PRECAUTIONS ON HOW TO USE THE HIGH-VOLTAGE VEHICLE

This vehicle has a high-voltage circuit of 350 V (nominal value) (Depending on the remaining capacity of the battery, generate a maximum operating voltage of 650 V). If the vehicle is handled incorrectly, electric leakage or shock may result. Also, the service technicians/engineers who perform inspection and service related to the high-voltage circuit of the electric vehicles are obligated to observe the legal requirements of your country/local area.

INSPECTION/TEST OF PROTECTIVE EQUIPMENT, BLOTTER STORAGE

Check and store the protective equipment in accordance with the legal requirements of your country/local area.

PROTECTIVE EQUIPMENT

caution

Use protective equipment that complies with the legal requirements of your country/local area.
Use insulating protective equipment which meets the requirements to withstand DC 650 V and AC 650 V.

Protective equipment	Name	Use
	Electric insulation helmet (with shield)	When you may contact with the exposed live wirings while handling the damaged vehicle Alternatively, when you prevent the electric shock according to need
	Electric insulation jacket	When you may contact with the exposed live wirings while handling the damaged vehicle Alternatively, when you prevent the electric shock according to need
	Electric insulation trousers	When you may contact with the exposed live wirings while handling the damaged vehicle Alternatively, when you prevent the electric shock according to need
	Electric insulation glove	Service plug removal and installation Work on live wirings when there is a problem When you may contact with the exposed live wirings while handling the damaged vehicle Alternatively, when you prevent the electric shock according to need
	Electric insulation boots	When you may contact with the exposed live wirings while handling the damaged vehicle Alternatively, when you prevent the electric shock according to need

TESTER AND SPECIAL TOOL

Be sure to use the tester and special tools specified in this manual.

HIGH-VOLTAGE COMPONENTS

The high-voltage components are described below. Also, wiring harness and connectors of high-voltage circuit are unified with a color of orange.

Drive battery [with built-in Battery Management Unit (BMU)]
Power Drive Unit (PDU) [with built-in Front electric motor control unit (FEMCU) and Generator Control Unit (GCU)]
Front motor
Rear motor [with built-in Rear Electric Motor Control Unit (REMCU)]
Generator
On Board Charger (OBC)/DC-DC converter
AC inverter <Some models>
Drive battery cable
EV home & Quick charger cable*
Service plug
Wiring harness and connector
A/C compressor
Junction box
High voltage sensor (for quick charging)

note	*: Quick charger cable is only equipped on models with quick charging system.

SERVICE PRECAUTIONS

danger

When servicing the high-voltage components, be sure to disconnect the service plug in order to shut off the high-voltage. When servicing the junction box, On Board Charger (OBC)/DC-DC converter, and AC inverter, disconnect the rear interlock connector in addition to the service plug removal.
If the high-voltage shut-off work is difficult because of the accidental damages, perform "Action when High Voltage Cannot Be Shut Off" () to secure the safety.

Remove the service plug under the rear center seat and disconnect the rear interlock connector under the luggage room by following the procedures below to shuts off the high-voltage to the high-voltage system. Also, when installing the service plug and the service lid, check the precautions.

SERVICE PLUG AND SERVICE LID REMOVAL STEPS

Prepare the service plug removal steps check sheet (Refer toSERVICE PLUG REMOVAL STEPS CHECK SHEET

1. Disconnect the charge connector if the vehicle is being charged.

2. Turn OFF the power supply mode of the electric motor switch.

3. Open the hood and back door.

4. Press the electric motor switch once to turn ON the power supply mode, then press and hold the electric motor switch for 5 seconds or more.

5. Close the driver's side front door, and wait for 5 minutes or more.

6. Check that the combination meter turns off, and the P indicator on the parking lock switch turns off.

warning

To avoid causing any trouble to the electric motor unit components, do not disconnect the 12V battery negative terminal for 5 minutes after turning off the power supply mode of the electric motor switch.
The voltage of the smooth condenser in the inverter must be decreased thoroughly. Therefore, do not remove the service plug for 5 minutes after the negative terminal of the 12V battery is disconnected.

Disconnect the negative terminal of the 12V battery, and wait for 5 minutes or more.

8. Remove the service lid cover.

9. Remove the service lid mounting bolts, and then remove the service lid.

10.

danger

Wear the electric insulation gloves when pulling out the service plug.
Do not pull out the service plug by halves. It is dangerous because the current is supplied during the lifting operation. Be sure to remove the service plug all at once.

warning

The voltage of the smooth condenser in the inverter must be decreased thoroughly. Therefore, do not remove the service plug for 5 minutes after the negative terminal of the 12V battery is disconnected.

Pull up the service plug lever a little, then pull up the lever more while pushing the tab, then pull out the service plug.

11.

danger

After removing the service plug, insulate the plug installed part of the drive battery side securely.

Remove the service plug.

12.

danger

During inspection, wear the electric insulation gloves. If the high-voltage cannot be shut off after the inspection, refer to "Action when High Voltage Cannot Be Shut Off".

When removing and installing each high-voltage part, be sure to perform the following inspection beforehand.

When the drive battery is removed and installed

- Check the drive battery front cable connector and drive battery rear cable (junction box) connector by following the procedures below.
  1. Remove the engine room under cover rear (Refer to Exterior - Engine Under CoverRemoval and Installation).
  2. Remove the front floor heat protector (rear) (Refer to Battery Management Unit (BMU) and Drive Battery - Drive BatteryDRIVE BATTERY REMOVAL AND INSTALLATION).
  3. Disconnect the drive battery front cable and drive battery rear cable (junction box) from the drive battery, and measure the voltages between the terminals as shown in the illustration using a high-voltage multimeter.
    Normal voltage: Approximately 0 V
    note For disconnecting the drive battery front cable connector and drive battery rear cable (junction box) connector, refer to "High-voltage Cable Connector Removal Steps".
  4. As the result of the voltage measurement, if the high-voltage is judged that it is not shut off, the internal malfunction of the drive battery may be suspected. Be very careful and remove the drive battery.

When the other high-voltage parts are removed and installed

Remove the power drive unit cover inside the engine compartment.
Remove the service lid of the power drive unit.
Using a high-voltage multimeter, measure the voltages between the terminals as shown in the illustration.
Normal voltage: Approximately 0 V
Remove the service lid on the rear side of the rear motor.
Using a high-voltage multimeter, measure the voltages between the terminals as shown in the illustration.
Normal voltage: Approximately 0 V
As the result of the voltage measurement, if the high-voltage is judged that it is not shut off, perform "Action when High Voltage Cannot Be Shut Off" () to secure the safety before servicing.

REAR INTERLOCK CONNECTOR DISCONNECTION STEPS

When servicing the junction box, On Board Charger (OBC)/DC-DC converter, and AC inverter, disconnect the rear interlock connector in addition to the service plug removal.

1. Remove the service plug.

2. Remove the EV control unit cover (LH) and (RH) (Refer toON BOARD CHARGER (OBC) &DC-DC CONVERTER REMOVAL AND INSTALLATION

3. Disconnect the rear interlock connector.

SERVICE PLUG AND SERVICE LID INSTALLATION STEPS

danger

Wear the electric insulation gloves when installing the service plug.

1. Install the service plug.

caution

Pull the service plug lever down until it clicks, because the interlock switch does not operate unless the service plug lever is pulled down properly.

2. Tighten the service lid mounting bolts to the specified torque.

3. Insert the 4 tabs of the service lid cover securely to install the service lid cover.

REAR INTERLOCK CONNECTOR CONNECTION STEPS

1. Connect the rear interlock connector.

ACTION WHEN HIGH VOLTAGE CANNOT BE SHUT OFF

Tool

caution

Use protective equipment that complies with the legal requirements of your country/local area.
Use insulating protective equipment which meets the requirements to withstand DC 650 V and AC 650 V.
In order to prevent a short circuit in the system caused by bolt falling off, use a tool with magnetic tip.
When using an extension tool, be sure to use an insulated tool.

Tool

Name

Use

Electric insulation socket

caution

This tool is the insulation tool which prevents the circuit of the equipment from shorting caused by tool dropping, etc. It does not isolate the operator from the equipment. When using this tool, be sure to wear the electric insulation gloves.

When shutoff of the high voltage is difficult, and the drive battery cable and the EV charging cable (Quick charger) connected to the drive battery are removed
When shutoff of the high voltage is difficult, and the drive battery cable and the motor (electric motor unit) cable connected to inverter are removed
Alternatively, when a short circuit of the equipment may be present with the damaged vehicle, etc.

danger

Be sure to wear the electric insulation gloves during this work.

danger

Be sure to use the electric insulation socket during this work.

When the high voltage remains even after the shut-off of the high voltage is performed, or when the high voltage shut-off work itself is difficult because of the accidental damages, perform the security according to the following procedure.

1. For disconnecting the drive battery front cable connector and drive battery rear cable (junction box) connector from the drive battery side (Refer to "High-voltage Cable Connector Removal Steps").

2. If steps 1 is difficult to perform or it is necessary to carry out any service work in the engine compartment or the electric motor unit compartment, disconnect the drive battery cable at the power drive unit side or REMCU side (Refer toPOWER DRIVE UNIT REMOVAL AND INSTALLATION

,POWER DRIVE UNIT REMOVAL AND INSTALLATION

ACTION WHEN HIGH-VOLTAGE SHUT-OFF SYSTEM IS OPERATED

A high-voltage shut-off system isolates high voltage in the event of a crash. When this system operates, diagnose the post-collision vehicles (Refer to SRS Airbag Control System - Work FlowWork Flow

). After the diagnosis, also erase the PHEV-ECU related DTC.

HIGH-VOLTAGE CABLE CONNECTOR (DRIVE BATTERY FRONT CABLE AT DRIVE BATTERY SIDE) REMOVAL STEPS

danger

When servicing the high-voltage components, be sure to disconnect the service plug.
When the connector lock is damaged, be sure to replace the high-voltage cable assembly.

caution

When unlocking the connector lock, do not use tools etc. otherwise the connector lock may be damaged. Be sure to unlock the connector lock by hands.

1. Move the lock (A) of the connector to the direction of the arrow.

2. Pull the connector to the direction of the arrow until it stops while pushing the lock (B).

3. Pull the connector to the direction of the arrow while pushing the lock (C) to disconnect the connector.

HIGH-VOLTAGE CABLE CONNECTOR [DRIVE BATTERY REAR CABLE (JUNCTION BOX) AT DRIVE BATTERY SIDE] REMOVAL STEPS

danger

When servicing the high-voltage components, be sure to disconnect the service plug.
When the connector lock is damaged, be sure to replace the high-voltage cable assembly.

caution

When unlocking the connector lock, do not use tools etc. otherwise the connector lock may be damaged. Be sure to unlock the connector lock by hands.

1. Move the lock (A) of the connector to the direction of the arrow (UNLOCK position).

2. Pull down the connector to the direction of the arrow until it stops while pushing the lock (B).

3. Pull the connector to the direction of the arrow while pushing the lock (C) to disconnect the connector.

HIGH-VOLTAGE CABLE CONNECTOR [CABLE BETWEEN JUNCTION BOX AND AC INVERTER] REMOVAL STEPS

danger

When servicing the high-voltage components, be sure to disconnect the service plug.
When servicing the junction box, On Board Charger (OBC)/DC-DC converter, and AC inverter, disconnect the rear interlock connector in addition to the service plug removal.
When the connector lock is damaged, be sure to replace the high-voltage cable assembly.

caution

When unlocking the connector lock, do not use tools etc. otherwise the connector lock may be damaged. Be sure to unlock the connector lock by hands.

1. Move the lock (A) of the connector to the direction of the arrow.

2. Pull the connector to the direction of the arrow until it stops while pushing the lock (B).

3. Pull the connector to the direction of the arrow while pushing the lock (C) to disconnect the connector.