1 of 1 5/6/2016 7:30 AM

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Battery, Hybrid Drive Service and Repair, Procedures: Battery Module... http://repair.alldata.com/alldata/article/display.action?componentid=377.

1 Battery, Hybrid Drive Service and Repair, Procedures: Battery Module of 1 5/6/2016 7:30 AM Battery Module Replacement NOTE: Put on gloves to protect your hands. IMA components are located in this area. The IMA is a high-voltage system. You must be familiar with the IMA system before working on or around it. Make sure you have read the IMA service precautions before doing repairs or service. 1. Disconnect the negative cable from the 12 V battery. 2. Remove the IPU lid. 3. Disconnect the MCM connector. 4. Disconnect the connectors (A), Y capacitor ground (B), clip (C) and wires (D), then wrap the wires with insulating tape (E). 5. Remove the bolts (F), stopper (G), and battery module (H). 6. Install the parts in the reverse order of removal, noting these items: ^ Connect the Y capacitor ground before you connect the connectors (A). ^ Connect the connectors (A) before you connect the wires (D) to the junction board.

Battery, Hybrid Drive Service and Repair, Procedures: IPU (Intelligent... http://repair.alldata.com/alldata/article/display.action?componentid=377.

2 Battery, Hybrid Drive Service and Repair, Procedures: IPU (Intelligent of 1 5/6/2016 7:31 AM IPU (Intelligent Power Unit) Lid Removal/Installation NOTE: Put on gloves to protect your hands. IMA components are located in this area. The IMA is a high-voltage system. You must be familiar with the IMA system before working on or around it. Make sure you have read the IMA service precautions before doing repairs or service. 1. Remove the rear seat back, 2003 model, models. 2. Turn the battery module switch OFF. 3. Remove the bolts (A) and the clip (B). 4. Remove the IPU lid (C). 5. Install the parts in the reverse order of removal.

3 Seats Service and Repair, Procedures: Rear Seat Removal/Installation 1 of 2 5/6/2016 7:33 AM Rear Seat Removal/Installation '03 Model NOTE: Take care not to scratch the body or tear the seat covers. 1. Remove the rear seat as shown. 2. Install the seat in the reverse order of removal, and note these items: - Before attaching the rear seat-back and cushion, make sure there are no twists or kinks in the seat belts. - When installing the seat cushion, slip the seat belt buckles through the slits in the seat cushion. '04-05 Models NOTE: Take care not to scratch the body or tear the seat covers. 1. Remove the rear seat as shown.

4 Seats Service and Repair, Procedures: Rear Seat Removal/Installation 2 of 2 5/6/2016 7:33 AM 2. Install the seat in the reverse order of removal, and note these items: - Before attaching the rear seat-back and cushion, make sure there are no twists or kinks in the seat belts. - When installing the seat cushion, slip the seat belt buckles through the slits in the seat cushion.

Battery System, Hybrid Drive Service Precautions, Technician Safety In... http://repair.alldata.com/alldata/article/display.action?componentid=375.

5 Battery System, Hybrid Drive Service Precautions, Technician Safety In of 3 5/6/2016 7:33 AM IMA System Service Precautions - The Insight IMA (Integrated Motor Assisted) system uses high voltage (144 V) circuits. Be sure to shut off the electrical circuits and isolate the IMA system and related parts before you work on them. - High voltage cables and their covers are identified by orange coloring. Caution labels are attached to high voltage and other related parts. Be careful not to touch these cables and parts without using adequate protective gear. The front floor under-cover protecting the high voltage cables is marked with this symbol. - If the 12 V battery has been discharged, or either of its cables has been disconnected, or the MCM (Motor Control Module) has been reset, the IMA battery level indicator (BAT) will not indicate the state of charge when you start the engine. To correct this, start the engine, and hold it 3,500 with no load (in neutral) until the IMA battery level indicator (BAT) functions properly. - Follow these instructions when you inspect or service the IMA system. - If the IMA system indicator is on, troubleshoot the IMA system first. - Wear insulated gloves whenever you inspect or service the IMA system. Be sure to check the gloves for pin holes, tears, and other damage. - Turn the battery module switch OFF, and secure it in the OFF position with the locking cover before you work on the IMA system. - Wait at least 5 minutes for the condensers to discharge after you turn off the battery module switch. - Before you disconnect the high voltage cable terminals, make sure the voltage between them is about 0 V when measured with a voltmeter. - When working on or around parts with no insulation, be sure to use insulated tools to prevent short circuiting. - The motor rotor contains very strong magnets and should be handled with special care. People with pacemakers or other magnetically sensitive medical devices should not handle the rotor. - Use the special tool to remove or install the rotor. WARNING: If you try to install the rotor by hand, it will suddenly be pulled toward the stator with great force which could cause serious hand or finger injury. Always use the special tool to remove or install the rotor. - Do not use the rotor if the fiberglass band around it is damaged. If the band breaks during use, magnets may come loose from the rotor. - Keep the rotor away from magnetically sensitive devices such as credit or ID cards with magnetic strips on them. - After disconnecting the high voltage terminals, busbar, etc., insulate the connections with electrical tape. - Make two signs saying, "WORKING ON HIGH VOLTAGE PARTS. DO NOT TOUCH!" Attach one to the steering wheel, and set the other one near the parts you're working on.

6 Battery System, Hybrid Drive Service Precautions, Technician Safety In of 3 5/6/2016 7:33 AM Turning off power to the high voltage circuit Follow this procedure before you work on or near any high voltage components. Follow it exactly, otherwise, you may injure yourself or damage equipment. 1. Turn the ignition switch OFF. 2. Remove the cargo floor mat. 3. Remove the battery module cover (A) from the IPU lid, and remove the locking cover (B) from the battery module switch. 4. Turn the switch (A) OFF, then turn the locking cover around (B) and put it back on the switch. 5. Wait for at least five minutes to let the condensers discharge. 6. Remove the IPU lid.

7 Battery System, Hybrid Drive Service Precautions, Technician Safety In of 3 5/6/2016 7:33 AM 7. Measure voltage at the junction board terminals. There should be 30 V or less. If voltage is present, there is a problem in the circuit; do the DTC troubleshooting first.

1. Itemizes repairs by listing the cost of parts and labor

1. Itemizes repairs by listing the cost of parts and labor Electrical/Electronic Systems UNiT 3: general ELECTriCAL SySTEM DiAGNOSiS LESSON 2: preliminary electrical/electronic system diagnosis I. Functions and components of a work order NOTE: See JS1-L2-U3 for