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

HYBRID / BATTERY CONTROL  HV BATTERY  REMOVAL  


CAUTION / NOTICE / HINT

COMPONENTS (REMOVAL)
A523065N02
1.531,1.01 2.531,1.177 1,0.167 1.479,0.969 2.563,1.219 1.083,0.25 3.635,0.792 4.635,0.958 1,0.167 5.604,2.177 5.427,2.177 5.427,2.177 5.021,1.698 false 3.531,1.333 3.844,1.333 false 6.552,0.188 6.865,0.188 false 2.531,1.104 2.844,1.104 false 3.344,1.031 3.438,0.865 3.438,0.865 3.625,0.865 false 5.677,2.063 5.958,2.417 0.281,0.354 18 false 3 5.75,0.052 6.667,0.51 0.917,0.458 18 false 1, 2, 5 4.219,1.208 4.875,1.552 0.656,0.344 18 false 4, 6 1.604,1.021 2.646,1.292 1.042,0.271 8 false 8.0 (82, 71 in.*lbf) 3.698,0.792 4.74,1.063 1.042,0.271 8 false 2.0 (20, 18 in.*lbf)

Procedure Part Name Code
Z101186

Z101188

Z101187

1 PRECAUTION - (Click here) - -
2 READ VALUE USING GTS - (Click here) - -
3 SERVICE PLUG GRIP G3834 - - -
4 REMOVE CONNECTOR COVER ASSEMBLY - (Click here) - -
5 TERMINAL VOLTAGE - (Click here) - -
6 INSTALL CONNECTOR COVER ASSEMBLY - (Click here) - -

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

A522011N12
1.927,0.458 3.115,0.458 false 2.677,0.927 2.677,0.458 false 2.51,1.698 2.844,1.698 false 4.375,2.917 4.708,2.917 false 5.51,3.615 5.844,3.615 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 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 4.458,2.167 4.771,2.365 0.313,0.198 10 false x6 6.719,1.073 7.063,1.479 0.344,0.406 18 false 7 6.333,2.104 6.677,2.51 0.344,0.406 18 false 8 3.479,0.323 3.823,0.729 0.344,0.406 18 false 9 2.938,1.563 3.281,1.969 0.344,0.406 18 false 10 1.26,2.563 1.604,2.969 0.344,0.406 18 false 11 3.979,4.156 4.323,4.563 0.344,0.406 18 false 13 5.896,3.49 6.24,3.896 0.344,0.406 18 false 12 2.281,3.396 2.625,3.802 0.344,0.406 18 false 14 4.802,2.771 5.146,3.177 0.344,0.406 18 false 15 3.26,0.365 3.479,0.625 0.219,0.26 10 false ●

Procedure Part Name Code
Z101186

Z101188

Z101187

7 REAR CENTER SEAT OUTER BELT ASSEMBLY 73350C - - -
8 BENCH TYPE REAR SEAT CUSHION ASSEMBLY - (Click here) - -
9 REAR SEAT CUSHION LOCK HOOK 72693 - - -
10 REAR DOOR SCUFF PLATE RH 67917A - - -
11 REAR UNDER SIDE COVER RH 76973F - - -
12 REAR DOOR SCUFF PLATE LH 67918A - - -
13 REAR UNDER SIDE COVER LH 76974F - - -
14 REAR UNDER COVER 76971G - - -
15 REAR SEAT CUSHION LEG SUB-ASSEMBLY 71033 - - -

A523067N03
4.292,3.948 4.458,3.948 4.458,3.948 4.635,4.156 false 6.26,4.177 6.542,4.177 false 6.292,2.708 6.573,2.708 false 5.427,3.021 5.771,3.333 5.771,3.333 5.917,3.333 false 3.771,3.625 3.927,3.625 3.927,3.625 4.146,3.385 false 1.99,3.344 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 6.563,0.188 6.844,0.188 false 3.979,3.813 4.531,4.167 0.552,0.354 18 false 16 6.74,4.042 7.156,4.448 0.417,0.406 18 false 17 6.625,2.573 7.042,2.979 0.417,0.406 18 false 18 3.406,3.458 3.823,3.865 0.417,0.406 18 false 19 5.979,3.219 6.396,3.625 0.417,0.406 18 false 20 3.781,0.563 4.198,0.969 0.417,0.406 18 false 21 1.573,0.656 1.99,1.063 0.417,0.406 18 false 22 1.875,1.417 2.292,1.823 0.417,0.406 18 false 23 3.698,1.521 4.115,1.927 0.417,0.406 18 false 24 2.781,3.813 3.198,4.219 0.417,0.406 18 false 25 1.688,2.688 2.104,3.094 0.417,0.406 18 false 26 5.5,1.323 5.917,1.729 0.417,0.406 18 false 27 5.458,2.146 5.875,2.552 0.417,0.406 18 false 28 6.26,0.052 6.677,0.458 0.417,0.406 18 false 29 2.823,0.427 3.094,0.677 0.271,0.25 10 false x5 1.552,3.208 1.823,3.458 0.271,0.25 10 false x2 0.656,2.427 0.927,2.677 0.271,0.25 10 false x2 5.365,2.635 5.635,2.885 0.271,0.25 10 false x2 5.458,1.896 5.729,2.146 0.271,0.25 10 false x2 4.646,3.469 4.917,3.719 0.271,0.25 10 false x2 4.365,1.26 4.635,1.51 0.271,0.25 10 false x4 6.146,3.552 6.417,3.802 0.271,0.25 10 false x2

Procedure Part Name Code
Z101186

Z101188

Z101187

16 NO. 1 EV BATTERY INTAKE DUCT G92D1A - - -
17 BATTERY COOLING BLOWER ASSEMBLY G9230 (Click here) - -
18 HYBRID BATTERY HOSE ASSEMBLY G9290A - - -
19 NO. 2 HYBRID BATTERY INTAKE DUCT G92D2 (Click here) - -
20 NO. 3 HV BATTERY PACK WIRE G92X3 - - -
21 NO. 1 HYBRID BATTERY SHIELD SUB-ASSEMBLY G920Q (Click here) - -
22 FLOOR UNDER WIRE 821H1 (Click here) - -
23 FLOOR WIRE 82161 (Click here) - -
24 HV SUPPLY BATTERY ASSEMBLY G9510 (Click here) - -
25 NO. 1 HV BATTERY CARRIER BRACKET SUB-ASSEMBLY G920B (Click here) - -
26 NO. 2 HYBRID BATTERY CARRIER BRACKET G92K4 (Click here) - -
27 NO. 3 HV BATTERY CARRIER BRACKET G92K5 (Click here) - -
28 NO. 4 HV BATTERY CARRIER BRACKET G92K6 (Click here) - -
29 RECOVERY INSPECTION - (Click here) - -

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during HV battery removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure Necessary Procedures Effect/Inoperative Function when Necessary Procedure not Performed Link
Replacement of HV battery
1.

Prediagnostic battery charge

2.

Battery diagnosis

3.

Battery status info update


HV battery status information cannot be updated (Click here)
Replacement of hybrid battery terminal block Perform high voltage fuse accumulated load history reset DTCs are stored (Click here)

CAUTION:
·
A340386

Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.

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

·
A340358

To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.



HINT:
·

When disposing of an HV battery, make sure to return it through an authorized collection agent who is capable of handling it safely. If the HV battery is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.

·

When the cable is disconnected / reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.


·

Learning completes when vehicle is driven.

Effect/Inoperative Function When Necessary Procedures are not Performed Necessary Procedures Link
Front Camera System Drive the vehicle straight ahead at 15 km/h (10 mph) or more for 1 second or more. (Click here)

·

Learning completes when vehicle is operated normally

Effect/Inoperative Function When Necessary Procedures are not Performed Necessary Procedures Link
Power door lock control system
·

Back door opener


Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch. (Click here)
Power back door system Fully close the back door by hand.
HINT:

Initialization is not necessary if the above procedures are performed while the back door is closed.


(Click here)
Air conditioning system After the ignition switch is turned to ON, the servo motor standard position is recognized. -



PROCEDURE

Hide 1. PRECAUTION

NOTICE:
·

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal.

Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>BEFORE DISCONNECTING BATTERY

·

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

·

When connecting a connector to the HV battery, confirm that the connector is securely connected through the following:

- Push the connector until a click sound is heard.

- Visually check and confirm that the connector is securely connected by pulling on it.

·

Make sure to insulate the high-voltage connectors and terminals of the HV battery with insulating tape after removing it.

If the HV battery stored without insulating the connectors and terminals, electric shock or fire may result.

·

When performing repairs around the HV battery, such as using a tap, do not allow metal shavings to enter the HV battery.

·

Do not touch any high voltage wire harnesses, connectors or parts with bare hands.

·
A522014

Hold the areas shown in the illustration and lift the HV battery.

·

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

·
A522015C01
0.865,0.615 1.521,1.24 1.521,1.24 1.469,0.844 true 2.021,3.198 2.354,2.885 true 1.5,1.281 1.708,1.479 0.208,0.198 10 true *a 1.76,3.177 1.969,3.375 0.208,0.198 10 true *a
*a Opening


Do not put your hands into the openings of the HV battery.

·

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

·

Do not climb on top of or stand on the HV battery.

·

Do not allow any foreign matter or water to enter the HV battery.

·

If any bolts, nuts or clips are dropped into the HV battery, make sure to remove them.



Hide 2. READ VALUE USING GTS

a.
A461168N07
0.5,0.094 1.521,0.417 1.021,0.323 18 false i, ii, iii, iv

i.

Connect the GTS to the DLC3.


ii.

Turn the ignition switch on (IG).


iii.

Enter the following menus: Powertrain / HV Battery / Data List / Hybrid/EV Battery Temperature 1 to 6.

Powertrain > HV Battery > Data List
Tester Display
Hybrid/EV Battery Temperature 1
Hybrid/EV Battery Temperature 2
Hybrid/EV Battery Temperature 3
Hybrid/EV Battery Temperature 4
Hybrid/EV Battery Temperature 5
Hybrid/EV Battery Temperature 6
50003 398 62,63,64,65,66,67

iv.

Read the Data List.

NOTICE:

If any of the temperatures listed in "Hybrid/EV Battery Temperature 1 to 6" are 50°C or more, leave the vehicle until the temperature drops to less than 50°C.




Hide 4.REMOVE CONNECTOR COVER ASSEMBLY

Z101186

Click here(Click here)

Hide 6.INSTALL CONNECTOR COVER ASSEMBLY

Z101186

CAUTION:

Wear insulated gloves.



a.
A523031C02
3.938,0.396 4.146,0.573 0.208,0.177 10 true *a 3.01,1.24 3.24,1.396 0.229,0.156 10 true *b 2.344,0.104 2.802,0.417 0.458,0.313 18 true i, ii
*a Bolt (A) *b Bolt (B)


i.

Using a T30 "TORX" socket wrench, install the connector cover assembly to the inverter with converter assembly with the bolt (A).

Torque:
2.0 N*m (20 kgf*cm, 18 in.*lbf)

NOTICE:

Do not touch the waterproof seal of the connector cover assembly.



ii.

Install the bolt (B).

Torque:
8.0 N*m (82 kgf*cm, 71 in.*lbf)



Hide 76973E 11.REMOVE REAR UNDER SIDE COVER RH

a.
A524800C01
0,0 0,0 false
V113147

Remove in this Direction - -



Hide 67918A 12.REMOVE REAR DOOR SCUFF PLATE LH

a.

Use the same procedure as for the RH side.


Hide 76974E 13.REMOVE REAR UNDER SIDE COVER LH

a.
A524801C01
0,0 0,0 false
V113147

Remove in this Direction - -



Hide 76971F 14.REMOVE REAR UNDER COVER

a.
A470638


Hide 71033 15.REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY

a.
A468763


Hide G9230 17.REMOVE BATTERY COOLING BLOWER ASSEMBLY

Z101186

Click here(Click here)

Hide G9290A 18.REMOVE HYBRID BATTERY HOSE ASSEMBLY

a.
A522022


Hide G92D2 19.REMOVE NO. 2 HYBRID BATTERY INTAKE DUCT

Z101186

CAUTION:

Wear insulated gloves.



a.
A522023


Hide G92X3 20.REMOVE NO. 3 HV BATTERY PACK WIRE

a.
A522024


Hide G920Q 21.REMOVE NO. 1 HYBRID BATTERY SHIELD SUB-ASSEMBLY

Z101186

CAUTION:

Wear insulated gloves.



a.
A522025C01
2.385,0.667 2.521,0.667 false 2.073,1.344 2.323,1.26 false 1.521,1.375 1.75,1.375 false 1.677,1.052 1.938,0.948 false 2.583,0.594 2.896,0.75 0.313,0.156 10 false *1 1.354,1.281 1.667,1.438 0.313,0.156 10 false *2 1.5,0.99 1.813,1.146 0.313,0.156 10 false *a 1.323,0.708 1.635,0.865 0.313,0.156 10 false *b 2.354,1.167 2.667,1.323 0.313,0.156 10 false *c 1.438,0.26 1.719,0.615 0.281,0.354 18 false i 3.146,0.052 3.313,0.344 0.167,0.292 18 true ii
*1 Service Plug Grip *2 Battery Cover Lock Striker
*a Projection *b Turn
*c Button - -


i.

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

HINT:

Insert the projection of the service plug grip and turn the button of the battery cover lock striker counterclockwise to release the lock.



ii.

Remove the 5 nuts and HV battery upper cover panel from the HV battery.



Hide 821H1 22.DISCONNECT FLOOR UNDER WIRE

Z101186

CAUTION:

Wear insulated gloves.


NOTICE:

Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.



a.
A522027C01
3.563,1.01 4,1.208 true 4.073,1.146 4.323,1.333 0.25,0.188 10 true *a 3.635,0.135 3.792,0.417 0.156,0.281 18 true i 3.375,1.219 3.594,1.5 0.219,0.281 18 true ii
*a Shield Ground - -


i.

Disconnect the 2 HV battery junction block assembly connectors.


ii.

Disconnect the shield ground from the HV battery.



Hide 82161 23.DISCONNECT FLOOR WIRE

Z101186

CAUTION:

Wear insulated gloves.



a.
A522028


Hide G9510 24.REMOVE 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 remove it. When removing the HV battery, be careful not to damage the parts around it.

·

When removing the HV battery from the vehicle, do not allow it to contact the vehicle.

·

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

·

Insulate the disconnected terminals or connectors with insulating tape.

·

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




a.
A522029


Hide G920B 25.REMOVE NO. 1 HV BATTERY CARRIER BRACKET SUB-ASSEMBLY

Z101186

CAUTION:

Wear insulated gloves.



a.
A522032


Hide G92K4 26.REMOVE NO. 2 HYBRID BATTERY CARRIER BRACKET

Z101186

CAUTION:

Wear insulated gloves.



a.
A522033


Hide G92K5 27.REMOVE NO. 3 HV BATTERY CARRIER BRACKET

Z101186

CAUTION:

Wear insulated gloves.



a.
A522034


Hide G92K6 28.REMOVE NO. 4 HV BATTERY CARRIER BRACKET

Z101186

CAUTION:

Wear insulated gloves.



a.
A522035


Hide 29.PERFORM RECOVERY INSPECTION

a.
A461169N01
1.417,0.167 1.698,0.521 0.281,0.354 18 false i

i.

Before returning the HV battery, make sure to perform a recovery inspection.

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>HV BATTERY>RECOVERY INSPECTION