SONATA HEV Battery Dismantling Manual Engworldwide.hyundai.com/worldwide/images/corporate/SONATA_HEV... · Precautions for handling the hybrid battery • Wear rubber-insulated gloves.

SONATA HYBRIDBattery 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. • 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 safetyplug and

connectors

Dismantlingthe 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 inverterpower cable terminals.

Disconnect theBMS extension connector.

Disconnect thecooling 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 caseBattery case

1 2

4 5

3