MENU
FOREWORD This workshop manual has been prepared to provide information regarding repair procedures on Hino Trucks. Applicable for HINO 155, 155h, 195, 195h series, equipped with J05E engine When making any repairs on your vehicle, be careful not to be injured through improper procedures. As for maintenance items, refer to the Owner's Manual. All information and specifications in this manual are based upon the latest product information available at the time of printing. Hino Motors Sales U.S.A. , Inc. reserves the right to make changes at any time without prior notice. Please note that the publications below have also been prepared as relevant workshop manuals for the components and systems in these vehicles.
Manual Name Chassis Workshop Manual J05E Engine Workshop Manual
Trouble shooting Workshop Manual
Pub. No. S1-LXJE12A EWD S5-LJ05E15A S7-LXJE12A 1/5 S7-LXJE12A 2/5 S7-LXJE12A 3/5 S7-LXJE12A 4/5 S7-LXJE12A 5/5
CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL Use this chart to the appropriate chapter numbers for servicing your particular vehicle. MANUAL No. CHAPTER
MODELS Production Code
S1-LXJE12A (U.S.A.), S1-LXJE13A (CANADA) HINO 155, 155h, 195, 195h XFC710, XFC720, XFC730, XFC740, XJC700, XJC710, XJC720, XJC730, XJC740
GENERAL INTRODUCTION
1-001
HYBRID
3-001
TRANSMISSION
4-001
PROPELLER SHAFT
6-001
AXLE
7-001
DIFFERENTIAL
8-001
BRAKE
9-001
STEERING
10-001
SUSPENSION
11-001
FRAME AND FRAME ACCESSORY
12-001
CAB MOUNTING AND CAB SUSPENSION
13-001
BODY INSIDE ACCESSORY
15-001
BODY OUTSIDE ACCESSORY
16-001
AIR BAG AND SEAT BELT
17-001
HEATER AND AIR CONDITIONER
18-001
ELECTRICAL
19-001
CONTROL SYSTEM
20-001
INDEX: CHASSIS GROUP 1/2
GENERAL INTRODUCTION ENGINE HYBRID
WORKSHOP MANUAL
TRANSMISSION CLUTCH PROPELLER SHAFT AXLE DIFFERENTIAL BRAKE STEERING SUSPENSION FRAME AND FRAME ACCESSORY CAB MOUNTING AND CAB SUSPENSION BODY CONSTRUCTION BODY INSIDE ACCESSORY BODY OUTSIDE ACCESSORY AIR BAG AND SEAT BELT
All rights reserved. This manual may not be reproduced or copied in whole in part, without the written consent of Hino Motors, Ltd.
HEATER AND AIR CONDITIONER
INDEX: CHASSIS GROUP 2/2
ELECTRICAL CONTROL SYSTEM
INDEX: CHASSIS GROUP
GENERAL INTRODUCTION WIRING DIAGRAM ACCORDING TO SYSTEM WIRE TO WIRE CONNECTOR
WORKSHOP MANUAL
JUNCTION CONNECTOR LOCATION RELAY LOCATION/FUSE AND RELAY BLOCK INDEX
All rights reserved. This manual may not be reproduced or copied in whole in part, without the written consent of Hino Motors, Ltd.
GENERAL INTRODUCTION
1–1
1
GENERAL INTRODUCTION 1-001
HOW TO IDENTIFY VEHICLE TYPE .............. 1-2
LUBRICANTS ................................................ 1-35
HOW TO IDENTIFY VEHICLE TYPE ...........................1-2 VEHICLE MODEL ...................................................1-2 VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE ..........................................................1-3
LUBRICANTS.............................................................1-35 RECOMMENDED LUBRICANTS .........................1-35
APPEARANCE OF VEHICLE ......................... 1-4 APPEARANCE.............................................................1-4 APPEARANCE OF VEHICLE .................................1-4
SAFETY INSTRUCTIONS AND READINESS TO WORK .............................................................. 1-5 WARNING ....................................................................1-5 GENERAL PRECAUTIONS ....................................1-5 IDENTIFICATION INFORMATION ..........................1-9 SAFETY INSTRUCTIONS FOR WORK..................... 1-12 PRECAUTIONS .................................................... 1-12 INTRODUCTION TO WORKSHOP MANUAL............ 1-16 GENERAL ............................................................. 1-16 INTRODUCTION TO DESCRIPTIONS................. 1-17 DEFINITION OF TERM.........................................1-19 TIGHTENING OF BOLTS AND NUTS ....................... 1-20 BOLTS AND NUTS ...............................................1-20 PURPOSES OF TIGHTENING TORQUE.............1-20 CAUTIONS TO PREVENT LOOSENESS.............1-20 TYPES AND IDENTIFICATION............................. 1-21 COMPATIBILITY (NO COMPATIBILITY IN BOLTS AND NUTS) ................................................................... 1-22 STRENGTH CLASSES AND SYMBOLS.............. 1-23 PART No................................................................ 1-24 LIST OF TIGHTENING TORQUE ......................... 1-25 TIGHTENING OF FLARE NUTS AND HOSES .... 1-27 HANDLING OF LIQUID GASKET..............................1-28 LIQUID GASKET................................................... 1-28
GLOSSARY ................................................... 1-29 DEFINITION OF ABBREVIATION IN THIS MANUAL .................................................................... 1-29 LIST OF ABBREVIATION ..................................... 1-29 GLOSSARY OF SAE AND HINO TERMS ............ 1-32
1–2
GENERAL INTRODUCTION/HOW TO IDENTIFY VEHICLE TYPE
HOW TO IDENTIFY VEHICLE TYPE HOW TO IDENTIFY VEHICLE TYPE
VEHICLE MODEL EN01E01ZZZ010102001001
ձ
ղ
ճ
մ
յ
ն
X
J
C
7
0
0
շ
ո L
࣮
չ
պ
ջ
ռ
ս
վ
տ
H
K
T
Q
M
A
3
REPORTED MODEL ձ ղ㸸ENGINE MODEL
CLASSIFICATION պ㸸DECK HEIGHT
ճ㸸VEHICLE MODEL C HEAVY DUTY TRUCK
X F J05E-UG (HV)
K HIGH FLOOR
X J J05E-TP (Diesel)
մ յ㸸CAB WIDTH, DRIVE, FRAME FORM, WHEEL BASE CAB WIDTH
DRIVE
FRAME FORM
WHEEL BASE
MEDIUM
ջ㸸TRANSMISSION T 6AT FRAME ASSEMBLY WIDTH 840 mm {33 in.}
7 0
WIDE
2WD
OPEN
7 1
WIDE
2WD
OPEN
LONG
3,500 mm {138 in.}
ռ㸸LOADING CAPACITY, GVW, REAR TIRES
7 2
WIDE
2WD
OPEN
SUPER LONG
3,800 mm {150 in.}
Q
6.58 t {14,500 lbs}
REAR DOUBLE
T
8.14 t {17,950 lbs}, 8.85 t {19,500 lbs}
REAR DOUBLE
2,900 mm {114 in.}
7 3
WIDE
2WD
OPEN
SUPER LONG
4,100 mm {161 in.}
7 4
WIDE
2WD
OPEN
SUPER LONG
4,400 mm {173 in.}
ն㸸TYPE OF SUSPENSION
ս㸸ENGINE HORSEPOWER, FUEL
0 FRONT RIGID, REAR RIGID
FUEL M DIESEL OIL
ո㸸STEERING WHEEL POSITION L LEFT HAND DRIVE
EXHAUST
VERY HIGH
US13 (13OBD)
վ㸸DESTINATION DESTINATION
չ㸸CAB FORM, BRAKE TYPE CAB FORM
HORSEPOWER
A U.S., CANADA
BRAKE TYPE
H
SINGLE CAB
VACUUM
տ㸸DECK FORM
Q
CREW CAB
VACUUM
3 CHASSIS WITH CAB
C
SINGLE CAB
HYDRAULIC
D
CREW CAB
HYDRAULIC
K
SINGLE CAB
VACUUM
L
CREW CAB
HYDRAULIC
SHTS01ZZZ0100001
H
J
H
(3) K
(4)
4
5
5
4
4
5
5
P
R
S
T
U
V
W
4
4
L
Y
5
K
4
5
H
X
5
G
COE SINGLE CAB COE SINGLE CAB
XFC720 XJC720 XFC740 XJC740 XJC700 XFC710 XJC710 XFC720 XJC720 XFC740 XJC740 XFC740 XJC740 XFC720 XJC720
HINO 195h HINO 195
HINO 195h HINO 195
HINO 155
HINO 155h
HINO 155
HINO 195h HINO 195
HINO 195h HINO 195
HINO 155h HINO 155 HINO 155h HINO 155
4,400 mm {173 in.} 3,800 mm {150 in.}
COE SINGLE CAB COE SINGLE CAB
VACUUM
VACUUM
4,400 mm {173 in.} HYDRAULIC
COE CREW CAB
VACUUM
VACUUM
3,800 mm {150 in.} HYDRAULIC
3,500 mm {138 in.}
2,900 mm {114 in.}
4,400 mm {173 in.} HYDRAULIC
3,800 mm {150 in.} HYDRAULIC
VACUUM
COE CREW CAB
COE SINGLE CAB
COE SINGLE CAB
4,400 mm {173 in.}
COE CREW CAB
XJC720 XFC740 XJC740
HINO 155 HINO 155h HINO 155
3,800 mm {150 in.}
COE CREW CAB VACUUM
2,900 mm {114 in.} HYDRAULIC
COE SINGLE CAB
XFC720
3,500 mm {138 in.} HYDRAULIC
HINO 155h
XJC710
HINO 195
COE SINGLE CAB
WHEEL BASE
X
(9)
CD
C
2018
0
(12)
6,580 kg {14,500 lbs.} 8,140 - 8,850 kg {17,950 - 19,500 lbs.}
1 2
DM
PM
J05E-TP
J05E-UG
1
(14)
K
1
CODE
Diesel
0
(16)
ASSEMBLY PLANT
1
(17)
HINO MOTORS, LTD. Hamura Plant in Japan
HINO MOTORS, LTD. Hamura Plant in Japan
Canada Plant (COE)
ASSEMBLY PLANT
For Canada
K
CODE
For USA
2023
2022
2021
2020
2019
YEAR
Hybrid
0
(15)
SEQUENTIAL NUMBER
VIS
CODE ENGINE MODEL APPLICATION
SERIES GVWR
P
N
M
L
K
CODE
0
(13)
CODE
HINO
MAKE
2017
J
2016
G H
2015
2014
F
E
CODE YEAR
CODE H
K
(11)
ASSEMBLY PLANT
(10)
MODEL YEAR
CHECK DIGIT
BRAKE SYSTEM
MAKE
H
(8)
4,100 mm {161 in.} HYDRAULIC
XJC700
XJC730 XFC710
HINO 195 HINO 195h
SERIES
2
(7)
COE SINGLE CAB
CAB TYPE
L
(6)
VDS
ENGINE MODEL
D
(5)
HINO 195
XFC730
HINO 195h
CODE CLASS MODEL
2AY
PRODUCTION CODE
INCOMPLETE VEHICLE
HINO MOTORS CANADA, LTD.
JHN
TYPE INCOMPLETE VEHICLE
MANUFACTURER
HINO MOTORS, LTD.
CODE
MODEL, CAB TYPE, WHEEL BASE, BRAKE SYSTEM
MANUFACTURER ,TYPE
(2)
WMI
(1)
GENERAL INTRODUCTION/HOW TO IDENTIFY VEHICLE TYPE 1–3
VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE EN01E01ZZZ010102001002
SHTS01ZZZ0100002
1–4
GENERAL INTRODUCTION/APPEARANCE OF VEHICLE
APPEARANCE OF VEHICLE APPEARANCE
APPEARANCE OF VEHICLE EN01E01ZZZ020102003001
SHTS01ZZZ0200001
GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK
1–5
SAFETY INSTRUCTIONS AND READINESS TO WORK WARNING
GENERAL PRECAUTIONS EN01E01ZZZ030101001001
Some recommended and standard maintenance services for your vehicle are included in this section. When performing maintenance on your vehicle be careful not to get injured by improper work. Improper or incomplete work can cause a malfunction of the vehicle which may result in personal injury and/or property damage. If you have any question about performing maintenance, please consult your Hino dealer. WARNING When working on your vehicle, observe the following general precautions to prevent death, personal injury and/ or property damage in addition to the particular DANGERS, WARNINGS, CAUTIONS and NOTICES in each chapter.
• • • •
Always wear safety glasses or goggles to protect your eyes. Remove rings, watches, ties, loose hanging jewelry and loose clothing before starting work on the vehicle. Bind long hair securely behind the head. When working on the vehicle, apply the parking brake firmly, place the gear shift lever in "Neutral" or "N" and block the wheels.
• Always turn off the starter switch to stop the engine, unless the operation requires the engine running. Removing the key from the switch is recommended. • To avoid serious burns, keep yourself away from hot metal parts such as the engine, exhaust manifold, radiator, muffler, exhaust pipe and tail pipe. • Do not smoke while working on the vehicle since fuel, and gas from battery are flammable. • Take utmost care when working on the battery. It contains corrosive sulfuric acid. • Large electric current flows through the battery cable and starter cable. Be careful not to cause a short which can result in personal injury and/or property damage. • Read carefully and observe the instructions specified on the jack before using it. • Use safety stands to support the vehicle whenever you need to work under it. It is dangerous to work under a vehicle supported only by a jack. • If it is necessary to run the engine after the hood is raised (tilted), make sure that the parking brake is firmly applied, the wheels are blocked, and the gear shift lever is positioned in "Neutral" before staring the engine. • Run the engine only in a well-ventilated area to avoid inhalation of carbon monoxide. • Keep yourself, your clothing and your tools away from moving parts such as the cooling fan and V-belts when the engine is running. • Be careful not to damage lines and hoses by stepping or holding your feet on them. • Be careful not to leave any tool in the engine compartment. The tool may be hit by moving parts, which can cause personal injury.
1–6
GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK
PRECAUTIONS IN TILTING AND LOWERING THE CAB ! WARNING Be sure to observe the following when tilting and lowering the cab to reduce the risk of an accident which may result in death, serious injury and/or property damage.
• Park the vehicle on a level place and ensure ample space around the cab before tilting the cab. • Apply the parking brake firmly and place the gearshift lever in “N” position (“P” position if your vehicle is equipped with automatic transmission). • Stop the engine and block the wheels. • Remove any articles in or over the cab and close the doors firmly. • Make sure there is no one in or around the cab and there are no obstacles in front of the vehicle or above the cab. • The catch (E), stopper (F), stay (G) and other parts such as the engine, radiator, and exhaust pipe can be very hot while your vehicle is operated. Be sure to confirm they have been cooled down before you start working under the cab. • Never raise or lower the cab only by yourself if your cab is equipped with heavy component such as a roof rack. • Never put your body under the cab while raising or lowering the cab. • Make sure the cab stopper stay is securely locked by the catch (E) and raise the stopper (F) to lock the catch (E) completely after raising the cab. • Before lowering the cab, make sure that any object such as hand tools, gloves or cloth are not left under the cab. • Make sure the handle (B) is caught by the catch after lowering the cab. Read the Owner’s manual for details.
F B
E G SHTS01ZZZ0300001
DEFINITION OF SAFETY TERMS Indicates an extremely hazardous situation if proper procedures are not followed and could result in death or serious injury. Indicates a potential hazardous situation if proper procedures are not followed and could result in death or serious injury. Indicates a hazardous situation if proper procedures are not followed and could result in serious injury or damage to parts/equipment. Indicates the need to follow proper procedures and to pay attention to precautions so that efficient service is provided.
Provides additional information to help you to perform the repair efficiently.
GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK
1–7
TOWING • When being towed, always place the gear shift lever in "Neutral" and release the parking brake completely. In order to protect the bumper, fit a protection bar against the lower edge of the bumper and put a wood block under the frame near the No. 1 cross member when attaching the towing chain. Never lift or tow the vehicle if the chain is in direct contact with the bumper. 1.
Towing procedures (1) Make sure that the propeller shaft of the vehicle to be towed is removed. When the differential gear or rear axle shaft is defective, remove both right and left rear axle shafts, then cover the hub opening to prevent loss of axle lubricant and entry of dirt or foreign matter. (2) Use a heavy duty cable or rope when towing the vehicle. Fasten the cable securely to the towing hook on the frame. (3) The angle of pulling direction of the cable fastened to the towing hook must not exceed 15° in horizontal and vertical directions from the straight ahead, level direction. Avoid using the hook in a way that subjects it to jerk, as in towing a vehicle trapped in a gutter. (4) Keep the gear shift lever in Neutral. (5) Make sure that the starter switch is kept in the "ON" position, if the engine is not running. (6) Make sure that the engine of the towed vehicle is kept running. If the engine is off, no compressed air/ no vacuum will be available for the brake. This is dangerous, as the brake system does not function if the engine is not running. In addition, the power steering system will not function. The steering wheel, therefore, will become unusually hard to turn, making it impossible to control the vehicle. (7) Note that the engine brake and exhaust brake cannot be applied, if the propeller shaft is removed. (8) Make a slow start to minimize shock. Towing speed should be less than 30 km/h {18 mile/h}.
2.
If the engine of the towed vehicle is defective, make sure that the vehicle is towed only by a tow truck designed for that purpose. (1) Front end towing (with front wheels raised off the ground) When towing from the front end with the front wheels raised off the ground, remove the rear axle shafts to protect the transmission and differential gears from being damaged. The hub openings should be covered to prevent the loss of axle lubricant or the entry of dirt or foreign matter. The above-mentioned precautions should be observed for vehicles equipped with either manual or automatic transmission, and for even short distance towing. After being towed, check and refill the rear axle housing with lubricant if necessary. (2) Rear end towing When being towed with the rear wheels raised off the ground, fasten and secure the steering wheel in a straightahead position.
HYBRID/HYBRID SYSTEM
3–11
SERVICE PLUG
COMPONENT LOCATOR EN01E03ZZZ040402007001
A 1 2
SHTS03ZZZ0400003
1
Service plug
2
Service plug cover
Tightening torque A
Unit: Nm {kgfcm, lbfft}
9 {92, 6.6}
UNIT CHECK EN01E03ZZZ040402007002
INSPECTING THE SERVICE PLUG 1.
INSPECTING THE SERVICE PLUG. (1) Using a circuit tester, measure the resistance value between service plug terminals. Inspection terminal
Standard value
1-2
1 or less
3–12
HYBRID/HYBRID SYSTEM
REPLACEMENT EN01E03ZZZ040402007003
REMOVING THE SERVICE PLUG 1.
DISCONNECTING THE AUXILIARY BATTERY. (1) Disconnect the auxiliary battery negative terminal.
2.
REMOVING THE SERVICE PLUG COVER. (1) Remove the bolts (4 pcs.) to remove the service plug cover.
3.
REMOVING THE SERVICE PLUG. (1) Wear insulated gloves to remove the service plug from the HV battery assembly.
SHTS03ZZZ0400004
! CAUTION To prevent another engineer from reconnecting the service plug you disconnected, carry that plug around with you in your pocket.
1
3 2
SHTS03ZZZ0400005
HYBRID/HYBRID SYSTEM
3–13
MOUNTING THE SERVICE PLUG 1.
MOUNTING THE SERVICE PLUG.
! CAUTION Double check that you have not left any tools or parts inside before connecting the service plug, and double check the status of high-voltage connector tightening and the status of connector connections. (1)
Wear insulated gloves to mount the service plug to the HV battery assembly.
3
1 2
SHTS03ZZZ0400006
SHTS03ZZZ0400007
2.
MOUNTING THE SERVICE PLUG COVER. (1) Mount the service plug cover with the bolts (4 pcs.) Tightening Torque: 9 N·m {92 kgf·cm, 6.6 lbf·ft}
3.
CONNECTING THE AUXILIARY BATTERY. (1) Connect the negative battery terminal of the auxiliary battery.
3–14
HYBRID/HYBRID SYSTEM
PCU
COMPONENT LOCATOR EN01E03ZZZ040402004001
A
A
SHTS03ZZZ0400008
Tightening torque A
115 {1,173, 84.8}
Unit: Nm {kgfcm, lbfft}
HYBRID/HYBRID SYSTEM
3–15
3
1 2
SHTS03ZZZ0400009
1
Service hole cover
2
Clip
3
Front panel
3–16
HYBRID/HYBRID SYSTEM
1 A
SHTS03ZZZ0400010
1
Inverter terminal cover
Tightening torque A
9 {92, 6.6}
Unit: Nm {kgfcm, lbfft}
HYBRID/HYBRID SYSTEM
3–17
A
1 B
A B
SHTS03ZZZ0400011
1
Motor cable
Tightening torque A
7.2-10.8 {73-110, 5.3-8.0}
Unit: Nm {kgfcm, lbfft} B
9 {92, 6.6}
3–18
HYBRID/HYBRID SYSTEM
REPLACEMENT EN01E03ZZZ040402004002
REMOVING THE PCU 1.
DISCONNECTING THE AUXILIARY BATTERY. (1) Disconnect the auxiliary battery negative terminal.
2.
REMOVING THE SERVICE PLUG. Reference: HYBRID, HYBRID SYSTEM, SERVICE PLUG, REPLACEMENT, REMOVING THE SERVICE PLUG (Page 3-12)
3.
DISCONNECTING THE MOTOR CABLE AND 24V POWER CABLE. (1) Unfasten clips (4 pcs.) to remove the under cover service hole cover.
SHTS03ZZZ0400012
(2)
SHTS03ZZZ0400013
Remove the bolts (4 pcs.) and remove the inverter terminal cover.
HYBRID/HYBRID SYSTEM (3)
Remove bolts (6 pcs.) and detach the motor cable.
CABLE SIDE
TERMINAL SIDE
SHTS03ZZZ0400014
4.
DISCONNECTING THE CONNECTOR. (1) Unfasten the clips (2 pcs.) and remove the front panel.
SHTS03ZZZ0400015
(2)
SHTS03ZZZ0400016
Disconnect the connectors (2 locations).
3–19
3–20
HYBRID/HYBRID SYSTEM 5.
SHTS03ZZZ0400017
REMOVING THE PCU. (1) Set the engine lifter on the PCU. (2) Remove the nuts (6 pcs.) to remove the PCU.
HYBRID/HYBRID SYSTEM
MOUNTING THE PCU 1.
MOUNTING THE PCU. (1) Set the engine lifter on the PCU. (2) Mount the PCU using the nuts (6 pcs.). Tightening Torque: 115 N·m {1,173 kgf·cm, 84.8 lbf·ft}
2.
CONNECTING THE CONNECTOR. (1) Connect the connectors (2 locations).
SHTS03ZZZ0400018
SHTS03ZZZ0400019
(2)
SHTS03ZZZ0400020
Mount the front panel using the clips (2 pcs.).
3–21
3–22
HYBRID/HYBRID SYSTEM 3.
CABLE SIDE
CONNECTING THE MOTOR CABLE AND 24V POWER CABLE. (1) Connect the motor cable using bolts (6 pcs.). Tightening Torque: 9 N·m {92 kgf·cm, 6.6 lbf·ft} (Cable side) 7.2-10.8 N·m {73-110 kgf·cm, 5.3-8.0 lbf·ft} (Terminal side)
TERMINAL SIDE
SHTS03ZZZ0400021
(2) Mount the inverter terminal cover with the bolts (4 pcs.) Tightening Torque: 9 N·m {92 kgf·cm, 6.6 lbf·ft}
SHTS03ZZZ0400022
(3)
SHTS03ZZZ0400023
Fasten clips (4 pcs.) to mount the under cover service hole cover.
4.
MOUNTING THE SERVICE PLUG. Reference: HYBRID, HYBRID SYSTEM, SERVICE PLUG, REPLACEMENT, MOUNTING THE SERVICE PLUG (Page 3-13)
5.
CONNECTING THE AUXILIARY BATTERY. (1) Connect the negative battery terminal of the auxiliary battery.
HYBRID/HYBRID SYSTEM
3–23
HV BATTERY
COMPONENT LOCATOR EN01E03ZZZ040402003001
1
A A A
A
2
2
2
3 4 4 B SHTS03ZZZ0400024
1
HV battery
3
Under cover
2
Clip*
4
Clip
*: Nonreusable part Tightening torque A
31 {316, 22.9}
Unit: Nm {kgfcm, lbfft} B
13 {133, 9.6}
3–24
HYBRID/HYBRID SYSTEM
A 1
SHTS03ZZZ0400025
1
Terminal cover
Tightening torque A
9 {92, 6.6}
Unit: Nm {kgfcm, lbfft}
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HYBRID/HYBRID SYSTEM
3–25
REPLACEMENT EN01E03ZZZ040402003002
REMOVING THE HV BATTERY ASSEMBLY 1.
REMOVING THE PCU Reference: HYBRID, HYBRID SYSTEM, PCU, REPLACEMENT, REMOVING THE PCU (Page 3-18)
2.
DISCONNECTING THE HARNESS. (1) Disconnect the connector clamp and connector.
SHTS03ZZZ0400026
(2)
Unfasten the nuts (4 pcs.) and remove the terminal cover.
(3) (4) (5)
Unfasten the nuts (2 pcs.) to disconnect the harness. Disconnect the hose clamp of the snorkel hose. Disconnect the grommets (3 locations).
SHTS03ZZZ0400027
SHTS03ZZZ0400028
3–26
HYBRID/HYBRID SYSTEM 3.
REMOVING THE UNDER COVER. (1) Remove the bolts (3 pcs.) and clips (10 pcs.). (2) Pull the under cover to the front, and remove the clips (5 pcs.) and under cover. NOTICE Clips (5 pcs.) inside the under cover are not reusable.
UNDER COVER
SHTS03ZZZ0400029
4.
REMOVING THE BOTTOM OF PCU. (1) Unfasten the bolts (10 pcs.) and remove the bottom of PCU.
HV BATTERY ASSEMBLY
PCU LOWER
SHTS03ZZZ0400030
NOTICE
• Be careful not to get the check valve at the bottom of the HV battery assembly caught on anything or do not remove it.
CHECK VALVE
SHTS03ZZZ0400031
• While taking care not to damage the check valve, place the HV battery assembly on a bench as shown in the figure.
CHECK VALVE BENCH SHTS03ZZZ0400032
HYBRID/HYBRID SYSTEM
3–27
5.
REMOVING THE HV BATTERY COOLING FAN. Reference: HYBRID, HYBRID SYSTEM, HV BATTERY COOLING FAN, REPLACEMENT, REMOVING THE HV BATTERY COOLING FAN (Page 3-32)
6.
REMOVING THE HV BATTERY ECU. Reference: HYBRID, HYBRID SYSTEM, HV BATTERY ECU, REPLACEMENT, REMOVING THE HV BATTERY ECU (Page 336)
7.
REMOVING THE SYSTEM MAIN RELAY JUNCTION BLOCK. Reference: HYBRID, HYBRID SYSTEM, SYSTEM MAIN RELAY JUNCTION BLOCK, REPLACEMENT, REMOVING THE SYSTEM MAIN RELAY JUNCTION BLOCK (Page 3-40)
3–28
HYBRID/HYBRID SYSTEM
MOUNTING THE HV BATTERY ASSEMBLY 1.
MOUNTING THE SYSTEM MAIN RELAY JUNCTION BLOCK. Reference: HYBRID, HYBRID SYSTEM, SYSTEM MAIN RELAY JUNCTION BLOCK, REPLACEMENT, MOUNTING THE SYSTEM MAIN RELAY JUNCTION BLOCK (Page 3-41)
2.
MOUNTING THE HV BATTERY ECU. Reference: HYBRID, HYBRID SYSTEM, HV BATTERY ECU, REPLACEMENT, MOUNTING THE HV BATTERY ECU (Page 338)
3.
MOUNTING THE HV BATTERY COOLING FAN. Reference: HYBRID, HYBRID SYSTEM, HV BATTERY COOLING FAN, REPLACEMENT, MOUNTING THE HV BATTERY COOLING FAN (Page 3-33)
4.
MOUNTING THE BOTTOM OF PCU. (1) Mount the bottom of PCU with the bolts (10 pcs.). Tightening Torque: 31 N·m {316 kgf·cm, 22.9 lbf·ft}
HV BATTERY ASSEMBLY
NOTICE Fasten the bolts beginning with reference bolt (A). PCU LOWER
REFERENCE BOLT (A) SHTS03ZZZ0400033
5.
MOUNTING THE UNDER COVER. (1) Mount the under cover using new clips (5 pcs.). (2) Mount the bolts (3 pcs.) and clips (10 pcs.). Tightening Torque: 13 N·m {133 kgf·cm, 9.6 lbf·ft}
6.
CONNECTING THE HARNESS. (1) Connect the grommets (3 locations). (2) Connect the harness using the nuts (2 pcs.). Tightening Torque: 7.2-10.8 N·m {73-110 kgf·cm, 5.3-8.0 lbf·ft}
UNDER COVER
SHTS03ZZZ0400034
(3)
SHTS03ZZZ0400035
Connect the snorkel hose with clamp.
HYBRID/HYBRID SYSTEM
3–29
(4) Mount the terminal cover with the nuts (4 pcs.). Tightening Torque: 9 N·m {92 kgf·cm, 6.6 lbf·ft}
SHTS03ZZZ0400036
(5) 7.
SHTS03ZZZ0400037
Connect the connector clamp and connector.
MOUNTING THE PCU. Reference: HYBRID, HYBRID SYSTEM, PCU, REPLACEMENT, MOUNTING THE PCU (Page 3-21)