Battery Bus Junction Board: Service and Repair

LI-ION BATTERY

BATTERY JUNCTION BOX : Disassembly and Assembly


WARNING:
- Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are handled incorrectly. Be sure to follow the correct work procedures when performing inspection and maintenance.
- Be sure to remove the service plug in order to shut off the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.
- Be sure to put the removed service plug in your pocket and carry it with you so that another person does not accidentally connect it while work is in progress.
- Be sure to wear insulating protective equipment consisting of glove, shoes and glasses before beginning work on the high voltage system.
- 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 or similar item to prevent other persons from contacting them.
- High Voltage Precautions.

CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do so in the Service Manual.

DISASSEMBLY

1.Remove the DC/DC converter (1). DC/DC Converter Disassembly and Assembly.





2.Remove the controller cover (1).






WARNING:


To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated tools.





3.Remove the mounting bolt (A), and then disconnect the service plug harness (1) from the bracket.

WARNING:


To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated tools.





4.Remove the mounting bolt (A) and the ground cable mounting nut (B), then remove the service plug bracket (1).

WARNING:


To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated tools.





5.Disconnect the high voltage harness connectors (A) and vehicle communications harness connector (B) from the battery junction box.
DANGER:


- Touching high voltage components without using the appropriate protective equipment will cause electrocution.
-To prevent electric shock hazards, immediately wrap insulating tape around disconnected high voltage connector terminals.





6.Remove the battery cover LH (1).






WARNING:


To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated tools.





7.Remove the mounting nuts (A), then remove the battery junction box.

WARNING:


To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated tools.





8.Remove the mounting nuts (A), then remove the battery junction box bracket (1).

WARNING:


To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated tools.

ASSEMBLY

Assemble in the reverse order of disassembly.