Recycling of Acura and Honda High-Voltage Battery Packs Information Manual for Vehicle Dismantlers – 2003-2016 Honda & Acura

Recycling of Acura and Honda High-Voltage Battery Packs Information Manual for Vehicle Dismantlers

(AJA03150) Version 3

 

APPLIES TO:

Brand Year Model Trim Level Remarks Battery Type Refer to Page:
Honda 2005–07 Accord Hybrid ALL Ni-MH 5
2014–15 Accord Hybrid ALL VIN will start with 1HG Li-Ion 8
2014 Accord Plug-In ALL VIN will start with JHM Li-Ion 13
2003–05 Civic Hybrid ALL Ni-MH 32
2006–11 Civic Hybrid ALL Ni-MH 34
2012–15 Civic Hybrid ALL Li-Ion 36
2011–12 CR–Z ALL Ni-MH 38
2013–16 CR–Z ALL Li-Ion 41
2000–06 Insight ALL Ni-MH 45
2010–14 Insight ALL Ni-MH 48
Acura 2013–14 ILX Hybrid ALL Li-Ion 52
2014, 2016 RLX Sport Hybrid ALL Li-Ion 54

 

OVERVIEW

Acura and Honda hybrid vehicles are equipped with high-voltage (HV) nickel-metal-hybrid (Ni-MH) or lithium-ion (Li-Ion) battery packs, which must be recycled when they have reached the end of their useful life or when the vehicle is dismantled.

This information manual is being provided to support vehicle dismantlers (vehicle salvage/scrap yards) that might not otherwise have access to Acura or Honda service manuals. This manual contains detailed instructions concerning the proper removal and handling of the high-voltage batteries found in these vehicles.

NOTE: This manual is only intended for vehicle dismantlers who disassemble and scrap vehicles at the end of their useful life. Vehicle repair technicians and other personnel who may need information about the removal or exchange of an Acura or Honda hybrid battery should follow the instructions made available through Service Express at www.techinfo.honda.com.

 

SERVICE INFORMATION

The information contained in this manual is intended for use by qualified technicians. Attempting to perform these procedures without the proper training, tools, and equipment could cause injury to you or others.

Any person who intends to use a procedure or a tool that is not recommended by Acura or Honda must first determine the risks to their personal safety.

When removing and preparing an Acura or Honda hybrid battery pack for recycling, be sure to follow all warnings and precautions provided in this manual and adhere to all federal, state, and local laws relating to the management of these batteries at your facility.

 

 

FOR YOUR SAFETY

Because this manual is intended for professionals, we do not provide warnings about many basic safety practices. If you have not received the appropriate safety training or do not feel confident about your knowledge of safe handling of the hybrid batteries, we strongly recommend that you not attempt to do the procedures described in this manual.

WARNING
Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed. Follow the procedures and precautions in this manual carefully.

 

IMPORTANT SAFETY PRECAUTIONS

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using appropriate safety equipment. When doing any service task, be especially careful of the following:

  • Read all of the instructions before you begin, and make sure you have the tools and the skills required to do the tasks safely and completely.
  • Protect your eyes by using proper safety glasses, goggles, or face shields.
  • Use other protective gear when necessary, such as insulated gloves or protective goggles.
  • Protect yourself and others whenever you have the vehicle up in the air. Anytime you raise the vehicle, either with a lift or a jack, make sure that it is always securely supported. Use safety stands if needed.
  • When removing or installing items marked with WARNING, always use insulated tools and wrap the items with insulating tape.
  • Hybrid Battery Labels. You will find safety and information labels affixed on or near the hybrid battery. Some examples are shown below.

WARNING

WARNING

WARNING

WARNING

 

SPECIAL TOOLS

In addition to basic mechanic tools, you will also need the following when removing a high-voltage battery.

  • Insulated gloves, protective goggles, and protective shoes. Check the gloves for pin holes, tears, or other damage.
  • ABC-rated fire extinguisher
  • Shop towels
  • Insulating tape
  • Voltmeter
  • Insulated tool set

 

BASIC PRECAUTIONS WHEN WORKING WITH HIGH VOLTAGE

  • The high-voltage cables and their covers are colored bright orange. Warning labels are attached to high-voltage and other related parts. When the system is energized, be careful not to touch these cables and parts without adequate protective gear.
  • Be sure to shut off the electrical circuits and isolate the high-voltage system and related parts before servicing the system.
  • Always use insulated tools when servicing, disassembling, or replacing items marked with in each procedure even if the hybrid battery module switch is turned to OFF.
  • Do not disassemble the hybrid battery module.
  • After disconnecting the high-voltage terminals, bus bars, etc., insulate the parts with insulating tape.
  • Do your best to avoid touching bare wires that could carry high voltage. If you must touch them, first put on insulated gloves and measure the voltage between the module and body ground. If the voltage is above the 12 V battery voltage, insulate the part with insulating tape before performing any operation to prevent shorting the high-voltage battery
  • When insulating a high-voltage area with insulating tape, be sure to cover it thoroughly.
  • Check around the battery module for leaks. If you find a leak, do your best to avoid touching it. If you must touch it, first put on insulated gloves and protective goggles.
  • Keep sparks and flames away from the high-voltage battery since the electrolyte may be flammable.
  • Seal the removed high-voltage battery in a polypropylene (PP) bag, and keep it in a well-ventilated area away from sparks and flames.

 

HV BATTERY RECYCLING CONTACT INFORMATION

Once you have removed the HV battery from the vehicle, please contact American Honda’s Hybrid Battery Consolidation Center at 1(800)-555-3497 for shipping instructions.

American Honda Hybrid Battery Consolidation Center
14286 Monte Vista Ave.
Chino, CA 91701
(800) 555-3497

 

NOTE: Some newer hybrid models use a lithium-ion battery. These batteries are handled as regulated hazardous material and returns require special handling with certified packaging and documentation.

 

.

HV BATTERY REMOVAL INSTRUCTIONS

2005–07 Accord Hybrid

  1. Disconnect the negative cable to the 12V battery.
  2. Remove the rear seat cushion and the seat-back.
  3. Remove bolt (A) and the switch cover.

switch cover

 

  1. Turn the battery module switch to OFF.
  2. Wait 5 minutes to allow the internal capacitors to discharge.
  3. Remove the bolts (A), then the lid (B).

Remove the bolts (A), then the lid (B)

 

  1. Remove the high-voltage cables (A), then wrap them with insulating tape (B).

high-voltage cables (A)

 

  1. Disconnect the connector (C), and the battery module connector (D).
  2. Remove the spare tire lid and the trunk front trim panel.
  3. From inside the trunk, remove the caps (A) and nuts (B).

remove the caps (A) and nuts (B)

 

  1. From inside the cabin, remove the bolts (A).

remove the bolts (A)

 

  1. Remove the battery module (B).
  2. Remove the stud bolts (C) from the battery module, if necessary.
  3. With the help of an assistant, carefully lift and remove the HV battery pack out of the vehicle without damaging it.

END

 

.

HV BATTERY REMOVAL INSTRUCTIONS

2014–15 Accord Hybrid

  1. Disconnect the negative cable to the 12V battery.
  2. Remove the rear seat cushion, the seat side bolsters, and the rear seat-back.
  3. Remove the main switch cover (A).

main switch cover (A)

 

  1. Raise the lever (A) while pushing the tab (B), then remove the service plug (C). NOTE: When removing or installing the service plug, use insulated tools.

service plug (C)

 

  1. Wait 5 minutes to allow the internal capacitors to discharge.
  2. Wrap the service plug base (A) with insulating tape.

service plug base (A)

 

  1. Remove the rear bulkhead gusset (A).

rear bulkhead gusset (A)

 

  1. Remove the front cover (A).

front cover (A)

 

  1. Remove the ground cable bolt (A).

ground cable bolt (A)

 

  1. Disconnect the cable terminals (B, C, and D).
  2. Remove the cable clamps (E).
  1. Disconnect the connector (A).

connector (A)

 

  1. Disconnect the high-voltage cable terminals (B and C).
  2. Remove the shield pipe bracket (D) and the cable clamps (E).
  3. Remove the left and right air inlet trim (A). The left side is shown below.

left and right air inlet trim (A)

 

  1. Remove the left and right air inlet ducts (A). The left side is shown below.

left and right air inlet ducts (A)

 

  1. Remove the following items:
  2. From the trunk of the vehicle, remove the fan inlet duct (A).

fan inlet duct (A)

 

  1. From the trunk of the vehicle, remove the right-rear frame bar (A) and the left-rear frame bar (B).

right-rear frame bar (A)

left-rear frame bar (B)

 

  1. From the trunk of the vehicle, remove the bolts (A).

remove the bolts (A)

remove the bolts (A)

 

  1. From the inside of the vehicle, remove the bolts (A). If available, use special tool 07AAB-5K0A110 as shown below.

NOTE: It is not necessary to use the special tool to remove the battery.

 

remove the bolts (A)

 

  1. With the help of an assistant, carefully lift and remove the HV battery pack from the trunk side of the vehicle without damaging it.

END

 

.

HV BATTERY REMOVAL INSTRUCTIONS

2014 Accord Plug-In

  1. Disconnect the negative cable to the 12V battery.
  2. Remove the rear seat cushion, the seat side bolsters, and the rear seat-back.
  3. Remove the main switch cover (A).

main switch cover (A)

 

  1. Turn the main switch (A) to OFF, then check that the OFF switch knob position is showing.

main switch (A)

 

  1. Wait 5 minutes to allow the internal capacitors to discharge.
  2. Remove the main switch lid (A).

main switch lid (A)

 

  1. Remove the rear bulkhead gusset (A).

rear bulkhead gusset (A)

 

  1. From inside the cabin, remove the right side cover (A).

right side cover (A)

 

  1. Disconnect the high-voltage connectors (B) and apply insulating tape around the connectors to prevent contact as shown on (C).

high-voltage connectors (B)

 

  1. Disconnect the left lower harness connectors (A).

left lower harness connectors (A)

 

  1. Disconnect the right lower harness connector (A).

right lower harness connector (A)

 

  1. Disconnect the upper harness connectors (A) and remove the harness clamp (B).

upper harness connectors (A)

 

  1. Remove the ground cable (A).

ground cable (A)

 

  1. Disconnect the high-voltage cable connector (A) and remove the harness clamp (B).

high-voltage cable connector (A)

 

  1. Remove the harness clamp (A), then disconnect the cable (B) and the ground cable (C).

ground cable (C)

 

  1. Remove the cover (A).

cover (A)

 

  1. Remove the right air inlet trim (A).

right air inlet trim (A).

 

  1. Remove the right battery inlet duct (A) and the inlet duct (B).

right battery inlet duct (A) and the inlet duct (B)

 

  1. Disconnect the high-voltage cable (A) terminals and remove the harness clamps (B).

high-voltage cable (A)

 

  1. Remove the following items:
  1. From the trunk side, remove the guard (A).

guard (A)

 

  1. Remove the fan outlet duct (A).

fan outlet duct (A)

 

  1. Remove the rear inlet duct (A) and the harness clamp (B).

rear inlet duct (A)

 

  1. From the cabin side, remove the bolts (A).

bolts (A)

 

  1. From the trunk side, remove the bolts (A).

bolts (A)

 

  1. From the cabin side, disconnect the high voltage cable (A) terminals and remove the harness clamps (B). Then remove the connector bracket (C).

high voltage cable (A)

 

  1. Disconnect the right lower harness connector (A).

right lower harness connector (A)

 

  1. Remove the connector bracket (B).
  2. Disconnect the sensor connector (A).

sensor connector (A)

 

  1. Remove the component (B).
  2. From the trunk side, remove the plates (A) and the battery insulator (B).

NOTE: Squeeze inward on the ends of the plates to release the lock tabs.

battery insulator (B).

 

  1. Remove the left battery outlet duct (A) and the right battery outlet duct (B).

left battery outlet duct (A)

right battery outlet duct (B)

 

  1. From the cabin side, disconnect the right lower harness connector (A) and remove the harness clamps (B).

right lower harness connector (A)

 

  1. Disconnect the right side wire harness connector (A).

right side wire harness connector (A)

 

  1. Remove the upper front bracket (A) and the harness clamps (B).

upper front bracket (A) and the harness clamps (B)

 

  1. From the trunk side, disconnect the left lower harness connector (A).

left lower harness connector (A)

 

  1. From the cabin side, remove the left upper mounting bracket (A) and the right upper mounting bracket (B).

left upper mounting bracket (A)

right upper mounting bracket (B)

 

  1. Remove the six battery mounting bolts (B) from the battery pack (A).

six battery mounting bolts (B)

 

  1. For the six battery mounting bolts (C) that cannot be removed, lift-up the bolts one at time and install an 80 mm long slit plastic tube (D) around the bolts if available.

NOTE:

  • The slit plastic tubes are included in the Accord PHEV Battery R&R Equipment Loan Kit (07PHEVBATOLKIT).
  • The plastic tubes keep the mounting bolts up and out of way to allow battery pack A to slide out.
  1. Place fender covers over the rear fenders and the trunk opening to avoid damaged to the vehicle.

six battery mounting bolts (C)

 

  1. If available, attach the battery removal/installation carrier (B) onto the battery pack. Loosely tighten the bolts (C).
  2. Install the carrier adapter mount (D) with the “A” mark (E) side to the right rear battery pack mount. Loosely tighten the bolts (F).
  3. Tighten the five bolts (C and F) to 24.4 N·m (2.49 kgf·m, 18.0 lbf·ft).
  1. If available, install the inside handle (A) to the battery removal/installation carrier (B) and install the pin (C).

battery removal/installation carrier (B)

 

  1. If available, set the battery removal/installation table (D) in the trunk area as shown (table legs extended).
  2. With the help of an assistant on the inside of the vehicle, carefully lift and transfer the battery pack onto the battery removal/installation table (B).

battery pack

 

  1. If attached, remove the inside handle (C) from the battery pack removal/installation carrier (D).
  2. With the help of an assistant at the rear of the vehicle, carefully lift-up the battery pack and remove it from the trunk area. If available, set the battery pack on the work surface provide with the Accord PHEV Battery R&R Equipment Loan Kit (07PHEVBATOLKIT).

battery pack removal/installation carrier

 

  1. From the cabin side, remove the cable bracket (A).

cable bracket (A)

 

  1. Disconnect the sensor connector (A).

sensor connector (A)

 

  1. Remove the sensor (B).
  1. Disconnect the left side wire harness connector (A).

left side wire harness connector (A)

 

  1. Remove the left side cover (B).
  2. Remove the left air inlet trim (A).

left air inlet trim (A).

 

  1. Remove the left battery inlet duct (A).

left battery inlet duct (A).

 

  1. From the trunk side, remove the lower mounting brackets (A).

lower mounting brackets (A).

lower mounting brackets (A).

 

  1. From the cabin side, remove the center frame bolts (A) and the harness clamp (B).

center frame bolts (A)

 

  1. From the trunk side, remove the rear cross member bolts (A).

rear cross member bolts (A).

 

  1. Place fender covers over the rear fenders and the trunk opening to avoid damaged to the vehicle.
  1. If available, attach the battery removal/installation carrier (A) onto the battery pack. Loosely tighten the bolts (C).

battery removal/installation carrier (A)

 

  1. If available, install the carrier adapter mount (D) with the “B” mark (E) side to right rear battery pack mount. Loosely tighten the bolts (F).
  2. Tighten the five bolts (C and F) to 24.4 N·m (2.49 kgf·m, 18.0 lbf·ft).
  3. If available, install the inside handle (A) to the battery removal/installation carrier (B) and install the pin (C).

battery removal/installation carrier (B)

 

  1. If available, set the battery removal/installation table (D) in the trunk area as shown (table legs folded).
  1. With the help of an assistant on the inside of the vehicle, carefully lift and transfer the battery pack onto the battery removal/installation table (A).

battery removal/installation table (A)

 

  1. Remove the inside handle (C) from the battery pack removal/installation carrier (D).
  2. With the help of an assistant at the rear of the vehicle, carefully lift-up the battery pack and remove it from the trunk area. If available, set the battery pack on the work surface provide with the Accord PHEV Battery R&R Equipment Loan Kit (07PHEVBATOLKIT).

battery pack

 

  1. If needed, flip the battery pack up-side-down, and remove the center frame (A).

center frame (A)

 

END

 

.

2003–05 Civic Hybrid

  1. Disconnect the negative cable to the 12V battery.
  2. Remove the rear seat cushion and the rear seat-back.
  3. Remove the battery module switch lid (A), then remove the locking cover (B).

battery module switch lid (A)

 

  1. Turn the battery module switch to OFF and wait 5 minutes. 5. Remove the bolts (A) and the clip (B)
  2. Remove the bolts (A) and the clip (B)

bolts (A)

 

  1. Disconnect the connectors (A), the capacitor ground (B), the clips (C), and the high voltage cables, and wrap the cables with insulating tape.

connectors (A)

 

  1. Remove the bolts (F), the stopper (G), and the HV battery pack (H).

END

 

.

2006–11 Civic Hybrid

  1. Disconnect the negative cable to the 12V battery.
  2. Remove the rear seat-back and the rear seat cushion.
  3. Remove the battery module switch lid.

battery module switch lid

 

  1. Turn the battery module switch (A) to OFF, then check that the bolt (B) is showing.

battery module switch

 

  1. Wait 5 minutes to allow the internal capacitors to discharge.
  2. Remove the bolts (A) and (B), then remove the lid (C).

lid (C)

 

  1. Remove the high-voltage cables (A), then wrap them with insulating tape (B).

high-voltage cables (A)

 

  1. Disconnect the connectors (C) and (D).
  2. Remove the bolts (E), then remove the HV battery pack (F).

END

 

.

2012–15 Civic Hybrid

  1. Disconnect the negative cable of the 12V battery.
  2. Remove the rear seat cushion, the seat side bolsters, and the rear seat-back.
  3. Remove the main switch cover (A).

main switch cover (A)

 

  1. Turn the battery module switch (B) to OFF, then check that the bolt (C) is showing.

battery module switch (B)

 

  1. Wait 5 minutes to allow the internal capacitors to discharge.
  2. Remove the cover.

cover

 

  1. Remove the air inlet duct.

air inlet duct

 

  1. Disconnect the connectors (A).

connectors (A)

 

  1. Remove the cables (B).
  2. Remove the battery pack.

battery pack

 

END

 

.

2011–12 CR-Z

  1. Disconnect the negative cable to the 12V battery.
  2. Remove all of the rear trim components.
  3. Remove the spare tire.
  4. Remove the cargo lid and floor box.
  5. Loosen the bolt (A) and remove the bolt (B). Remove lid (C).

lid (C)

 

  1. Turn the battery module switch (A) to OFF, then check that the bolt (B) is showing.

battery module switch (A)

 

  1. Wait at least 5 minutes to allow the capacitors to discharge.
  2. Pull up the duct cover (A) by hand to detach the clips and the hooks (B), then remove the duct cover.

duct cover (A)

 

  1. Remove the bolts and the cover guard (A).

cover guard (A).

 

  1. Remove the air ducts (A).

air ducts (A).

 

  1. Remove the bolts (A, B) and the clips (C), then remove the cover (D).

cover (D)

 

  1. Remove the bolts (A) and the lid (B).

lid (B)

 

  1. Disconnect the four power cables (A) from the phase motor current sensor, then wrap the end of the 12V power cable (B) with insulating tape.

four power cables (A)

 

  1. Remove the cable clamp (C).
  2. Disconnect the connector (A).

connector (A)

 

  1. Remove the bolts (B, C), then remove the HV battery pack (D).

END

 

.

HV BATTERY REMOVAL INSTRUCTIONS

2013–16 CR-Z

  1. Disconnect the negative cable to the 12V battery.
  2. Remove all of the rear trim components as needed.
  3. Remove the spare tire.
  4. Remove the cargo lid and floor box.
  5. Remove the battery module switch lid (A) from the cover.

battery module switch lid (A)

 

  1. Remove the bolt (A) from the battery module switch.

bolt (A)

 

  1. Turn the battery module switch OFF by sliding the extension of the switch in the direction of the arrow as shown.
  1. Remove the bolt (A).

bolt (A)

 

  1. Wait at least 5 minutes to allow the capacitors to discharge.
  2. Pull up the duct cover (A) by hand to detach the clips and the hooks (B), then remove the duct cover.

duct cover (A)

 

  1. Remove the bolts and the cover guard (A).

cover guard (A)

 

  1. Remove the bolts (A, B) and the clips (C), then remove the cover (D).

cover (D)

 

  1. Remove the lid (A).

lid (A)

 

  1. Remove the motor power cable terminals (W, V, U).

motor power cable terminals (W, V, U)

 

  1. Remove the 12V power cable (A) and wrap the end of the cable terminal with insulating tape.
  2. Remove the cable clamp (B).
  3. Disconnect the harness connector (A) and remove the ground cable mounting bolt (B).

harness connector (A)

 

  1. Remove the bolts (A), then remove the HV battery pack (B).

HV battery pack (B)

 

END

 

.

HV BATTERY REMOVAL INSTRUCTIONS

2000–06 Insight

  1. Disconnect the negative cable to the 12V battery.
  2. Turn the ignition switch to OFF.
  3. Remove the cargo floor mat.
  4. Remove the battery module switch cover (A) from the lid, then remove the locking cover (B).

battery module switch cover (A)

 

  1. Turn the battery module switch (A) to OFF, then install the locking cover (B).

battery module switch (A)

 

  1. Wait for at least 5 minutes to allow the capacitors to discharge.
  2. Remove the trunk right side shelf support (A).

trunk right side shelf support (A)

 

  1. Remove the mid-frame cover clips and the lid.

mid-frame cover clips and the lid

 

  1. Remove the foam inserts.
  2. Remove the mid-frame (A), then remove the front and rear braces (B) from the junction board.

mid-frame (A)

 

  1. Disconnect the high-voltage cables (C) from the output terminals on the junction board and wrap them with insulating tape.
  2. Remove the battery module air duct mounting bolt (A), then push the duct forward.

battery module air duct mounting bolt (A)

 

  1. Remove the mounting bolts (B) from the battery module (C). Disconnect the connectors (D) and Y condenser terminal (E).
  2. If special tool 07YAK-001010A is available, install it on the battery module (A) using the six knurled bolts (B).

NOTE: It is not necessary to use the special tool to remove the battery.

battery module (A)

 

  1. With the help of an assistant, lift the HV battery pack out of the vehicle and carefully set it down on a flat surface.

END

 

.

HV BATTERY REMOVAL INSTRUCTIONS

2010–14 Insight

  1. Disconnect the negative cable of the 12V battery.
  2. Remove the rear cargo floor lid.
  3. Remove the cargo floor box and the spare tire.
  4. Pull up the cargo side lid (A) and detach the pins (B). Then remove the cargo side lid.

cargo side lid (A)

cargo side lid (A)

 

  1. Pull up on both sides of the spare tire beam cover (A) and detach the hooks (B). Then remove the cover.

 

spare tire beam cover (A)

 

  1. Remove the bolts, then remove the spare tire beam (A).

spare tire beam (A)

 

  1. Loosen the bolt (A) and remove the bolt (B).

bolt (B)

 

  1. Remove the battery module switch lid (C) from the IPU cover.
  2. Turn the battery module switch (A) to OFF, then check that the bolt (B) is showing.

battery module switch (A)

 

  1. Wait for at least 5 minutes to allow the capacitors to discharge.
  2. Remove the clips (A, B) and the air duct (C).

air duct (C)

 

  1. Remove the bolts (A, B) and the clips (C).

bolts (A, B)

 

  1. Remove the cover (D).
  2. Remove the power cables (A).

power cables (A).

 

  1. Remove the cable (B) and wrap it with insulating tape.
  2. Disconnect the connector (A).

connector (A).

 

  1. Remove the terminal (B).
  2. Remove the bolts (C).
  3. With the help of an assistant, lift the HV battery pack out of the vehicle and carefully set it down on a flat surface.

END

 

.

HV BATTERY REMOVAL INSTRUCTIONS

2013–14 ILX Hybrid

  1. Disconnect the negative cable of the 12V battery.
  2. Remove the rear seat cushion, the seat side bolsters, and the rear seat-back.
  3. Remove the battery module switch lid (A) from the cover.

battery module switch lid (A)

 

  1. Turn the battery module switch (B) to OFF, then check that the bolt (C) is showing.

battery module switch (B)

 

  1. Wait at least 5 minutes to allow the capacitors to discharge.
  2. Remove the cover.

cover

 

  1. Remove air inlet duct.

air inlet duct

 

  1. Remove the cables (A).

cables (A)

 

  1. Disconnect the battery module connector (B) and the connector (C).
  2. Remove the HV battery pack.

HV battery pack

 

END

 

.

HV BATTERY REMOVAL INSTRUCTIONS

2014–16 RLX Sport Hybrid

  1. Disconnect the negative cable of the 12V battery.
  2. Pull the rear seat armrest down.
  3. Insert the built-in key into the key cylinder (A), then turn it to the left.

key cylinder (A)

 

  1. Push the button (B) to open the cover (C).
  2. Pull up the inner partition (A). Then remove the trunk release handle (B) and the main switch cover (C).

main switch cover (C)

 

  1. Raise the lever (A) while pushing the tab (B), then remove the service plug (C).

service plug (C)

 

  1. Wrap the service plug base (A) with insulating tape.

service plug base (A)

 

  1. Remove the rear seat cushion and the seat-back.
  2. Remove the trunk release handle cable clamps (A) and the rear bulkhead plate (B).

trunk release handle cable clamps (A)

 

  1. Remove the IPU front cover (A).

IPU front cover (A)

 

  1. Remove the center console.
  1. Remove the inlet rear seat under trim (A).

inlet rear seat under trim (A).

 

  1. Remove the duct cover (A).

duct cover (A).

 

  1. Remove the air inlet duct (A).

air inlet duct (A)

 

  1. Disconnect the cable terminal (A), the ground cable terminal (B) and the cable terminals (C).

cable terminal

 

  1. Remove the cable clamps (D).
  1. Disconnect cable terminals (A) and the ground cable terminal (B).

cable terminals (A)

 

  1. Remove the cable clamp (C).
  2. Disconnect the harness connectors (A).

harness connectors (A)

 

  1. Remove the following items:
  1. Remove the outlet joint (A).

outlet joint (A)

 

  1. From the trunk of the vehicle, remove the bolts (A).

bolts (A)

 

  1. From the front side of the battery pack assembly, remove the rear cover mounting bolts (A).

rear cover mounting bolts (A).

rear cover mounting bolts (A).

 

  1. From the rear side of the battery pack assembly, remove the bolts (A) and the nuts (B).

bolts (A) and the nuts (B)

 

  1. Remove the rear cover (C).
  2. Disconnect the cable terminals (A).

cable terminals (A)

 

  1. Disconnect the harness terminal (B) and the harness connectors (C).
  1. Disconnect the harness connector (A), the harness terminal (B) and the ground cable terminal (C).

harness connector (A)

 

  1. Remove the harness clamp (D) and the relay holder (E).
  2. Remove the battery side insulators (A).

battery side insulators (A).

battery side insulators (A)

 

  1. Disconnect the harness connectors (A).

 

harness connectors (A)

 

  1. Remove the harness clamp (B).
  1. Remove the upper frame (A) and the air outlet duct (B).

 

air outlet duct (B).

 

  1. Disconnect the cable terminal (A).

cable terminal (A).

 

  1. Remove the junction board (A), then wrap the battery terminal (B) with insulating tape.

junction board (A)

 

  1. Remove the contactor board cover (A).

contactor board cover (A)

 

  1. Disconnect the cable terminal (B).
  2. Remove the contactor board (C), then wrap the battery terminal (D) with insulating tape.
  1. Remove the cable clamps (A) and the cable (B).

cable (B)

 

  1. Remove the HV battery pack (A), the battery inlet duct (B), and the lower frame (C).

HV battery pack (A)

 

END


 

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