Removal And Installation

ON BOARD CHARGER

Removal and Installation


WARNING:
- Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are handled incorrectly. Be sure to follow the correct work procedures when performing inspection and maintenance.
- Be sure to remove the service plug in order to disconnect the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.
- To prevent the removed service plug from being connected by mistake during the procedure, always carry it in your pocket or put it in the tool box.
- Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses before beginning work on the high voltage system.
- Clearly identify the persons responsible for high voltage work and ensure that other persons do not touch the vehicle. When not working, cover high voltage parts with an insulating cover sheet or similar item to prevent other persons from contacting them.
- Refer to "High Voltage Precautions" High Voltage Precautions.

CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do so in the Service Manual.

REMOVAL


WARNING:
Disconnect high voltage. Refer to "How to Disconnect High Voltage" Service and Repair.
1.Check voltage in high voltage circuit. (Check that condenser are discharged.)
a.Lift up the vehicle and remove the Li-ion battery under covers. Refer to "Removal and Installation" Service and Repair (without Li-ion battery heater models), "Removal and Installation" Service and Repair (with Li-ion battery heater models).
b.Disconnect high voltage harness connector from front side of Li-ion battery. Refer to "Removal and Installation" Service and Repair (without Li-ion battery heater models), "Removal and Installation" Service and Repair (with Li-ion battery heater models).





c.Measure voltage between high voltage harness connector terminals.
DANGER:


Touching high voltage components without using the appropriate protective equipment will cause electrocution.
Standard: 5 V or less

CAUTION:
For voltage measurements, use a tester which can measure to 500 V or higher.
2.Remove rear under cover. Refer to "REAR DIFFUSER : Exploded View" .
3.Drain coolant from radiator. Refer to "Draining and Refilling" Coolant Draining And Refilling.





4.Disconnect water hoses (1) from on-board charger.

WARNING:


To prevent electric shock hazards, be sure to put on insulating protective gear before beginning work on the high voltage system.
5.Remove rear seatback. Refer to "SEATBACK : Removal and Installation" Seatback.
6.Remove seat cushion. Refer to "SEAT CUSHION : Removal and Installation" Seat Cushion.
7.Remove luggage floor upper finisher. Refer to "LUGGAGE FLOOR UPPER FINISHER : Removal and Installation" Luggage Floor Upper Finisher.
8.Remove luggage floor front finisher. Refer to "LUGGAGE FLOOR FRONT FINISHER : Removal and Installation" Luggage Floor Front Finisher.





9.Disconnect high voltage harness connector (A) of on-board charger, and high voltage harness connector (B) of noise filter.

WARNING:
-To prevent electric shock hazards, be sure to put on insulating protective gear before beginning work on the high voltage system.
- Protect the terminals of disconnected high voltage harness connector with insulation tape so that they are not exposed.





- Follow steps shown below to remove a 2-step type high voltage connector.





- Follow steps shown below to remove a 3-step type high voltage connector.










10.Disconnect 12V system connector (A) of on-board charger.

WARNING:


To prevent electric shock hazards, be sure to put on insulating protective gear before beginning work on the high voltage system.





11.Remove grounding plate (1) of on-board charger.

WARNING:


To prevent electric shock hazards, be sure to put on insulating protective gear before beginning work on the high voltage system.





12.Remove on-board charger mounting bolt (A).






WARNING:


To prevent electric shock hazards, be sure to put on insulating protective gear before beginning work on the high voltage system.





13.Move on-board charger toward vehicle left side while avoiding right side trim, then remove on-board charger by tilting it toward the front while avoiding tower bar.






WARNING:


To prevent electric shock hazards, be sure to put on insulating protective gear before beginning work on the high voltage system.

CAUTION:
- Take care that coolant does not contact the high voltage harness connectors.
- If coolant contacts a high voltage harness connector, immediately use an air blow and fully remove the liquid.

INSTALLATION

Pay attention to the following and install by following the procedure for removal in the reverse order.

WARNING:


To prevent electric shock hazards, be sure to put on insulating protective gear before beginning work on the high voltage system.

CAUTION:
- Be sure to reinstall high voltage harness clips in their original positions. If a clip is damaged, replace it with a new clip before installing.
- Be sure to perform correct air bleeding after adding coolant. Refer to "Draining and Refilling" Coolant Draining And Refilling.





- If on-board charger was replaced, apply high voltage warning label at position (A), with top facing in the direction of arrow.
- Follow the procedure below and connect the 2-step type high voltage harness connector.





- Follow the procedure below and connect the 3-step type high voltage harness connector.





- After all parts are installed, be sure to check equipotential. Refer to "Inspection" Inspection.