sonata hybrid battery dismantling manual
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SONATA HYBRID Battery Dismantling Manual. Precautions for handling the hybrid battery. Wear rubber-insulated gloves. Use insulated tools. Do not have any metal objects in your possession while working. Do not cause any impact on the battery. - PowerPoint PPT PresentationTRANSCRIPT
SONATA HYBRIDBattery Dismantling Man-
ual
Precautions for handling the hybrid battery• Wear rubber-insulated gloves.• Use insulated tools.• Do not have any metal objects in your possession while working.• Do not cause any impact on the battery. • Do not disassemble the battery without specific equipment.• Be sure to discharge the battery to store and transport it safely.
Battery dismantling procedure
Turning offthe engine
Disconnecting the 12V batteryterminal
Disconnectingthe safety plug and
connectors
Dismantling the hybrid
battery
Discharging the hybrid battery
Disconnection of the 12V battery terminal
Remove the 12V battery cover.
Disconnect the negative terminal.
Unfasten a nut.
CautionDisconnect the
negative terminal of the battery first.
If the positive terminal is disconnected first, there is a possibility of electric
shock.
Negative terminal of the 12V battery
Open the trunk.
1 2
3 4 5
Disconnection of the safety plug
Uncover the safety plug cover.
Pull the lever.
Release the lock of the plug.
Disconnect the safety plug. After disconnection, wait 5
minutes for the electric discharge .
Safety plug cover
1 2
4 5 6
3
Removal of the rear seat
Remove the rear seat back.
Remove the rear seat cushion.
Unfasten 5 bolts.
Bolts for fastening the rear seat back
1 2
3 4
Removal of the luggage partition trim
Luggage partition trim Remove the luggage partition trim.
Fasteners and a nut for fastening trunk
trims
Unfasten a nut.
Unfasten 2 fasteners.
1 3
4 5 6
2
Unfasten 3 fasteners and 5 screws.
Removal of trunk trims
Remove the luggage cover mat.
Unfasten 11 fasteners.
Unfasten a bolt.
Remove the luggage side trim(LH).
Remove the battery case trim.
1 2
3 4 5
Remove the luggage side trim(RH).
Removal of cooling ducts
Detach the inlet cooling duct. Detach the outlet cooling duct.
Unfasten 5 nuts.Outlet cooling duct / Inlet cooling duct
1 2
3 4
Uncovering the high voltage safety cover
Uncover the high voltage safety cover.
Unfasten 3 torx bolts.
High voltage safety cover
1 2
3
Disconnection of battery connectors
Disconnect the inverter
power cable terminals.
Disconnect theBMS extension
connector.
Disconnect the cooling fan connector.
Unfasten 3 nuts.
Caution• Orange colored cables carry high current.• Be cautious when working with electric terminals.
Battery connectors
1 2
4 5
3
Dismantling the battery
Dismantle the battery. Finish dismantling the battery.
Unfasten 6 bolts.
Caution• Be cautious about transportation because a battery weighs about 42kg.• Do not cause any impact on the battery.
Battery case
Battery case
1 2
4 5
3