Removal

HYBRID / BATTERY CONTROL: HV BATTERY: REMOVAL

1. PRECAUTION

Service Precautions

2. READ OUTPUT DTC

(a) Check for DTCs Hybrid Battery System.

NOTICE:
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.

3. REMOVE SERVICE PLUG GRIP

Removal

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

5. REMOVE INVERTER COVER Removal

6. CHECK TERMINAL VOLTAGE Removal

7. INSTALL INVERTER COVER Removal

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

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

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

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

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

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

14. REMOVE REAR NO. 2 FLOOR BOARD SUB-ASSEMBLY Removal

15. REMOVE REAR NO. 1 FLOOR BOARD Removal

16. REMOVE REAR SEAT ASSEMBLY

Removal

17. REMOVE REAR DOOR SCUFF PLATE LH Removal

18. REMOVE REAR DOOR SCUFF PLATE RH Removal

19. REMOVE REAR SEAT SIDE GARNISH LH Removal

20. REMOVE REAR SEAT SIDE GARNISH RH Removal

21. REMOVE HYBRID VEHICLE BATTERY SHIELD SHEET

(a) Remove the hybrid vehicle battery shield sheet.





22. REMOVE HYBRID BATTERY COVER SHEET

(a) Remove the hybrid battery cover sheet.





23. REMOVE REAR FLOOR BOARD SPACER

(a) Remove the 2 clips and rear floor board spacer.





24. REMOVE NO. 1 HYBRID BATTERY INTAKE DUCT

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





25. REMOVE BATTERY COOLING BLOWER ASSEMBLY Removal

26. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT

(a) Remove the clip and No. 1 hybrid battery exhaust duct.





27. REMOVE UPPER HYBRID BATTERY COVER SUB-ASSEMBLY

CAUTION:
Be sure to wear insulated gloves and protective goggles.

(a) Using the service plug grip, remove the battery cover lock striker.





Text in Illustration





HINT
Insert the projection part of the service plug grip, and turn the button of the battery cover lock striker counterclockwise, and release the lock.

(b) 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.
(a) Remove the 2 nuts, then disconnect the frame wire from the hybrid battery junction block.





(b) Disconnect the clamp and frame wire.

29. REMOVE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Removal

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

(a) Disconnect the 2 wire harness clamps.





(b) Remove the bolt and No. 7 hybrid battery upper carrier bracket.

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

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





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

(a) Disconnect the wire harness protector clamp.





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

33. REMOVE REAR CENTER SEAT BACK HINGE SUB-ASSEMBLY

(a) Remove the 2 bolts and rear center seat back hinge sub-assembly.





34. REMOVE HV BATTERY

CAUTION:
Wear insulated gloves.

NOTICE:
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.

(a) Remove the No. 2 hybrid vehicle battery carrier sheet.





Text in Illustration





(b) Remove the No. 3 hybrid vehicle battery carrier sheet.

(c) Remove the hybrid vehicle battery lower cover plate.

(d) Disconnect the connector and electrical key oscillator clamp.





(e) Remove the 4 bolts shown in the illustration.





(f) Remove the HV battery.

NOTICE:
* 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 hybrid battery, make sure to use an engine lifter.

HINT
Attach tape to the feet and edges of the battery to protect tools and the vehicle body.

35. REMOVE BATTERY SMART UNIT Removal

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

CAUTION:
Wear insulated gloves.

(a) Disconnect the connector.





(b) Remove the bolt and electric vehicle battery plug assembly as shown in the illustration.

(c) Using the service plug grip, remove the battery cover lock striker.





Text in Illustration





HINT
Insert the projection part of the service plug grip, and turn the button of the battery cover lock striker counterclockwise, to release the lock.

(d) 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 insulated gloves.

(a) Disconnect the 3 wire harness clamps.





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

(c) Disengage the 2 claws and remove the HV battery thermistor.





38. REMOVE NO. 1 HYBRID BATTERY COVER INTAKE DUCT

(a) 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.

(a) 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.

(a) Remove the 2 clamps and No. 1 hybrid battery packing.





41. REMOVE NO. 2 HYBRID BATTERY PACK WIRE

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