

      • Hold the areas shown in the illustration and lift up the HV battery assembly.

      • Since the HV battery assembly is very heavy, 4 people are needed to remove the HV battery assembly. When removing the HV battery assembly, do not damage the parts around it.

    5. Remove the HV battery assembly from the vehicle.

      Note:

      • Since the HV battery assembly is very heavy, 4 people are needed to remove the HV battery assembly. When removing the HV battery assembly, do not damage the parts around it.

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

      • When removing/installing/moving the HV battery assembly, make sure not to tilt it more than 80°.

      Tip:

      When removing and installing the HV battery, do so from the back door opening.

    6. C298844C01

      *a

      Attachment

      Place the HV battery assembly on attachments.

  21. REMOVE NO. 3 HYBRID BATTERY EXHAUST DUCT

    1. Remove the No. 3 hybrid battery exhaust duct from the No. 1 hybrid battery exhaust duct.

  22. REMOVE NO. 4 HYBRID BATTERY EXHAUST DUCT

    1. Remove the No. 4 hybrid battery exhaust duct from the No. 2 hybrid battery exhaust duct.

  23. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY

    CAUTION:

    Wear insulated gloves and use insulated tools.

    1. C298352

      Disconnect the 4 connectors.

      Note:

      Insulate the removed connector with insulating tape.

    2. C298353

      Remove the 3 nuts and hybrid battery junction block assembly.

  24. REMOVE LOWER NO. 2 HYBRID BATTERY CARRIER PATCH

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  25. REMOVE BATTERY VOLTAGE SENSOR

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  26. REMOVE NO. 2 HYBRID BATTERY PACK WIRE

    CAUTION:

    Wear insulated gloves.

    1. C307321

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

  27. REMOVE HYBRID BATTERY COVER SUB-ASSEMBLY LH

    CAUTION:

    Wear insulated gloves and use insulated tools.

    1. C298389C02

      *a

      Bolt

      *b

      Nut

      Remove the 4 bolts, 3 nuts and hybrid battery cover sub-assembly LH.

  28. REMOVE HYBRID BATTERY COVER SUB-ASSEMBLY RH

    CAUTION:

    Wear insulated gloves and use insulated tools.

    1. C298392C02

      *a

      Bolt

      *b

      Nut

      Remove the 4 bolts, 3 nuts and hybrid battery cover sub-assembly RH.

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

    CAUTION:

    Wear insulated gloves and use insulated tools.

    1. C313832C01

      *1

      No. 1 Hybrid Vehicle Battery Carrier Bracket Sub-assembly LH Side

      *2

      No. 1 Hybrid Vehicle Battery Carrier Bracket Sub-assembly RH Side

      Disconnect the wire harness clamp from the No. 1 hybrid vehicle battery carrier bracket sub-assembly LH side.

    2. Remove the 2 nuts and No. 1 hybrid vehicle battery carrier bracket sub-assembly LH side.

    3. Remove the 2 nuts and No. 1 hybrid vehicle battery carrier bracket sub-assembly RH side.

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

    CAUTION:

    Wear insulated gloves and use insulated tools.

    1. C298396

      Disconnect the 4 wire harness clamps.

    2. Remove the 2 nuts and No. 1 hybrid battery shield sub-assembly.

  31. REMOVE NO. 2 HYBRID BATTERY COVER INTAKE DUCT

    CAUTION:

    Wear insulated gloves and use insulated tools.

    1. C312841

      Remove the No. 2 hybrid battery cover intake duct from the HV battery assembly.

    2. C313401

      Remove the 3 nuts and battery cooling blower assembly LH.

  32. REMOVE NO. 1 HYBRID BATTERY COVER INTAKE DUCT

    CAUTION:

    Wear insulated gloves and use insulated tools.

    1. C313397

      Disconnect the intake temperature sensor and wire harness clamp.

    2. C312842

      Remove the No. 1 hybrid battery cover intake duct from the HV battery assembly.

    3. C313400

      Remove the 3 nuts and battery cooling blower assembly RH.

  33. REMOVE NO. 2 HYBRID BATTERY EXHAUST DUCT

    CAUTION:

    Wear insulated gloves and use insulated tools.

    1. C312843

      Remove the clip and 3 nuts.

    2. C312845C01

      *1

      Hybrid Battery End Plate
      V100135

      Raise Hybrid Battery Stack
      V100136

      Remove No. 2 Hybrid Battery Exhaust Duct

      Raise the hybrid battery stack vertically and remove the No. 2 hybrid battery exhaust duct.

      Note:

      • Make sure to hold the hybrid battery stack by the hybrid battery end plates shown in the illustration.

      • Make sure to raise the hybrid battery stack as much as necessary for the removal of the No. 2 hybrid battery exhaust duct.

      • Make sure to hold the hybrid battery stack by the hybrid battery end plates shown in the illustration.

  34. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT

    CAUTION:

    Wear insulated gloves and use insulated tools.

    1. C312844

      Remove the clip and 3 nuts.

    2. C312846C01

      *1

      Hybrid Battery End Plate
      V100135

      Raise Hybrid Battery Stack
      V100136

      Remove No. 1 Hybrid Battery Exhaust Duct

      Raise the hybrid battery stack vertically and remove the No. 1 hybrid battery exhaust duct.

      Note:

      • Make sure to hold the hybrid battery stack by the hybrid battery end plates shown in the illustration.

      • Make sure to raise the hybrid battery stack as much as necessary for the removal of the No. 1 hybrid battery exhaust duct.

      • Make sure to hold the hybrid battery stack by the hybrid battery end plates shown in the illustration.