HIGH VOLTAGE BATTERY REMOVAL/INSTALLATION


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Warning
•  Vehicles damaged in an accident could have electrical leakage due to internal damage of the high voltage battery. If servicing is carried out under electrical leakage conditions, it could cause electrical shock and result in serious injury or, in the worst case, death.
•  Refer to [Handling high voltage battery on damaged vehicle] in [DAMAGED VEHICLE HANDLING] in the general information and determine if an internal inspection of the high voltage battery is necessary. (See DAMAGED VEHICLE HANDLING [(E)].) Perform servicing only if an internal inspection of the high voltage battery is unnecessary. If it is determined that an internal inspection of the high voltage battery is necessary, contact the technical assistance for your market without performing servicing.

Replacement parts

Wiring harness clip
 
Quantity: 2
 
Location of use: High voltage cable

Oil and chemical type

Refrigerant
 
Type: HFO-1234yf (R-1234yf)
Compressor oil
 
Type: ND-OIL11

Warning
<<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

Warning
<<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.)

1.  Verify that the READY indicator on the instrument cluster is not illuminated.

•  If the READY indicator is turned on, switch the main power OFF.

2.  Disconnect the negative lead-acid battery terminal. (See NEGATIVE LEAD-ACID BATTERY TERMINAL DISCONNECTION/CONNECTION.)

3.  Partially peel back the cover.

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4.  Remove the service hole cover.

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5.  Wear insulating gloves and remove the service plug using the following procedure.

Warning
<<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.
Caution
<<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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6.  After removing the service plug, leave it for 10 min.

7.  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.)
Caution
<<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.
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(2)  Remove the terminal cover.
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(3)  Measure the voltage at the high voltage cable connection.
Note
•  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.
•  Verify that the waterproof rubber on the terminal cover is securely installed.
•  Be careful not to damage the interlock, and install it securely.
(4)  Install the terminal cover.
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8.  Drain the refrigerant. (See REFRIGERANT RECOVERY.)

9.  Remove the gusset. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

10.  Remove the floor under cover. (See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

11.  Remove the shield.

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12.  Disconnect the cooler pipe (high voltage battery side). (See REAR COOLER PIPE REMOVAL/INSTALLATION.)

13.  Disconnect the connectors shown in the figure.

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14.  Wear insulating gloves and disconnect the high voltage cable connector using the following procedure.

•  After disconnecting the high voltage cable connectors, wear insulating gloves and wrap the terminals with electrical tape to insulate them.
(1)  Pull out the lock tab.
(2)  Pull out the connector while pressing the lock lever.
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15.  Disconnect the high voltage cable (high voltage battery side). (See HIGH VOLTAGE CABLE REMOVAL/INSTALLATION.)

•  After disconnecting the high voltage cable, wear insulating gloves, wrap the terminals with electrical tape, and then insulate.

16.  Remove the rear wheel and tire (RH). (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

17.  Remove the rear mudguard (RH). (See MUDGUARD REMOVAL/INSTALLATION.)

18.  Wear insulating gloves and disconnect the high voltage cable connectors using the following procedure.

•  After disconnecting the high voltage cable connectors, wear insulating gloves and wrap the terminals with electrical tape to insulate them.
(1)  Pull out the lock tab.
(2)  Pull out the connector while pressing the lock lever.
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19.  Detach the wiring harness clips shown in the figure.

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20.  Remove the side shields.

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21.  Wear insulating gloves and disconnect the high voltage cable connector shown in the figure.

•  After disconnecting the high voltage cable connectors, wear insulating gloves and wrap the terminals with electrical tape to insulate them.
(1)  Pull out the lock tab.
(2)  Pull out the connector while pressing the lock lever.
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22.  Remove the bolts and ground cables shown in the figure.

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23.  Loosen the bolts shown in the figure.

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Warning
<<High voltage>>
•  Use a table lifter and cross beams of the sizes shown in the figure or larger. If the table lifter or the cross beams are smaller than the specified sizes, they will not be able to support the high voltage battery (weight approx. 320 kg {705 lb}) and the table lifter will fall, which may cause serious injury or death, and equipment damage. In addition, the high voltage battery may be damaged and the high voltage parts may be exposed, which could cause electrical shock or a fire.
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Caution
•  The high voltage battery is very heavy with a weight of approx. 320 kg {705 lb}. If handled incorrectly, the high voltage battery and the equipment could be damaged due to it falling over or falling down. Carefully handle the high voltage battery.

24.  Wear insulating gloves and remove the bolts shown in the figure.

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25.  Wear insulating gloves and align the center of the table with the center of gravity of the high voltage battery to support the high voltage battery.

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26.  Wear insulating gloves and remove the bolts shown in the figure.

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Warning
•  When lowering the table lifter, verify that the vehicle on the auto lift is not tilted or unbalanced. If the vehicle is tilted or unbalanced, it may fall off the auto lift and cause a serious injury or death, and equipment damage.

27.  Wear insulating gloves, and while verifying that the vehicle, high voltage battery, and the table lifter are not tilted and unbalanced, lower the table lifter slowly to remove the high voltage battery.

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Caution
•  If the high voltage battery is subjected to an impact, it could be damaged. When carrying a high voltage battery, carefully handle it so that it does not get hit.

28.  Install the eye bolts (M12) using the nuts to the positions shown in the figure, suspend the high voltage battery, and then move it onto a palette.

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Example of high voltage battery transportation method

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29.  Remove the bracket.

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30.  Install in the reverse order of removal. (See High Voltage Battery Installation Note.)

Caution
•  Before connecting the service plug, check the tightness of the high voltage terminals and the connection status of the connectors.

31.  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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32.  Install the service hole cover.

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33.  Close the cover.

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34.  Connect the negative lead-acid battery terminal. (See NEGATIVE LEAD-ACID BATTERY TERMINAL DISCONNECTION/CONNECTION.)

Caution
<<High voltage>>
•  Even if a small amount of compressor oil other than ND-OIL11 is used, electrical insulation may deteriorate significantly and electrical leakage may occur.

35.  When replacing the high voltage battery add compressor oil to the refrigeration cycle.

Compressor oil

Category

Supplemental amount (reference)

ND-OIL11
50 ml {50 cc, 1.7 US fl oz}

36.  Charge the refrigerant. (See REFRIGERANT CHARGING.)

37.  Perform the air-conditioning system performance test. (See REFRIGERANT SYSTEM PERFORMANCE TEST.)


High Voltage Battery Installation Note

1.  Temporarily install the bracket.

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2.  Wear insulating gloves and place the high voltage battery on the table lifter.

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3.  Wear insulating gloves and slowly raise the table lifter while verifying the position of the high voltage battery positioning pin.

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4.  Wear insulating gloves and raise the table lifter while adjusting its position so that the hooks on the bracket align with the rear edge of the high voltage battery.

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5.  Wear insulating gloves and temporarily tighten the bolts shown in the figure.

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6.  Wear insulating gloves and tighten the bolts shown in the figure until the high voltage battery contacts the vehicle body.

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7.  Tighten the bolts shown in the figure.

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8.  Wear insulating gloves and tighten the bolts shown in the figure.

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9.  Wear insulating gloves and tighten the bolts shown in the figure.

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