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Removal And Installation




PTC ELEMENTS HEATER

Removal and Installation


WARNING:
- Because EV (electric vehicle) and HEV (hybrid vehicle) 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.
- Clearly identify the persons responsible for high voltage work and ensure that other persons never 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.

CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the service plug is removed. Therefore never change the vehicle to READY status unless instructed to do so in the Service Manual.

REMOVAL


WARNING:
Disconnect high voltage circuit. Refer to "How to Disconnect High Voltage" Service and Repair.
1.Check voltage in high voltage circuit. (Check that condenser are discharged.)
a.Lift up the vehicle, and then remove Li-ion battery under covers.
- Refer to "Exploded View" Service and Repair. (Type 1: Without Li-ion battery heater)
- Refer to "Exploded View" Service and Repair. (Type 2: With Li-ion battery heater)
b.Disconnect high voltage connector from front side of Li-ion battery.
- Refer to "Removal and Installation" Service and Repair. (Type 1: Without Li-ion battery heater)
- Refer to "Removal and Installation" Service and Repair. (Type 2: With Li-ion battery heater)





c.Measure voltage between high voltage harness terminals.
DANGER:


Touching high voltage components without using the appropriate protective equipment will cause electrocution.
Standard: 5 V or less

CAUTION:
For voltage measurements, use a tester which can measure to 500 V or higher.
2.Remove front under cover. Refer to "FRONT UNDER COVER : Removal and Installation" Front Under Cover.
3.Drain out heater fluid. Refer to "Draining and Refilling" Draining And Refilling.
4.Remove front tire LH. Refer to "Removal and Installation" Removal And Installation.





5.Remove front side of the front fender protector LH (1) and move to secure work space.





6.Remove mounting bolts (A), and then remove PTC elements heater lower cover (1).

WARNING:
To prevent electric shock hazards, be sure to wear protective gear.





7.Disconnect high voltage harness connector (A) and low voltage harness connector (B) from PTC elements heater.

WARNING:
- To prevent electric shock hazards, be sure to wear protective gear.
- To prevent electric shock hazards, immediately wrap insulating tape around disconnected high voltage connector terminals.
- Follow the procedure below and remove the high voltage harness connector.





8.Remove fixing clamps, and then disconnect heater hoses (1).






WARNING:
- To prevent electric shock hazards, be sure to wear protective gear.
- When removing the PTC elements heater, be careful that the heater fluid never contact the high voltage harness connector.
- If heater fluid contacts the high voltage harness connector, immediately dry the high voltage connector completely with an air blow gun.
9.Remove 12 V battery. Refer to "Removal and Installation" Removal And Installation.





10.Remove mounting bolts (A), and then remove battery bracket (1).

WARNING:
To prevent electric shock hazards, be sure to wear protective gear.





11.Remove bonding wire (1) monting bolts (A).

WARNING:
To prevent electric shock hazards, be sure to wear protective gear.





12.Remove PTC elements heater mounting nuts (A).

WARNING:
Be sure to put on insulating protective gear before beginning work on the high voltage system.
13.Remove PTC elements heater (1) from below the vehicle.






WARNING:
To prevent electric shock hazards, be sure to wear protective gear.





14.Remove mounting bolts (A), and then remove PTC elements heater bracket (1).





15.Remove mounting nuts (A), and then remove bonding wires (1).

INSTALLATION

Note the following items, and then install in the reverse order of removal.

WARNING:
To prevent electric shock hazards, be sure to wear protective gear.

CAUTION:
Be sure to reinstall high voltage harness clips in their original positions. If a clip is damaged, replace it with a new clip before installing.





- If the PTC elements heater was replaced, first check that there is no dust or dirt on the surface of the PTC elements heater, then apply the new high voltage warning label at position (A).
- Follow the procedure below and remove the PTC elements heater.





- Follow the procedure below and connect the high voltage harness connector.





- After all parts are installed, be sure to check the equipotential. Refer to "Inspection" Inspection.
NOTE:
When adding heater fluid. Refer to "Draining and Refilling" Draining And Refilling.
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