Removal

HYBRID / BATTERY CONTROL: HV BATTERY: REMOVAL

1. PRECAUTION

HINT
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 doing removal or installation inside the battery. If this DTC is output, perform troubleshooting fir this DTC first.

3. REMOVE REAR NO. 2 FLOOR BOARD (for Separate Type) Removal

4. REMOVE REAR DECK FLOOR BOX Removal

5. REMOVE REAR NO. 3 FLOOR BOARD Removal

6. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

7. REMOVE SERVICE PLUG GRIP Removal

8. REMOVE INVERTER TERMINAL COVER Removal

9. CHECK TERMINAL VOLTAGE Removal

10. INSTALL INVERTER TERMINAL COVER Installation

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

12. REMOVE REAR SEAT CUSHION ASSEMBLY 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 DOOR SCUFF PLATE LH Removal

17. REMOVE REAR DOOR SCUFF PLATE RH

HINT
Use the same procedure described for the LH side.

18. REMOVE REAR SIDE SEAT BACK ASSEMBLY LH Removal

19. REMOVE REAR SIDE SEAT BACK ASSEMBLY RH Removal

20. REMOVE REAR NO. 4 FLOOR BOARD Removal

21. REMOVE DECK FLOOR BOX LH Removal

22. REMOVE DECK TRIM SERVICE HOLE COVER Removal

23. REMOVE REAR DECK TRIM COVER Removal

24. REMOVE LUGGAGE HOLD BELT STRIKER ASSEMBLY (for LH Side) Removal

25. REMOVE TONNEAU COVER HOLDER CAP (for LH Side) Removal

26. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH Removal

27. REMOVE TONNEAU COVER HOLDER CAP (for RH Side)

HINT
Use the same procedure described for the LH side.

28. REMOVE LUGGAGE HOLD BELT STRIKER ASSEMBLY (for RH Side)

HINT
Use the same procedure described for the LH side.

29. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH Removal

30. REMOVE REAR FLOOR BOARD SPACER

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

31. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT

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

32. 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.

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.

33. REMOVE NO. 1 HYBRID BATTERY INTAKE DUCT

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

34. REMOVE BATTERY COOLING BLOWER ASSEMBLY

NOTICE:
* Be sure not to touch the fan part of the battery cooling blower assemblies.
* Do not lift the battery cooling blower assemblies using the wire harness.

(a) Disconnect the 3 wire harness clamps.

(b) Disconnect the battery cooling blower assembly connector and clamp.

(c) Remove the 2 bolts, nut and battery cooling blower assembly.

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

(a) Disconnect the wire harness clamp.

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

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

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

37. 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.

38. REMOVE FRAME WIRE

CAUTION:
* Wear insulating gloves.
* Insulate the removed terminals with insulating tape.
(a) Remove the 2 nuts, then disconnect the frame wire from the hybrid battery junction block assembly.

(b) Disconnect the clamp and frame wire.

39. REMOVE HV BATTERY ASSEMBLY

CAUTION:
Wear insulating 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) Disconnect the connector and electrical key oscillator clamp.

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

(c) Remove the HV battery.

40. REMOVE HYBRID BATTERY JUNCTION BLOCK

CAUTION:
Wear insulating gloves.

(a) Disconnect the 2 connectors from the hybrid battery junction block.

(b) Disconnect the 2 connectors from the hybrid battery junction block.

41. REMOVE BATTERY SMART UNIT

CAUTION:
Wear insulating gloves.

(a) Disconnect the 3 connectors.

(b) Remove the 2 nuts and battery smart unit.

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

CAUTION:
Wear insulating gloves.

(a) Disconnect the connector.

(b) Remove the bolt and EV battery plug as shown in the illustration.

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

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.

(d) Remove the 3 nuts and No. 1 hybrid vehicle battery carrier bracket sub-assembly.

43. REMOVE NO. 4 HYBRID VEHICLE BATTERY CARRIER BRACKET SUB-ASSEMBLY

CAUTION:
Wear insulating 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.

44. REMOVE NO. 1 HYBRID BATTERY COVER INTAKE DUCT

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

45. 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 battery cover with the No. 1 hybrid battery shield sub-assembly.

46. 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.

47. REMOVE NO. 2 HYBRID BATTERY PACK WIRE

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