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•The colors of the high voltage harnesses and connectors are all orange. Orange High
Voltage labels are applied to the Li-ion battery and other high voltage devices. Do not
touch the Li-ion battery or other high voltage devices without always wearing appropriate
PPE.
•
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 and sign or similar item to prevent other persons from contactingthem.
•
Be sure to put the removed service plug in your pocket and carry it with you so
another person does not accidentally reinstall it while work is in progress.
•
The high voltage battery retains high voltage at all times. Personal Protective
Equipment (PPE) must always be worn when touching or working on high voltage
components to avoid risk of electrical shock and severe personal injury or death.
•
Immediately insulate disconnected high voltage connectors and terminals with
insulated tape.
•
The vehicle contains parts that contain powerful magnets. If a person who is wearing
a pacemaker or other medical device is close to these parts, the medical device may be
affected by the magnets. Such persons must not perform work on the vehicle.
•
Because this vehicle uses components that contain high voltage and powerful
magnetism, do not carry any metal products which may cause short circuits, or any
magnetic media (cash cards, credit cards, etc.) which may be damaged when working on
the vehicle.
•
Keep removed Li-ion battery packs away from rain to avoid electric shock.
• Do not heat removed battery packs higher than 158° F (70° C) .
There is the possibility of a hybrid system malfunction occurring if the vehicle is changed to
READY
status while the service plug is removed.
DG–41
Page 42 of 54
6-2 Lithium-ion (Li-ion) Battery Pack Removal
6-2.1 Exploded Views
Li-ion Battery Exploded View
: Vehicle front
1. Li-ion battery assembly 2. Bracket (RH) 3. Bracket (LH)
A. View A B. View B
A
B
B
1
A
3
2
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DG–42
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Trunk Room Trim Exploded View
: Clip
: Pawl
: Vehicle front
, , , ,: Indicates that the part is connected at points with same symbol in actual vehicle
1. Rear seatback center finisher 2. Trunk front finisher 3. Trunk side finisher LH
4. Trunk center box 5. Thinsulate 6. Trunk rear plate
7. Trunk net hook 8. Trunk floor carpet 9. Trunk side finisher RH
10. Trunk side finisher lid
1
2
3
4
6
5
3
10
9
8
7
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DG–43
Page 44 of 54
Li-ion Battery Cooling System Exploded View
, ,: Indicates that the part is connected at points with same symbol in actual vehicle
1. Battery outlet duct C 2. Battery outlet duct B 3. Battery cooling fan
4. Battery outlet duct A 5. Battery inlet duct B 6. Battery inlet duct A
7. Battery front duct 8. DC/DC inlet duct 9. DC/DC outlet duct
3
4
2
1
9
8
5
6
7
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DG–44
Page 45 of 54
6-2.2 Removal Procedure1. Discharge high voltage battery. Refer to
3-2.4 Discharge Procedures (DG–18)
2. Remove the service plug. Refer toAlternate Procedure 2 (Remove Service Plug) (DG–27).
3. Lift up seat cushion while pulling the seat cushion hook levers, and then disengage seat cushion hook.
4. Remove seat cushion from vehicle.
5. Remove seat belt from seat belt hook.
6. Remove seatback fixing nuts (A) .
7. Lift up seatback, disengage seatback frame (B) from engaging portion (C) , and then remove seatback.
8. Remove battery inlet duct A and battery front duct. Refer to the Li-ion Battery Cooling System Exploded View in
6-2.1 Exploded Views (DG–42).
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A
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A
A
A
A
B
C
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DG–45
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9. Remove the rear seat back finisher (1) , and rear seatback plate (2) .
10. Remove the trunk room finisher, trunk side finisher LH, and trunk side finisher RH. Refer to the Trunk Room Trim Exploded View in
6-2.1 Exploded Views (DG–42).
11. Remove fuse and fusible link box from Li-ion battery according to the following steps. a. Remove the fuse and fusible link box cover toremove harness mounting nuts (A) and (B) .
b. Remove the relay (1) from fuse and fusible link box.
c. Remove the fuse and fusible link box from Li-ion battery, and move to side.
12. Remove the cover of 12V battery positive terminal.
13. Remove the DC/DC harness (1) from 12V battery.
14. Disconnect sub oil pump inverter harness connectors (A)
15. Disconnect positive terminal from 12V battery, and disconnect fusible link harness connector (12V battery
side) (A) .
12
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1
B
A
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1
A
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A
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DG–46
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16. Remove the ground cable (1) .
Touching high voltage components without wearing
appropriate Personal Protective Equipment (PPE) will
cause electrocution.17. Remove the hybrid control unit (1) and Vehicle Sound for Pedestrians (VSP) control assembly (2) from Li-ion
battery.
Touching high voltage components without wearing
appropriate Personal Protective Equipment (PPE) will
cause electrocution.
18. Remove the terminal covers (1) and (2) .
Touching high voltage components without wearing
appropriate Personal Protective Equipment (PPE) will
cause electrocution.
19. Remove the terminal cover (1) .
Touching high voltage components without wearing
appropriate Personal Protective Equipment (PPE) will
cause electrocution.
1
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12
AAYIA0236ZZ
1
2
AAYIA0237ZZ
1
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DG–47
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20. Disconnect A/C high voltage harness (1) .
Immediately protect the terminals of the disconnected
high voltage harness connector socket using insulated
tape so that they are not exposed.
Touching high voltage components without wearing
appropriate Personal Protective Equipment (PPE) will
cause electrocution.21. Remove the high voltage cover (1) .
Touching high voltage components without wearing
appropriate Personal Protective Equipment (PPE) will
cause electrocution.
22. Remove the high voltage harness bracket mounting nut (A) and high voltage harness mounting nuts (B) .
Immediately protect the terminals of the disconnected
high voltage harness connector socket using insulated
tape so that they are not exposed.
Touching high voltage components without wearing
appropriate Personal Protective Equipment (PPE) will
cause electrocution.
1
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1
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B
A
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DG–48
