Installation sequence
Follow the removal sequence in reverse.
Repair kit: Service Kit A (Part No.: MK443502), Service kit C (Part No.: MK443504)
Work before removal
Maintenance workflow
– The way to handle high voltage devices differs depending on presence/absence of diagnosis codes and, if issued, on the type of the diagnosis code. Before working, see the following chart to grasp a general idea of handling procedures.
Removal: High voltage cooling system
• Remove the water hose in high voltage cooling system. (See “HIGH VOLTAGE COOLING SYSTEM”.)
•Preparation
– Apply chocks to the front and rear wheels to prevent the vehicle from moving.
– Start the engine and shift the shift lever from N to D. After 5 seconds or longer, check that the hybrid electric vehicle warning lamp is off (the hybrid electric vehicle system is normal).
<When hybrid electric vehicle warning lamp is off>
• Turn the starter switch to OFF.
<When hybrid electric vehicle warning lamp is on>
• Turn the starter switch to OFF. After 35 seconds passed, start the engine and shift the shift lever from N to D.
• After 5 seconds or longer, check the hybrid electric vehicle warning lamp for its on/off status. If it is ON, refer to the corresponding diagnosis code. (See Gr00.)
• Turn the starter switch to OFF.
• After turning the starter switch to OFF, pull out the key and keep it to prevent other workers from carelessly turning the starter switch to ON.
• When the diagnosis codes listed below occur, work with insulated gloves since high voltage may still remain.
Removal procedure
•Removal: Safety plug
Slide the lever of the safety plug upward.
• Pull the lever of the safety plug and rotate it 90 degrees.
• Remove the safety plug from the high voltage battery box by pulling it out.
• Install the safety plug cover & packing to prevent foreign substances and water from mixing.
• Keep the safety plug to prevent other workers from carelessly installing it.
• During preparation, if a diagnosis code that indicates possible remaining of high voltage (except P0AA6 (65): Leak) occurs, wait for an hour and resume the work.
• Removal: High voltage cable (between high voltage battery box and motor electronic control unit)
– While pushing in the arm, remove the high voltage cable by pulling out the female connector.
– Make the device side and high voltage cable side terminals watertight and dust-tight with tape.
• During preparation, if a diagnosis code that indicates possible remaining of high voltage (except P0AA6 (65): Leak) occurs, measure voltage between the direct current high voltage terminals of
the motor electronic control unit and make sure that the voltage is below 36 V. If this is the case, you can proceed with the work without wearing insulated gloves.
Removal: High voltage cable (between motor electronic control unit and motor generator)
• While pushing in the arm, remove the high voltage cable by pulling out the female connector.
• Make the device side and high voltage cable side terminals watertight and dust-tight with tape.
Inspection procedure
•Inspection: Insulation resistance
– Measure insulation resistance between the high voltage terminal and inner peripheral aluminum part inside each high voltage cable. Use an insulation tester whose range is wider than 1000 V.
– If the measured value deviates from the standard value, replace the high voltage cable.
• Measure insulation resistance between each high voltage terminal of the motor electronic control unit and the chassis ground (if provided on the vehicle). Use an insulation tester whose range is wider than 1000 V.
• The outside surface (aluminum part) of the connector on the motor electronic control unit side is for shielding. The inner connector is the high voltage terminal.
• If the measured value deviates from the standard value, replace the motor electronic control unit.
• Measure insulation resistance between each high voltage terminal of the motor generator and the chassis ground (if provided on the vehicle). Use an insulation tester whose range is wider than
1000 V.
• The outside surface (aluminum part) of the connector on the motor generator side is for shielding. The inner connector is the high voltage terminal.
• If the measured value deviates from the standard value, replace the clutch housing & motor generator. (See Gr22.)
Replacement procedure
Replacement: High voltage battery box
• If the high voltage battery box is replaced for failure, leave the safety plug of the abnormal high voltage battery box removed and perform insulating treatment to the high voltage terminals to avoid accidents such as electric shock.
Installation procedure
• Installation: Strap and packing
Apply soapy water on the rubber section of each strap and packing where it contacts with the battery box. Then install each strap and packing by aligning it with the center of the box bracket.
• Installation: High voltage cable (between high voltage battery box and motor electronic control unit)
– Insert the high voltage cable until a click is heard.
– Check that the cable is installed securely by lightly pulling the female connector.
Installation: Safety plug
• Check that the starter switch is OFF and all the high voltage devices, high voltage cables and 24 V wiring are correctly connected.
• Insert the safety plug into the terminal part securely. Then, push in the lever and rotate it 90 degrees.
• Slide the lever of the safety plug downward until it locks.
Work after installation
• Hybrid electric vehicle system activation
– Turn the starter switch to ON and check that the READY indicator lamp on the meter cluster illuminates.
– If the READY indicator lamp does not illuminate, the hybrid electric vehicle system is faulty. Perform troubleshooting to deal with the fault. In addition, if diagnosis code P1A66 (75): “Voltage Sensor Failure” occurs, the safety plug may not be properly installed.
Reinstall the safety plug.
