Part 1
HV BATTERY
Removal & Installation and Disassembly & Reassembly
NOTICE:
^ When working on the high voltage systems, always wear insulating gloves.
^ After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU.
^ Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle.
^ After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes.
1. PRECAUTION
2. REMOVE REAR FLOOR BOARD NO.2
3. REMOVE DECK FLOOR BOX REAR
4. REMOVE REAR FLOOR BOARD NO.3
5. DISCONNECT BATTERY NEGATIVE TERMINAL
6. REMOVE SERVICE PLUG GRIP
7. REMOVE DECK TRIM COVER REAR
a. Disconnect the 4 clips shown in the illustration, then remove the deck trim cover rear.
8. REMOVE TONNEAU COVER ASSY
9. REMOVE REAR SEAT CUSHION ASSY
a. Undo the 2 joints shown in the illustration, then remove the rear seat cushion.
10. REMOVE REAR FLOOR BOARD NO.1
a. Remove the 2 bolts and luggage hold belt strikers.
b. Remove the 5 clips shown in the illustration and the rear floor board No. 1.
11. REMOVE REAR SIDE SEAT BACK FRAME LH
a. Remove the bolt from the rear side seat back frame LH.
b. Undo the 3 joints, then remove the rear side seat back frame LH.
12. REMOVE REAR SIDE SEAT BACK FRAME RH
a. Remove the bolt from the rear side seat back frame RH.
b. Undo the 4 joints, then remove the rear side seat back frame RH.
13. REMOVE REAR FLOOR BOARD NO.4
a. As shown in the illustration, while lifting up the rear floor board No. 4, undo the 2 joints and remove the rear floor board No. 4.
14. REMOVE DECK FLOOR BOX LH
a. Remove the clip and deck floor box LH.
15. REMOVE DECK TRIM SIDE PANEL ASSY LH
a. Remove the bolt and luggage hold belt striker assembly.
b. Remove the 2 bolts from the deck trim side panel assembly LH.
c. Remove the clip from the deck trim side panel assembly LH.
d. Undo the 8 clips, then pull out a part of the weather strip and remove the deck trim side panel assembly LH.
e. Disconnect the lighting connector.
16. REMOVE DECK TRIM SIDE PANEL ASSY RH
a. Remove the bolt and luggage hold belt striker assembly.
b. Remove the 2 bolts from the deck trim side panel assembly RH.
c. Remove the clip from the deck trim side panel assembly RH.
d. Undo the 7 clips, then pull out a part of the weather strip and remove the deck trim side panel assembly RH.
17. REMOVE BATTERY CARRIER BRACKET
a. Remove the 7 bolts and battery carrier bracket.
18. REMOVE QUARTER VENT DUCT INNER NO.2
a. Disconnect the clamp and battery blower relay No. 1.
b. Remove the 2 clips.
c. Slide the ventilation inner duct No. 2 to the battery side, then remove it.
19. REMOVE BATTERY BRACKET REINFORCEMENT
a. Remove the 7 bolts and battery bracket reinforcement.
20. REMOVE QUARTER VENT DUCT
a. Disconnect the connector.
b. Remove the clamp, then disconnect the wire harness.
c. Remove the bolt, clip and quarter ventilator duct.
21. REMOVE BATTERY CARRIER PANEL NO.6
a. Remove the 3 bolts, 2 nuts and battery carrier panel No. 6.
22. REMOVE JUNCTION TERMINAL
NOTICE: Wear insulating gloves.
23. REMOVE FRAME WIRE
NOTICE:
^ Wear insulating gloves.
^ Insulate the removed terminals with insulating tape.
a. Remove the 2 nuts, then disconnect the frame wire from the system main relay No. 2 and No. 3.
24. REMOVE HV BATTERY ASSY
a. Remove the earth bolt and 4 bolts shown in the illustration.
b. Disconnect the system main relay connector.
NOTICE: Wear insulating gloves.
c. Disconnect the interlock connector.
NOTICE: Wear insulating gloves.
d. Remove the clamp, then disconnect the battery ECU connector.
NOTICE: Wear insulating gloves.
e. Disconnect the battery room ventilation hose from the floor panel.
NOTICE: Wear protective glasses.
f. Remove the HV battery.
NOTICE: Wear insinuating gloves.
25. REMOVE BATTERY COVER SUB-ASSY
a. Remove the protector shown in the illustration.
b. Remove the 6 bolts, 2 nuts, clip, battery cover and battery carrier catch bracket No. 1.
26. REMOVE WIRING HARNESS PROTECTOR COVER NO.1
NOTICE: Wear insulating gloves.
27. REMOVE WIRING HARNESS PROTECTOR COVER NO.3
NOTICE: Wear insulating gloves.
28. REMOVE BATTERY CARRIER CUSHION NO.3
NOTICE: Wear insulating gloves.
29. REMOVE MAIN BATTERY CABLE
NOTICE: Wear insulating gloves.
30. REMOVE MAIN BATTERY CABLE NO.2
NOTICE: Wear insulating gloves.
31. REMOVE BATTERY CURRENT SENSOR
NOTICE: Wear insulating gloves.
32. REMOVE WIRING HARNESS PROTECTOR COVER NO.2
NOTICE: Wear insulating gloves.
33. REMOVE WIRING HARNESS PROTECTOR COVER NO.4
NOTICE: Wear insulating gloves.