HIGH VOLTAGE CABLE REMOVAL/INSTALLATION
id300400000600
Replacement part
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Gasket
Quantity: 1
Location of use: high voltage cable (junction box No.3 side)
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Warning
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<<High voltage>>
• If the necessary measures are not taken before servicing an electric vehicle, it could cause electrical shock and result in serious injury or, in the worst case, death. Before servicing the electric vehicle, refer to [HIGH VOLTAGE SERVICE CAUTIONS] in the general information and implement the necessary measures. (See
HIGH VOLTAGE SERVICE CAUTIONS.)
High Voltage Part Inspection And Removal/Installation Notes
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Warning
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<<High voltage>>
• If necessary measures such as wearing the correct protective gear are not taken when inspecting or removing/installing the high voltage parts, it could cause electrical shock and result in serious injury or, in the worst case, death.
• Before inspecting or removing/installing the high voltage parts, refer to [HIGH VOLTAGE SERVICE CAUTIONS] in the general information and [High Voltage Part Inspection and Removal/Installation Notes] of the high voltage system service cautions and implement the necessary measures and preparations. (See
HIGH VOLTAGE SERVICE CAUTIONS.) (See
HIGH VOLTAGE SYSTEM SERVICE CAUTIONS.)
High Voltage Cable Removal
1. Using the M-MDS, verify that a DTC indicating a high voltage insulation malfunction has been stored. (See DTC INSPECTION.)
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• If any of the following DTCs indicating a high voltage insulation malfunction is stored, repair the malfunctioning location according to the applicable DTC troubleshooting and go to the next step.
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• If a DTC indicating a high voltage insulation malfunction is not stored, go to the next step.
2. Load the vehicle on the auto lift so that it can be lifted up.
3. Verify that the READY indicator on the instrument cluster is not illuminated.
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• If the READY indicator is turned on, switch the main power OFF.
4. Disconnect the negative lead-acid battery terminal. (See NEGATIVE LEAD-ACID BATTERY TERMINAL DISCONNECTION/CONNECTION.)
5. Partially peel back the cover.
6. Remove the service hole cover.
7. Wear insulating gloves and remove the service plug using the following procedure.
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Warning
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<<High voltage>>
• Touching the terminal on the vehicle side can result in serious injury or death from electric shock. For this reason, after removing the service plug, cover the vehicle-side terminals with insulating tape so that they cannot be touched.
• Do not touch high voltage parts for 10 min after removing service plug. Electric charges may be stored on the condenser for 10 min after the service plug is removed, and touching high voltage parts during that time can result in serious injury or death from electric shock.
• Service plugs must be removed by workers inspecting/removing/installing high voltage parts. Keep the removed service plug on your person until inspection/removal/installation of the high voltage parts is completed to prevent other workers from accidentally installing the service plug.
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Caution
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<<High voltage>>
• After removing the service plug, cover the vehicle side terminals with insulating tape to prevent foreign matter from adhering to them.
• When you are keeping the service plug on your person, cover the service plug terminals with insulating tape to prevent damage to them.
• Do not switch the main power ON (READY on) after removing the service plug. If the main power is switched ON (READY on) after removing the service plug, the vehicle may malfunction.
- (1) Slide the lock in the direction of the arrow shown in the figure. (Do not pull out completely)
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- (2) Raise the lever.
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- (3) Press the area indicated by arrow (1) shown in the figure, release the tabs, and then raise the lever until it is perpendicular.
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- (4) Hold the lever and pull the service plug straight up.
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8. After removing the service plug, leave it for 10 min.
9. Wear insulating gloves and measure the voltage at the high voltage cable connection (junction box No.3 side) using the following procedure.
- (1) Remove the seal cover. (See SEAL COVER REMOVAL/INSTALLATION.)
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Caution
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<<High voltage>>
• Be careful not to allow foreign matter or water droplets to enter the junction box No.3. Since the junction box No.3 has a high voltage circuit, there is a risk of malfunction if foreign matter or water drops enter it.
• Remove the terminal cover by pulling it straight up. The terminal cover is fitted with an interlock switch. This interlock switch may be damaged if the terminal cover is removed while being tilted.
• Do not touch the moisture-proof seal on the terminal cover. If the seal is touched or damaged, replace the terminal cover.
- (2) Remove the terminal cover.
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- (3) Measure the voltage at the high voltage cable connection.
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Note
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• Use a voltmeter with a measurement range of
450 V DC or more.
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― Verify that the voltmeter indicates 0 V and go to the next step.
10. Wear insulating gloves and remove the bolts shown in the figure.
11. Wear insulating gloves and remove the bolts shown in the figure.
12. Disconnect the connector shown in the figure.
13. Wear insulating gloves and disconnect the high voltage cable (junction box No.3 side).
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• After disconnecting the high voltage cable, wear insulating gloves, wrap the terminals with electrical tape, and then insulate.
14. Wear insulating gloves, remove the nuts shown in the figure, and then remove the high voltage cable from the vehicle.
15. Lift up the vehicle.
16. Remove the gusset. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)
17. Remove floor under cover No.1. (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)
18. Disconnect the connector shown in the figure.
19. Wear insulating gloves and remove the bolt shown in the figure.
20. Wear insulating gloves and disconnect the high voltage cable (high voltage battery side)
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• After disconnecting the high voltage cable, wear insulating gloves, wrap the terminals with electrical tape, and then insulate.
21. Disconnect the clips shown in the figure from the bracket.
22. Remove the bracket from the high voltage cable.
23. Remove the nuts and remove the bracket from the high voltage cable.
High Voltage Cable Installation
1. Install the bracket to the high voltage cable.
2. Install the bracket.
3. Lift up the vehicle.
4. Wear insulating gloves, hook (1) the high voltage cable hook with the bracket, and then install (2) the clips to the bracket.
5. Wear insulating gloves and connect the high voltage cable (high voltage battery side) to the high voltage battery.
6. Wear insulating gloves and tighten the bolt.
7. Connect the connector shown in the figure.
8. Install the gusset. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)
9. Install floor under cover No.1. (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)
10. Unload the vehicle from the auto lift.
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Caution
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<<High voltage>>
• Install the gasket so that the gasket of the high voltage cable (junction box No.3 side) does not protrude from the groove of the junction box No.3.
11. Wear insulating gloves and install the high voltage cable (junction box No.3 side).
12. Wear insulating gloves and tighten the bolts shown in the figure.
13. Wear insulating gloves and tighten the bolts shown in the figure.
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Caution
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<<High voltage>>
• Be careful that foreign matter, water droplets, or other substance do not enter the junction box No.3. Because the junction box No.3 contains a high voltage circuit, there is the risk of malfunction if foreign matter, water droplets, or other substance enter the junction box No.3.
• Remove the terminal cover by lifting it straight up. Because there is an interlock switch on the terminal cover, if the terminal cover is tilted when it is removed, the interlock switch may be damaged.
• Do not contact the moisture seal on the terminal cover. If the moisture seal was contacted or damaged, replace the moisture seal.
14. Install the terminal cover.
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Caution
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• Before connecting the service plug, check the tightness of the high voltage terminals and the connection status of the connectors.
15. Wear insulating gloves and install the service plug using the following procedure.
- (1) Insert the service plug as far as it will go.
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- (2) Depress the lever completely.
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- (3) Slide the lock in the direction of the arrow shown in the figure until the hook is engaged.
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16. Install the service hole cover.
17. Close the cover.
18. Connect the negative lead-acid battery terminal. (See NEGATIVE LEAD-ACID BATTERY TERMINAL DISCONNECTION/CONNECTION.)
