RM38T0EC _51 Engine / Hybrid System _144957 HYBRID / BATTERY CONTROL _0604247 HV BATTERY A

HYBRID / BATTERY CONTROL  HV BATTERY  INSTALLATION  


CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)
A524795N01
3.073,0.167 4.073,0.333 1,0.167 0.979,1.927 1.979,2.094 1,0.167 0.26,3.354 1.26,3.521 1,0.167 3.146,3.865 4.146,4.031 1,0.167 6.115,3.438 7.115,3.604 1,0.167 5.979,2.271 6.979,2.438 1,0.167 5.667,1.708 6.667,1.875 1,0.167 4.604,0.948 5.354,1.115 0.75,0.167 0.219,3.313 1.302,3.563 1.083,0.25 0.938,1.885 2.021,2.135 1.083,0.25 5.625,1.667 6.708,1.917 1.083,0.25 5.938,2.229 7.021,2.479 1.083,0.25 4.563,0.906 5.396,1.156 0.833,0.25 6.26,4.177 6.542,4.177 false 6.292,2.708 6.573,2.708 false 5.406,3.021 5.688,3.24 5.688,3.24 5.833,3.24 false 3.771,3.625 3.927,3.625 3.927,3.625 4.146,3.385 false 2.052,3.438 2.375,3.906 2.375,3.906 2.521,3.906 false 1.125,2.552 1.25,2.771 1.25,2.771 1.375,2.771 false 3.146,2.042 3.292,1.635 3.292,1.635 3.417,1.635 false 4.865,1.823 5.125,1.417 5.125,1.417 5.25,1.417 false 4.833,2.51 5.031,2.26 5.031,2.26 5.156,2.26 false 3.188,0.823 3.333,0.667 3.333,0.667 3.458,0.667 false 1.021,0.771 1.302,0.771 false 1.302,1.531 1.583,1.531 false 2.74,0.438 2.938,0.26 2.938,0.26 3.063,0.26 false 0.521,2.375 0.854,2.01 0.854,2.01 0.979,2.01 false 1.271,3.438 1.427,3.438 1.427,3.438 1.5,3.26 false 4.281,1.208 4.479,1.031 4.479,1.031 4.604,1.031 false 5.406,1.906 5.531,1.792 5.531,1.792 5.656,1.792 false 5.344,2.573 5.844,2.354 5.844,2.354 5.969,2.354 false 4.156,3.938 4.281,3.938 4.281,3.938 4.542,3.563 false 4.167,4.583 4.323,4.583 4.323,4.583 4.521,4.469 false 5.792,3.729 5.792,3.521 5.792,3.521 6.104,3.521 false 6.01,3.521 6.01,3.677 false 3.833,4.458 4.313,4.75 0.479,0.292 18 false 13 6.74,4.042 7.156,4.448 0.417,0.406 18 false 12 6.625,2.573 7.042,2.979 0.417,0.406 18 false 11 3.406,3.458 3.823,3.865 0.417,0.406 18 false 10 5.875,3.083 6.292,3.49 0.417,0.406 18 false 9 3.781,0.563 4.198,0.969 0.417,0.406 18 false 8 1.573,0.656 1.99,1.063 0.417,0.406 18 false 7 1.875,1.417 2.292,1.823 0.417,0.406 18 false 6 3.698,1.521 4.115,1.927 0.417,0.406 18 false 5 2.781,3.813 3.198,4.219 0.417,0.406 18 false 4 1.688,2.688 2.104,3.094 0.417,0.406 18 false 3 5.5,1.323 5.917,1.729 0.417,0.406 18 false 2 5.458,2.146 5.875,2.552 0.417,0.406 18 false 1 2.823,0.427 3.094,0.677 0.271,0.25 10 false x5 1.563,3.271 1.833,3.521 0.271,0.25 10 false x2 0.656,2.427 0.927,2.677 0.271,0.25 10 false x2 5.365,2.625 5.635,2.875 0.271,0.25 10 false x2 5.458,1.896 5.729,2.146 0.271,0.25 10 false x2 4.646,3.458 4.917,3.708 0.271,0.25 10 false x2 6.052,2.281 7.083,2.531 1.031,0.25 8 false 7.5 (76, 66 in.*lbf) 1.031,1.927 2.063,2.177 1.031,0.25 8 false 7.5 (76, 66 in.*lbf) 0.313,3.354 1.344,3.604 1.031,0.25 8 false 7.5 (76, 66 in.*lbf) 4.688,0.948 5.719,1.198 1.031,0.25 8 false 19 (194, 14) 3.219,3.865 4.25,4.115 1.031,0.25 8 false 7.5 (76, 66 in.*lbf) 3.146,0.177 4.177,0.427 1.031,0.25 8 false 7.5 (76, 66 in.*lbf) 6.177,3.438 7.156,3.719 0.979,0.281 8 false 7.5 (76, 66 in.*lbf) 5.729,1.719 6.76,1.969 1.031,0.25 8 false 7.5 (76, 66 in.*lbf) 4.344,1.271 4.615,1.521 0.271,0.25 10 false x4

Procedure Part Name Code
Z101186

Z101188

Z101187

1 NO. 4 HV BATTERY CARRIER BRACKET G92K6 (Click here) - -
2 NO. 3 HV BATTERY CARRIER BRACKET G92K5 (Click here) - -
3 NO. 2 HYBRID BATTERY CARRIER BRACKET G92K4 (Click here) - -
4 NO. 1 HV BATTERY CARRIER BRACKET SUB-ASSEMBLY G920B (Click here) - -
5 HV SUPPLY BATTERY ASSEMBLY G9510 (Click here) - -
6 FLOOR WIRE 82161 (Click here) - -
7 FLOOR UNDER WIRE 821H1 (Click here) - -
8 NO. 1 HYBRID BATTERY SHIELD SUB-ASSEMBLY G920Q (Click here) - -
9 NO. 3 HV BATTERY PACK WIRE G92X3 - - -
10 NO. 2 HYBRID BATTERY INTAKE DUCT G92D2 (Click here) - -
11 HYBRID BATTERY HOSE ASSEMBLY G9290A - - -
12 BATTERY COOLING BLOWER ASSEMBLY G9230 (Click here) - -
13 NO. 1 EV BATTERY INTAKE DUCT G92D1A - - -

V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)
V100146

N*m (kgf*cm, ft.*lbf): Specified torque

A523066N11
4.563,1.958 5.313,2.125 0.75,0.167 4.521,1.917 5.354,2.167 0.833,0.25 1.927,0.458 3.115,0.458 false 2.677,0.927 2.677,0.458 false 2.333,1.927 2.615,1.698 2.615,1.698 2.844,1.698 false 4.375,2.917 4.708,2.917 false 4.625,3.594 4.958,3.594 false 5.792,1.854 5.927,2.188 5.927,2.188 6.063,2.188 false 3.594,4.292 3.927,4.292 false 1.865,3.531 2.198,3.531 false 0.802,2.708 1.135,2.708 false 6.427,1.031 6.51,1.219 6.51,1.219 6.646,1.219 false 4.375,2.115 4.417,2.042 4.417,2.042 4.552,2.042 false 4.656,4.563 4.802,4.563 4.802,4.563 4.906,4.479 false 6.479,0.198 6.813,0.198 false 3.281,3.323 3.594,3.521 0.313,0.198 10 false x2 0.729,1.521 1.042,1.719 0.313,0.198 10 false x2 4.438,2.188 4.75,2.385 0.313,0.198 10 false x6 6.719,1.073 7.115,1.5 0.396,0.427 18 false 22 6.344,2.104 6.75,2.5 0.406,0.396 18 false 21 3.479,0.323 3.823,0.729 0.344,0.406 18 false 20 2.938,1.563 3.281,1.969 0.344,0.406 18 false 17 1.26,2.563 1.604,2.969 0.344,0.406 18 false 16 3.979,4.156 4.323,4.563 0.344,0.406 18 false 18 5.042,3.458 5.385,3.865 0.344,0.406 18 false 19 2.281,3.406 2.625,3.813 0.344,0.406 18 false 15 4.969,2.74 5.375,3.156 0.406,0.417 18 false 14 3.26,0.365 3.479,0.625 0.219,0.26 10 false ● 4.635,1.958 5.406,2.188 0.771,0.229 8 false 16 (163, 12) 4.365,4.417 4.792,4.719 0.427,0.302 18 false 23 6.146,0.083 6.542,0.51 0.396,0.427 18 false 24

Procedure Part Name Code
Z101186

Z101188

Z101187

14 REAR SEAT CUSHION LEG SUB-ASSEMBLY 71033 (Click here) - -
15 REAR UNDER COVER 76971G - - -
16 REAR UNDER SIDE COVER RH 76973F - - -
17 REAR DOOR SCUFF PLATE RH 67917A - - -
18 REAR UNDER SIDE COVER LH 76974F - - -
19 REAR DOOR SCUFF PLATE LH 67918A - - -
20 REAR SEAT CUSHION LOCK HOOK 72693 - - -
21 BENCH TYPE REAR SEAT CUSHION ASSEMBLY - (Click here) - -
22 REAR CENTER SEAT OUTER BELT ASSEMBLY 73350C - - -
23 SERVICE PLUG GRIP G3834 - - -
24 UTILITY - (Click here) - -

V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf) ● Non-reusable part

PROCEDURE

Hide G92K6 1.INSTALL NO. 4 HV BATTERY CARRIER BRACKET

Z101186

CAUTION:

Wear insulated gloves.



Torque:
7.5 N*m (76 kgf*cm, 66 in.*lbf)

Hide G92K5 2.INSTALL NO. 3 HV BATTERY CARRIER BRACKET

Z101186

CAUTION:

Wear insulated gloves.



Torque:
7.5 N*m (76 kgf*cm, 66 in.*lbf)

Hide G92K4 3.INSTALL NO. 2 HYBRID BATTERY CARRIER BRACKET

Z101186

CAUTION:

Wear insulated gloves.



Torque:
7.5 N*m (76 kgf*cm, 66 in.*lbf)

Hide G920B 4.INSTALL NO. 1 HV BATTERY CARRIER BRACKET SUB-ASSEMBLY

Z101186

CAUTION:

Wear insulated gloves.



Torque:
7.5 N*m (76 kgf*cm, 66 in.*lbf)

Hide G9510 5.INSTALL HV SUPPLY BATTERY ASSEMBLY

Z101186

CAUTION:

Wear insulated gloves.


NOTICE:
·

Do not allow foreign matter, such as grease or oil, to adhere to the bolts of the HV battery.

·

To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.

·

Use cardboard or another similar material to protect the HV battery and vehicle body from damage.

·

Since the HV battery is very heavy, 2 people are needed to install it. When installing the HV battery, be careful not to damage the parts around it.

·

When removing/installing/moving the HV battery, make sure not to tilt it more than 80°.

·

While lowering the HV battery into the vehicle, do not allow it to contact the vehicle.

·

As bolts with 2 different lengths are used, make sure to install each bolt to the correct position.

·

If the HV battery has been struck or dropped, replace it.




Torque:
19 N*m (194 kgf*cm, 14 ft.*lbf)

Hide 82161 6.CONNECT FLOOR WIRE

Z101186

CAUTION:

Wear insulated gloves.



Hide 821H1 7.CONNECT FLOOR UNDER WIRE

Z101186

CAUTION:

Wear insulated gloves.


NOTICE:

Make sure that the connectors are connected securely.



Hide G920Q 8.INSTALL NO. 1 HYBRID BATTERY SHIELD SUB-ASSEMBLY

Torque:
7.5 N*m (76 kgf*cm, 66 in.*lbf)

Hide G92X3 9.INSTALL NO. 3 HV BATTERY PACK WIRE

Hide G92D2 10.INSTALL NO. 2 HYBRID BATTERY INTAKE DUCT

Z101186

CAUTION:

Wear insulated gloves.



Torque:
7.5 N*m (76 kgf*cm, 66 in.*lbf)

Hide G9290A 11.INSTALL HYBRID BATTERY HOSE ASSEMBLY

Hide G9230 12.INSTALL BATTERY COOLING BLOWER ASSEMBLY

Z101186

Click here(Click here)

Hide 71033 14.INSTALL REAR SEAT CUSHION LEG SUB-ASSEMBLY

a.
A537180N01
4.333,1.583 4.49,1.781 0.156,0.198 10 true 2 3.25,1.563 3.406,1.76 0.156,0.198 10 true 1 4.875,0.844 5.031,1.042 0.156,0.198 10 true 3 2.74,1.365 2.896,1.563 0.156,0.198 10 true 4 2.167,1.031 2.323,1.229 0.156,0.198 10 true 5 2.865,0.073 3.021,0.271 0.156,0.198 10 true 6 1.833,0.073 1.99,0.375 0.156,0.302 18 true i

i.

Temporarily install the rear seat cushion leg sub-assembly with the 6 bolts.


ii.

Fully tighten the 6 bolts in the order shown in the illustration.

Torque:
16 N*m (163 kgf*cm, 12 ft.*lbf)



Hide 76971F 15.INSTALL REAR UNDER COVER

Hide 76973E 16.INSTALL REAR UNDER SIDE COVER RH

Hide 76974E 18.INSTALL REAR UNDER SIDE COVER LH

Hide 67918A 19.INSTALL REAR DOOR SCUFF PLATE LH

a.

Use the same procedure as for the RH side.


Hide 24. PERFORM UTILITY

NOTICE:
·

Perform "Battery Status Info Update" after replacing the malfunctioning HV battery.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID BATTERY SYSTEM>UTILITY

·

Perform "Prediagnostic Battery Charge" after replacing the malfunctioning HV battery.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID BATTERY SYSTEM>UTILITY

·

Perform "Battery Diagnosis" after replacing the malfunctioning HV battery.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HYBRID BATTERY SYSTEM>UTILITY