Disassembly And Assembly
LI-ION BATTERY
HEATER RELAY UNIT : 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 disconnect the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.
- To prevent the removed service plug from being connected by mistake during the procedure, always carry it in your pocket or put it in the tool box.
- Be sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses before beginning work on the high voltage system.
- Refer to "High Voltage Precautions" Type 2.
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.
WORK ENVIRONMENT FOR DISASSEMBLY OF LI-ION BATTERY
1.Must be an indoor environment.
- The work environment must be able to be isolated from the outside by shutters or other means to prevent the intrusion of rain, snow, sand, and other substances.
- The environment must prevent the entry of sweat during work, and also prevent condensation from occurring as a result of high temperature and humidity.
2.No entry of foreign materials.
- In addition to being indoors, the environment must not permit the entry during disassembly work of metal powders, oil, or foreign substances resulting from causes such as servicing of other vehicles.
- If there is any risk of the above, use a plastic curtain or other means to block off the work area, or take other necessary steps.
3.The floor must be dry.
- The floor must not become wet as a result of causes such as vehicles entering when it is raining or snowing.
4.Work space
- Space approximately the size of one vehicle must be secured as the disassembly space.
- A sign indicating that disassembly is in progress or other measures must be taken so that persons other than the workers do not enter the work space.
DISASSEMBLY
1.Clean any contamination and dust from the battery pack.
2.Remove service plug retainer (1).
WARNING:
To prevent electric shock hazards, be sure to wear protective gear.
3.Remove mounting bolts (A), (B) and mounting nuts (C), then remove battery pack upper case.
WARNING:
To prevent electric shock hazards, be sure to wear protective gear.
4.Remove bus bar (1) that connects service plug switch and left front module stack.
DANGER:
To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated tools.
WARNING:
After removing, close bus bar cover.
5.Remove mounting bolts (A) and nuts (B) of service plug switch bracket (1).
WARNING:
To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated tools.
6.Disconnect high voltage harness (A) and connector (B) on reverse side of service plug switch bracket, then remove service plug switch bracket (1).
DANGER:
- To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated tools.
- To prevent electric shock hazards, immediately wrap insulating tape around disconnected high voltage harness connector (high voltage terminal) and terminals.
7.Disconnect heater relay harness connector (A) and heater harness connector (B) and than remove harness clips (C).
WARNING:
To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated tools.
8.Remove mounting nuts (A) and then remove heater relay unit (1).
WARNING:
To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated tools.
9.Remove harness 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.
1.Install heater relay unit.
WARNING:
To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated tools.
2.Install service plug switch bracket.
WARNING:
To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated tools.
3.Follow the procedure below and install battery pack upper case.
a.Tighten mounting nuts and bolts in numerical order as shown in the figure.
WARNING:
To prevent electric shock hazards, be sure to wear protective gear.
b.Install ground bolt (A).
WARNING:
To prevent electric shock hazards, be sure to wear protective gear.
4.Install service plug retainer (1).
WARNING:
To prevent electric shock hazards, be sure to wear protective gear.
CAUTION:
- Check the following items after installing battery pack: Refer to "HEATER RELAY UNIT : Inspection" Inspection.
AIR LEAK INSPECTION
ELECTRIC EQUIPOTENTIAL TEST