HV BATTERY INSTALLATION

PROCEDURE

  1. INSTALL NO. 2 HYBRID BATTERY EXHAUST DUCT

    CAUTION:

    Wear insulated gloves and use insulated tools.

    1. C312847C01

      *1

      Hybrid Battery End Plate
      V100135

      Raise Hybrid Battery Stack
      V100136

      Install No. 2 Hybrid Battery Exhaust Duct
      V100137

      Secure Clip

      Raise the hybrid battery stack vertically.

      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 raise the hybrid battery stack vertically.

    2. Install the No. 2 hybrid battery exhaust duct to the HV battery, and secure it with the clip.

    3. Install the hybrid battery stack with the 3 nuts.

      7.5 N*m

      76 kgf*cm

      66 in.*lbf

  2. INSTALL NO. 1 HYBRID BATTERY EXHAUST DUCT

    CAUTION:

    Wear insulated gloves and use insulated tools.

    1. C312848C01

      *1

      Hybrid Battery End Plate
      V100135

      Raise Hybrid Battery Stack
      V100136

      Install No. 2 Hybrid Battery Exhaust Duct
      V100137

      Secure Clip

      Raise the hybrid battery stack vertically.

      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 raise the hybrid battery stack vertically.

    2. Install the No. 1 hybrid battery exhaust duct to the HV battery, and secure it with the clip.

    3. Install the hybrid battery stack with the 3 nuts.

      7.5 N*m

      76 kgf*cm

      66 in.*lbf

  3. INSTALL NO. 2 HYBRID BATTERY COVER INTAKE DUCT

    CAUTION:

    Wear insulated gloves and use insulated tools.

    1. C313401

      Install the battery cooling blower assembly LH with the 3 nuts.

      7.5 N*m

      76 kgf*cm

      66 in.*lbf

    2. C312841

      Install the No. 2 hybrid battery cover intake duct.

  4. INSTALL NO. 1 HYBRID BATTERY COVER INTAKE DUCT

    CAUTION:

    Wear insulated gloves and use insulated tools.

    1. C313400

      Install the battery cooling blower assembly RH with the 3 nuts.

      7.5 N*m

      76 kgf*cm

      66 in.*lbf

    2. C312842

      Install the No. 1 hybrid battery cover intake duct.

    3. C313397

      Connect the intake temperature sensor and wire harness clamp.

  5. INSTALL NO. 1 HYBRID BATTERY SHIELD SUB-ASSEMBLY

    CAUTION:

    Wear insulated gloves and use insulated tools.

    1. Install the No. 1 hybrid battery shield sub-assembly with the 2 nuts.

      7.5 N*m

      76 kgf*cm

      66 in.*lbf

    2. Connect the 4 wire harness clamps.

  6. INSTALL 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

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

      7.5 N*m

      76 kgf*cm

      66 in.*lbf

    2. Install the No. 1 hybrid vehicle battery carrier bracket sub-assembly RH side with the 2 nuts.

      7.5 N*m

      76 kgf*cm

      66 in.*lbf

    3. Connect the wire harness clamp to the No. 1 hybrid vehicle carrier bracket sub-assembly LH side.

  7. INSTALL HYBRID BATTERY COVER SUB-ASSEMBLY LH

    CAUTION:

    Wear insulated gloves and use insulated tools.

    1. C298389C02

      *a

      Bolt

      *b

      Nut

      Install the hybrid battery cover sub-assembly LH with the 4 bolts and 3 nuts.

      7.5 N*m

      76 kgf*cm

      66 in.*lbf

  8. INSTALL HYBRID BATTERY COVER SUB-ASSEMBLY RH

    CAUTION:

    Wear insulated gloves and use insulated tools.

    1. C298392C03

      *a

      Bolt

      *b

      Nut

      Install the hybrid battery cover sub-assembly RH with the 4 bolts and 3 nuts.

      7.5 N*m

      76 kgf*cm

      66 in.*lbf

  9. INSTALL NO. 2 HYBRID BATTERY PACK WIRE

    CAUTION:

    Wear insulated gloves.

    1. Connect the 2 wire harness clamps and install the No. 2 hybrid battery pack wire.

  10. INSTALL BATTERY VOLTAGE SENSOR

    Click here

  11. INSTALL LOWER NO. 2 HYBRID BATTERY CARRIER PATCH

    Click here

  12. INSTALL HV BATTERY JUNCTION BLOCK ASSEMBLY

    CAUTION:

    Wear insulated gloves and use insulated tools.

    1. Install the hybrid battery junction block assembly with the 3 nuts.

      7.5 N*m

      76 kgf*cm

      66 in.*lbf

    2. C298352

      Connect the 4 connectors.

      Note:

      Make sure that the connectors are securely attached.

  13. INSTALL NO. 4 HYBRID BATTERY EXHAUST DUCT

    1. Install the No. 4 hybrid battery exhaust duct to the No. 2 hybrid battery exhaust duct.

  14. INSTALL NO. 3 HYBRID BATTERY EXHAUST DUCT

    1. Install the No. 3 hybrid battery exhaust duct to the No. 1 hybrid battery exhaust duct.

  15. INSTALL HV BATTERY ASSEMBLY

    CAUTION:

    Wear insulated gloves and protective goggles.

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

    2. Install the HV battery assembly from the rear of the vehicle.

      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 install 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.

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

      Note:

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

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

    4. C298381C02

      *a

      Bolt

      *b

      Ground Bolt

      *c

      Nut

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

      19 N*m

      194 kgf*cm

      14 ft.*lbf

    5. C346100

      Connect the front floor carpet assembly with the 4 clips.

  16. CONNECT WIRE HARNESS

    CAUTION:

    Wear insulated gloves and use insulated tools.

    1. Connect the connector and wire harness clamp to the battery cooling blower assembly LH.

    2. Connect the connector and wire harness clamp to the battery cooling blower assembly RH.

    3. Connect the 6 wire harness clamps and 2 connectors to the HV battery assembly.

    4. C346104C01

      *a

      Ground Terminal

      Using an insulated tool wrapped with electrical tape, connect the 2 No. 5 floor wires (high-voltage cables) and ground terminal with the 3 nuts.

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

  17. INSTALL AUXILIARY BATTERY

    CAUTION:

    Wear insulated gloves.

    1. Install the auxiliary battery.

      Click here

    2. C346102

      Connect the 6 wire harness clamps and connector.

    3. Connect the positive (+) auxiliary battery terminal.

      6.5 N*m

      66 kgf*cm

      58 in.*lbf

  18. HIGH VOLTAGE CABLE CONNECTION CONDITION

    Click here

  19. INSTALL NO. 2 HYBRID VEHICLE BATTERY SHIELD REINFORCEMENT

    Click here

  20. INSTALL NO. 1 EV BATTERY INTAKE DUCT

    1. Install the No. 1 hybrid battery intake duct with the 2 clips.

  21. INSTALL NO. 2 HYBRID BATTERY INTAKE DUCT

    1. Install the No. 2 hybrid battery intake duct with the 2 clips.

  22. INSTALL DECK TRIM SIDE PANEL ASSEMBLY LH

    Click here

  23. INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH

    Click here

  24. INSTALL REAR FLOOR FINISH PLATE (w/o Full Size Spare Tire)

    Click here

  25. INSTALL REAR DECK TRIM COVER (w/ Full Size Spare Tire)

    Click here

  26. INSTALL REAR SEAT ASSEMBLY

    Click here

  27. INSTALL NO.1 INVERTER RESERVE TANK BRACKET (for 2WD)

    Click here

  28. CONNECT INVERTER RESERVE TANK ASSEMBLY

    Click here

  29. CONNECT WIRE HARNESS

    Click here

  30. INSTALL SERVICE PLUG GRIP

    Click here

  31. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Click hereClick hereClick here