Removal

HYBRID / BATTERY CONTROL: HV BATTERY: REMOVAL

1. PRECAUTION

HINT
Service Precautions.

2. CHECK FOR DTCS

(a) Check for DTCs Hybrid Battery System.

NOTICE:
Confirm that P0AA6 (Hybrid Battery Voltage System Isolation Fault) is not output before doing removal or installation work inside the battery. If this DTC is output, perform troubleshooting procedure for this DTC first.

3. REMOVE LUGGAGE COMPARTMENT FLOOR MAT Removal

4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Removal

5. REMOVE BATTERY SERVICE HOLE COVER Removal

6. REMOVE SERVICE PLUG GRIP Removal

7. REMOVE COOL AIR INTAKE DUCT SEAL Removal

8. REMOVE CONNECTOR COVER ASSEMBLY Removal

9. CHECK TERMINAL VOLTAGE Removal

10. INSTALL CONNECTOR COVER ASSEMBLY Installation

11. INSTALL COOL AIR INTAKE DUCT SEAL Installation

12. REMOVE REAR SEATBACK ASSEMBLY

HINT
Removal.

13. REMOVE TOOL WITH STAY BOX SUB-ASSEMBLY

14. REMOVE REAR FLOOR FINISH PLATE Removal

15. REMOVE NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY

16. REMOVE FRONT LUGGAGE COMPARTMENT TRIM COVER Removal

17. REMOVE ROPE HOOK Removal

18. REMOVE INNER LUGGAGE COMPARTMENT TRIM COVER Removal

19. REMOVE AUXILIARY BATTERY Removal

20. REMOVE BATTERY COOLING BLOWER ASSEMBLY

HINT
Removal.

21. REMOVE BATTERY SMART UNIT

HINT
Removal.

22. REMOVE NO. 3 HYBRID BATTERY EXHAUST DUCT Removal

23. REMOVE INVERTER TERMINAL

CAUTION:
Wear insulated gloves.

NOTICE:
Insulate the removed terminals with insulating tape.

(a) Remove the nut and disconnect the frame wire from the inverter terminal.

(b) Remove the bolt, nut and inverter terminal.

24. REMOVE HYBRID VEHICLE CONVERTER

CAUTION:
Wear insulated gloves.

NOTICE:
Insulate the removed terminals with insulating tape.

(a) Remove the nut, disengage the 4 clamps and disconnect the wire harness from the hybrid vehicle converter.

(b) Disconnect the connector from the hybrid vehicle converter.

25. REMOVE NO. 2 HYBRID BATTERY EXHAUST DUCT

(a) Remove the clip and No. 2 hybrid battery exhaust duct.

26. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT

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

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

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

28. 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.

29. REMOVE HV BATTERY

CAUTION:
Wear insulated gloves.

NOTICE:
Insulate the removed terminals with insulating tape.

(a) Disconnect the frame wire clamp.

(b) Disconnect the battery room ventilation hose.

(d) Remove the grommet and hybrid battery hose assembly.

(e) Remove the 4 bolts from the HV battery.

(f) Turn the luggage compartment floor mat over.

(g) Cut and shape a piece of cardboard so that it fits the area between the HV battery bolt attachment positions, and then insert it as shown in the illustration.

Text in Illustration

(h) Using a tire lever to hold up the HV battery, insert the cardboard until it cannot be inserted any further.

NOTICE:
Bind the frame wire with electrical tape to prevent it from getting caught when moving the battery or other parts.

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

(i) Use a tire lever from the cabin side to lift the HV battery up over the tabs on the body.

Text in Illustration

HINT
Attach tape to the tire lever to prevent damage to the body of the vehicle.

(j) Using a tire lever to hold up the HV battery, insert a wooden block or equivalent as shown in the illustration.

Text in Illustration

(k) Pull the HV battery together with the cardboard toward the rear of the vehicle.

Text in Illustration

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

(l) Disconnect the clamp as shown in the illustration.

(m) Using a suitable adaptor such as a rope, remove the HV battery while tilting the HV battery.

NOTICE:
While lowering the HV battery from the vehicle, do not allow it to contact the vehicle.

30. REMOVE ELECTRICAL KEY OSCILLATOR Removal

31. REMOVE EARTH WIRE

CAUTION:
Wear insulated gloves.

(a) Remove the nut and earth wire.

32. REMOVE FRONT HYBRID BATTERY SHIELD

CAUTION:
Wear insulated gloves.

(a) Remove the 2 bolts, nut and front hybrid battery shield.

33. REMOVE REAR NO. 1 HYBRID BATTERY SHIELD

CAUTION:
Wear insulated gloves.

(a) Remove the 2 nuts and rear No. 1 hybrid battery shield.

34. REMOVE NO. 2 HYBRID BATTERY PACK WIRE

CAUTION:
Wear insulated gloves.

(a) Disconnect the 2 clamps from the HV battery shown in the illustration.

(b) Disconnect the 2 clamps from the HV battery shown in the illustration.

(d) Disconnect the connector and 4 clamps and remove the No. 2 hybrid battery pack wire.

35. REMOVE HYBRID BATTERY SERVICE PLUG COVER

CAUTION:
Wear insulated gloves.

(a) Remove the 4 nuts and hybrid battery service plug cover.

36. REMOVE UPPER HYBRID BATTERY COVER SUB-ASSEMBLY

CAUTION:
Wear insulated gloves.

(a) Remove the nut, disengage the 3 clamps and disconnect the wire harness from the HV battery.

(b) Remove the 2 nuts and upper hybrid battery cover sub-assembly.

37. SEPARATE WIRE HARNESS

CAUTION:
Wear insulated gloves.

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

Text in Illustration

(b) Disengage the 5 clamps and separate the wire harness from the HV battery.

(c) Remove the 2 bolts and EV battery plug.

(d) Remove the 2 nuts, disengage the clamp and separate the wire harness from the HV battery.

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

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

(a) Remove the 3 bolts, nut, guide and No. 2 hybrid battery shield sub-assembly.

39. REMOVE UPPER HYBRID BATTERY COVER SUB-ASSEMBLY

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

(a) Remove the 2 bolts, 8 nuts and upper hybrid battery cover sub-assembly.

(b) Remove the 2 bolts and 2 bushings with the 2 washers.

40. REMOVE HYBRID BATTERY HOSE ASSEMBLY

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

(a) Remove the hybrid battery hose assembly from the HV battery.

41. REMOVE NO. 1 BATTERY INSULATOR DUCT

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

(a) Remove the No. 1 battery insulator duct from the HV battery.

42. REMOVE NO. 2 BATTERY INSULATOR DUCT

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

(a) Remove the No. 2 battery insulator duct from the HV battery.