Removal

HYBRID BATTERY CONTROL: HV BATTERY: REMOVAL

REMOVAL

1. PRECAUTION Service Precautions
2. CHECK FOR DTCS
(a) Check for DTCs Hybrid Control System.
NOTICE: Confirm that P0AA6 (High voltage insulation is unusual) is not output before doing removal or installation work inside the battery. If the DTC is output, perform troubleshooting procedures first.

3. REMOVE LUGGAGE TRIM SERVICE HOLE COVER

(a) Release the 2 claws and remove the luggage trim service hole cover.
4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Removal
5. REMOVE SERVICE PLUG GRIP
CAUTION:
- Remove the service plug grip to interrupt a high voltage circuit at the time of the check.
- Keep the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.
- All the high voltage wiring connectors are orange colored.
- Be sure to turn the power switch off before removing the service plug grip.

(a) Slide the latch upward and open the service hole cover.

(b) Wear insulated gloves. Remove the service plug grip after sliding the lever of the service plug grip.
CAUTION:
- Keep the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.
- After disconnecting the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals.
NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU.

6. REMOVE NO. 2 ENGINE ROOM SIDE LH COVER Removal
7. REMOVE CONNECTOR COVER ASSEMBLY Removal
8. CHECK TERMINAL VOLTAGE Removal
9. INSTALL CONNECTOR COVER ASSEMBLY Removal
10. INSTALL NO. 2 ENGINE ROOM SIDE LH COVER Removal
11. REMOVE LUGGAGE COMPARTMENT FLOOR MAT
12. REMOVE SPARE WHEEL COVER CLAMP
13. REMOVE SPARE WHEEL COVER ASSEMBLY
14. REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM HOOK Removal
15. REMOVE REAR FLOOR FINISH PLATE Removal
16. REMOVE LUGGAGE COMPARTMENT REAR TRIM COVER Removal
17. REMOVE LUGGAGE COMPARTMENT INNER TRIM COVER LH Removal
18. REMOVE REAR SEAT HEADREST ASSEMBLY
19. REMOVE REAR CENTER SEAT HEADREST ASSEMBLY
20. REMOVE REAR SEAT CUSHION ASSEMBLY Removal
21. REMOVE SEPARATE TYPE REAR SEATBACK ASSEMBLY RH Removal
22. REMOVE SEPARATE TYPE REAR SEATBACK ASSEMBLY LH Removal
23. REMOVE REAR SIDE SEATBACK ASSEMBLY LH Removal
24. REMOVE REAR SIDE SEATBACK ASSEMBLY RH Removal
25. REMOVE REAR DOOR SCUFF PLATE LH Removal
26. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH
27. REMOVE REAR DOOR SCUFF PLATE RH Removal
28. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH
29. DISCONNECT REAR SEAT INNER WITH CENTER BELT ASSEMBLY LH Removal
30. REMOVE ROOF SIDE INNER GARNISH LH Removal
31. REMOVE ROOF SIDE INNER GARNISH RH Removal
32. REMOVE REAR SEAT OUTER BELT ASSEMBLY (for LH Side) Removal
33. REMOVE REAR SEAT OUTER BELT ASSEMBLY (for RH Side) Removal
34. REMOVE REAR SEAT SHOULDER BELT COVER Removal
35. REMOVE REAR SEAT SHOULDER BELT HOLE COVER Removal
36. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY Removal
37. REMOVE FRONT LUGGAGE COMPARTMENT TRIM COVER Removal
38. REMOVE ROOM PARTITION BOARD LH Removal
39. REMOVE ROOM PARTITION BOARD RH Removal
40. REMOVE NO. 1 HV BATTERY INTAKE DUCT Removal
41. REMOVE NO. 2 HV BATTERY INTAKE DUCT Removal
42. REMOVE BATTERY COOLING BLOWER ASSEMBLY Removal
43. REMOVE NO. 5 HV BATTERY INTAKE DUCT Removal
44. REMOVE NO. 3 HV BATTERY INTAKE DUCT

(a) Remove the No. 3 HV battery intake duct.
CAUTION: Wear insulated gloves.

45. REMOVE NO. 4 HV BATTERY INTAKE DUCT

(a) Remove the 2 clips and No. 4 HV battery intake duct.
CAUTION: Wear insulated gloves.

46. REMOVE NO. 2 HV BATTERY EXHAUST DUCT Removal
47. REMOVE WIRE HARNESS CLAMP BRACKET Removal
48. REMOVE UPPER BATTERY CARRIER SUB-ASSEMBLY Removal
49. DISCONNECT FRAME WIRE Removal
50. INSTALL SPARE WHEEL COVER ASSEMBLY
51. INSTALL SPARE WHEEL COVER CLAMP
52. INSTALL LUGGAGE COMPARTMENT FLOOR MAT
53. REMOVE HV BATTERY

(a) Disconnect the wire harness clamp from the No. 1 battery cover.

(b) Release the 2 claws and remove the terminal block cover.
CAUTION: Wear insulated gloves.

(d) Disconnect the battery pack wire connector.
CAUTION: Wear insulated gloves.

(e) Remove the grommet and battery room ventilation hose.
CAUTION: Wear insulated gloves.

(f) Remove the 4 bolts from the HV battery.
CAUTION: Wear insulated gloves.

(g) Remove the 2 bolts from the HV battery.

(h) Prepare a piece of cardboard of 750 mm (29.53 in.) X 500 mm (19.69 in.) or larger.
(i) Using a tire lever to hold up the HV battery, insert the cardboard until it cannot be inserted any farther.
CAUTION: Wear insulated gloves.
NOTICE: Bind the frame wire with electrical tape to prevent it from getting caught when moving the battery or other parts.

(j) Pull the HV battery together with the cardboard toward the rear of the vehicle.
CAUTION: Wear insulated gloves.

(k) Using an engine sling device, remove the HV battery while tilting the HV battery 45° at the rear end.
CAUTION: Wear insulated gloves.
NOTICE: Use cardboard or other similar material to protect the HV battery and vehicle body from damage.

54. REMOVE NO. 1 BATTERY COVER LID Removal
55. REMOVE NO. 5 BATTERY CARRIER PANEL Removal
56. REMOVE NO. 1 HV BATTERY EXHAUST DUCT Removal
57. REMOVE FILTER NOISE CAPACITOR Removal
58. REMOVE HV RELAY ASSEMBLY Removal
59. REMOVE BATTERY SMART UNIT Removal
60. REMOVE HYBRID VEHICLE CONVERTER Removal
61. REMOVE INVERTER TERMINAL

(a) Remove the nut and inverter terminal from the HV battery.
CAUTION: Wear insulated gloves.

62. REMOVE BATTERY INSULATOR RUBBER

(a) Remove the 3 bolts, nut and battery carrier bracket.
CAUTION: Wear insulated gloves.

(b) Remove the battery insulator rubber.
CAUTION: Wear insulated gloves.