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Battery Pack Disassembly and Reassembly: Reassembly: Procedure

WARNING: This page is about a different variant/trim than selected.
NOTE:

Numbered call-outs in figure pertain to list numbers in following procedure.

Fig 1: Exploded View Of Battery Pack Components With Torque Specifications For Reassembly (1 Of 4)
GHH376620Courtesy of HONDA, U.S.A., INC.
Torque: N.m (kgf.m, lbf.ft)
NOTE:

Numbered call-outs in figure pertain to list numbers in following procedure.

Fig 2: Exploded View Of Battery Pack Components With Torque Specifications For Reassembly (2 Of 4)
GHH376621Courtesy of HONDA, U.S.A., INC.
Torque: N.m (kgf.m, lbf.ft)
NOTE:

Numbered call-outs in figure pertain to list numbers in following procedure.

Fig 3: Exploded View Of Battery Pack Components With Torque Specifications For Reassembly (3 Of 4)
GHH376622Courtesy of HONDA, U.S.A., INC.
Torque: N.m (kgf.m, lbf.ft)
NOTE:

Numbered call-outs in figure pertain to list numbers in following procedure.

Fig 4: Exploded View Of Battery Pack Components With Torque Specifications For Reassembly (4 Of 4)
GHH376623Courtesy of HONDA, U.S.A., INC.
Torque: N.m (kgf.m, lbf.ft)
  1. High Voltage Battery Module Temperature Sensor - Install
    GHH376624GHH376625GHH376626Courtesy of HONDA, U.S.A., INC.HONDA, U.S.A., INC.HONDA, U.S.A., INC.
    GHH376624GHH376625GHH376626Courtesy of HONDA, U.S.A., INC.HONDA, U.S.A., INC.HONDA, U.S.A., INC.
    GHH376624GHH376625GHH376626Courtesy of HONDA, U.S.A., INC.HONDA, U.S.A., INC.HONDA, U.S.A., INC.
    		 NOTE:  Always install the high voltage battery module temperature sensor in the same position as before removal.

    1. Install the high voltage battery module temperature sensor (A) as shown by the arrow.

    2. Make sure the locking tab (B) locks the high voltage battery module temperature sensor as shown.

    3. Install the harness clamp (C).

    4. Attach the high voltage battery module temperature sensor harness (D) to the harness holder (E).
  2. Battery Module 2 and Battery Module 3 - Install

    1. Install battery module 2, battery module 3, battery middle duct (A), and each plate according to the following table and figure.

    NOTICE: 

    • Check the marking on each plate before starting work.
    • Be careful not to pinch the seal part of the battery middle duct.
    • Install the battery middle duct with the cooling air outlet (B) facing downward.
    Battery module No. Plate name Punch mark
    Battery module 2 R. end front plate (C) 10
    L. middle front plate (D) 60
    Battery module 3 R. end rear plate (E) 30
    L. middle rear plate (F) 80
    GHH376627Courtesy of HONDA, U.S.A., INC.
  3. Battery Module 1 and Battery Module 4 - Install

    1. Install battery module 1, battery module 4, battery middle duct (A), and each plate according to the following table and figure.

    NOTICE: 

    • Check the marking on each plate before starting work.
    • Be careful not to bite the seal part of the battery middle duct.
    • Install the battery middle duct with the cooling air outlet (B) facing downward.
    Battery module No. Plate name Punch mark
    Battery module 1 L. end front plate (C) 50
    R. middle front plate (D) 20
    Battery module 4 L. end rear plate (E) 70
    R. middle rear plate (F) 40
    GHH376628Courtesy of HONDA, U.S.A., INC.
  4. Battery Lower Duct, IPU Lower Frame - Install
  5. Side Plate End Bindbar (Battery Module 2 - Battery Module 3) - Loosely Install
  6. Right Battery Module Assy. (Battery Module 2 and Battery Module 3) - Install
    Fig 5: Right Battery Module Assembly Bolts With Tightening Sequence
    GHH376629Courtesy of HONDA, U.S.A., INC.

    NOTICE: 

    • Tighten with the specified torque in the order shown in the figure.
    • Make sure that the battery middle duct and battery lower duct seals do not get caught or lifted.
    • Align the dowel pins and install them.
  7. IPU Sub Harness - Install
  8. Side Plate End Bindbar (Battery Module 1 - Battery Module 4) - Loosely Install
  9. Left Battery Module Assy. (Battery Module 1 and Battery Module 4) - Install
    Fig 6: Left Battery Module Assembly Bolts With Tightening Sequence
    GHH376630Courtesy of HONDA, U.S.A., INC.

    NOTICE: 

    • Tighten with the specified torque in the order shown in the figure.
    • Make sure that the battery middle duct and battery lower duct seals do not get caught or lifted.
    • Align the dowel pins and install them.
  10. Busbar (Battery Module 3-4) - Install
    GHH376631Courtesy of HONDA, U.S.A., INC.
    		 NOTICE: 
    • High voltage electricity flows in the battery terminal and busbar after disconnecting the service plug. Do all procedures one by one and keep the terminal covers closed when you are not working on them.
    • When installing the busbar, measure the voltage according to the following procedure and confirm that it is normal.

    1. Open the battery module terminal cover (A).

    2. Measure the voltage between the terminals (B).

    • If the measured value is outside the normal value, go back to step 2-1, and reassemble the battery module.
    • If the measured value is normal, proceed to the next step.
    Standard:  1 V or less 
    GHH376632Courtesy of HONDA, U.S.A., INC.
    		 3. Install the busbar (A).

    4. Close the terminal covers (B).

    NOTE:  Never reuse a bent or damaged busbar.
  11. Busbar (Battery Module 1-2) - Install
    GHH376633Courtesy of HONDA, U.S.A., INC.
    		 NOTICE: 
    • High voltage electricity flows in the battery terminal and busbar after disconnecting the service plug. Do all procedures one by one and keep the terminal covers closed when you are not working on them.
    • When installing the busbar, measure the voltage according to the following procedure and confirm that it is normal.

    1. Open the battery module terminal cover (A).

    2. Measure the voltage between the terminals (B).

    • If the measured value is outside the normal value, go back to step 2-1, and reassemble the battery module.
    • If the measured value is normal, proceed to the next step.
    Standard:  1 V or less 
    GHH376634Courtesy of HONDA, U.S.A., INC.
    		 3. Install the busbar (A).

    4. Close the terminal covers (B).

    NOTE:  Never reuse a bent or damaged busbar.
  12. IPU Upper Frame - Install
    GHH376635Courtesy of HONDA, U.S.A., INC.
    		 1. Install the upper frame.

    2. Install the tabs (A).

    3. Connect the connectors (B).
  13. Service Plug Base - Install
    GHH376636Courtesy of HONDA, U.S.A., INC.
    		 NOTICE: 

    High voltage electricity flows in the battery terminal and busbar after disconnecting the service plug. Do all procedures one by one and keep the terminal covers closed when you are not working on them.

    1. Open the battery module terminal covers (A).

    2. Measure the voltage between the terminals (B).

    • If the measured value is outside the normal value, go back to step 2-1, and reassemble the battery module.
    • If the measured value is normal, proceed to the next step.
    Standard:  1 V or less 
    GHH376637Courtesy of HONDA, U.S.A., INC.
    		 3. Install the terminals (A).

    4. Close the terminal covers (B).

    5. Install the harness clamp (C).
  14. Battery Pack Assy - Install 
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