SONATA HYBRID
Battery Dismantling Manual
Precautions for handling the hybrid battery
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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 off
the engine
Disconnecting
the 12V
battery
terminal
Disconnecting
the safety
plug and
connectors
Dismantling
the hybrid
battery
Discharging
the hybrid
battery
Disconnection of the 12V battery terminal
1
2
Caution
Disconnect the negative
terminal of the battery first.
If the positive terminal is
disconnected first, there is a
possibility of electric shock.
Open the trunk.
3
Negative terminal of the 12V battery
Remove the 12V battery cover.
4
5
Unfasten a nut.
Disconnect the negative terminal.
Disconnection of the safety plug
1
2
Safety plug cover
4
3
Uncover the safety plug cover.
5
Pull the lever.
Release the lock of the plug.
6
Disconnect the safety plug.
After disconnection, wait 5 minutes
for the electric discharge .
Removal of the rear seat
1
2
Bolts for fastening the rear seat back
Remove the rear seat cushion.
3
4
Unfasten 5 bolts.
Remove the rear seat back.
Removal of the luggage partition trim
1
2
Unfasten 3 fasteners and 5 screws.
Luggage partition trim
4
3
5
Fasteners and a nut
for fastening trunk trims
Remove the luggage partition trim.
6
Unfasten a nut.
Unfasten 2 fasteners.
Removal of trunk trims
1
2
Unfasten a bolt.
Remove the luggage cover mat.
3
Unfasten 11 fasteners.
4
Remove the battery case trim.
5
Remove the luggage side trim(LH).
Remove the luggage side trim(RH).
Removal of cooling ducts
1
2
Outlet cooling duct / Inlet cooling duct
3
Unfasten 5 nuts.
4
Detach the inlet cooling duct.
Detach the outlet cooling duct.
Uncovering the high voltage safety cover
1
2
Unfasten 3 torx bolts.
3
High voltage safety cover
Uncover the high voltage safety cover.
Disconnection of battery connectors
1
2
3
Disconnect the
BMS extension connector.
4
Disconnect the
cooling fan connector.
5
Unfasten 3 nuts.
Battery connectors
Disconnect the inverter
power cable terminals.
Caution
• Orange colored cables carry high current.
• Be cautious when working with electric terminals.
Dismantling the battery
1
2
Battery case
4
3
Battery case
5
Unfasten 6 bolts.
Caution
• Be cautious about
transportation because a
battery weighs about 42kg.
• Do not cause any impact on
the battery.
Dismantle the battery.
Finish dismantling the battery.