Li-Ion Battery Controller Disassembly and Assembly

LI-ION BATTERY

LI-ION BATTERY CONTROLLER : 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 rear battery cover (1).






WARNING:


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





4.Remove the front battery cover (1).






WARNING:


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





5.Remove the mounting bolts (A) and harness connectors (B), then remove the Li-ion battery controller (1).

WARNING:
-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 connector terminals.

ASSEMBLY

Assemble in the reverse order of disassembly.