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1. Battery tray cover and plug hole cover removal and installation
warningBefore the service work, make sure that the service plug is removed from the main drive lithium-ion battery assembly.
 
 
Required Special Tool:
  • MB992855: Guide pin
 
 
Battery tray cover removal
1. Remove the bolts.
2. Using glass adhesive knife. [Blade length: 48 mm (1.89 inches)]
notePrepare the blade spare due to the possibility that the blade of the glass adhesive knife will break during work.
3. While holding the glass adhesive knife and the end of battery tray cover at right angle, pull the blade of the glass adhesive knife parallel to the end of the battery tray cover to detach the adhesive and remove the battery tray cover.
4.
caution
  • Do not scrape away the remaining adhesive more than necessary to prevent adhesion failure.
  • Smoothly form the surface of the adhesive left on the flange. If there is a step on the surface of the adhesive, there is a possibility of leakage from the step after reapplying the adhesive.
  • When battery tray cover and battery tray assembly are damage with a knife etc, apply repair paint to the damaged part.
Scrape away the remaining adhesive on the flange of the battery tray cover and battery tray assembly with a sharp knife etc. around the whole circumference so that the thickness is about 1 mm (0.039 inch).
5. Remove the chip of adhesive cleanly.
6. Remove the cover pads.
7. Remove the breather caps.
 
 
 
Plug hole cover removal
1. Remove the battery tray cover.
2. Remove the plug hole plate.
3. Remove the upper plug hole plate.
4. Remove the plug hole cover.
 
 
Plug hole cover installation
1.
caution
  • Butyl rubber tape 3M ATD Part No.8625 or equivalent: Application surface should be free of oil, grease or foreign materials.
  • First, tighten all the bolts by hand until they are seated. Then after final tightening, check that all the bolts are tightened to the specified torque.
Apply the butyl rubber tape 3M ATD Part No.8625 or equivalent to the plug hole cover as shown. Then install it to the battery tray cover.
2. Install the upper plug hole plate.
3. Install the plug hole plate.
4. Install the battery tray cover.
 

 
 
Battery tray cover installation
1. Install the breather cap.
2.
cautionApplication surface should be free of oil, grease or foreign materials.
Position the cover pads as shown.

3.
Measure the position where the adhesive flow prevention dam (inner pad) is attached to the adhesive left on the flange portion of the battery tray assembly with a vernier caliper etc. and mark it.

4.
Attach four adhesive flow prevention dam (inner pad) inside the marking.

5.
Attach 11 adhesive flow prevention dams (outer pads) to the inside of the bolt hole.
6. Cut the nozzle tip of the sealant gun in the following procedure.
(1) Cut so that the inner diameter of the nozzle tip becomes 5 mm (0.197 inch).
(2) Cut it obliquely so that the nozzle tip height is 8 mm (0.315 inch).
(3) In order to make it easier to apply the adhesive, cut the opposite side that cut to 8 mm (0.315 inch) so that the inside diameter is about 3 mm (0.118 inch) and the height is about 3 mm (0.118 inch).
(4) Whether the adhesive can be applied with the standard dimension [5 × 8 mm (0.197 × 0.315 inch)] is trial applied, and if it is less than standard, perform the cutting operation again.
7. Using the sealant gun.

8.
cautionAfter applying adhesive, make sure that the adhesive flow prevention dam has not fallen down toward the adhesive side.
Apply adhesive YOKOHAMA RUBBER HAMATITE WS-272 or equivalent to the battery tray assembly.
9. Install the special tool MB992855 to the battery tray assembly.
10.
cautionInstallation of the battery tray cover should be done by two or more persons.
Install the battery tray cover while checking the hole positions of both the guide pin and the battery tray cover mounted on the battery tray assembly.
11. Tighten the mounting bolts of the battery tray cover in the order of 1 to 11 with specified torque and remove the special tool MB992855.

12.
In order to prevent the battery tray cover from floating up, install C type clamps (11 pieces).
13. Make sure that the mounting bolts of the battery tray cover is tightened to the specified torque.
14. Carried out the air leak check after 45 minutes have elapsed from the start of adhesive application. (Refer to .)
15. Remove the C type clamp (11 pieces).