Service Bulletin

Service Bulletin
March 27, 2015
14-011
51025-01662 Version 2
High Voltage Lithium Ion Battery Replacement Equipment
Supersedes 14-011, dated March 8, 2014, to revise the information highlighted in yellow.
AFFECTED VEHICLES
Year
2014
Model
Accord Plug-In
Trim
ALL
VIN Range
ALL
REVISION SUMMARY
The 2015 Accord Hybrid information was removed from this service bulletin.
INTRODUCTION
Each replacement high voltage lithium ion battery assembly order includes the loan of a special tool kit that includes the
tools required for the battery replacement procedure. The battery and the kit are shipped on a two-level rack, which
disassembles into tables to be used as work spaces.
This service bulletin explains how to unload/reload the rack and its contents. For battery ordering, handling, and return
information, see Parts Information Bulletin A13-0003.
The approximate total weight of the battery, the special tool kit, and the rack is 750 lbs.
BATTERY
TOOL
CRATE
CUSTOMER INFORMATION: The information in this bulletin is intended for use only by skilled technicians who have
the proper tools, equipment, and training to correctly and safely maintain your vehicle. These procedures should not be
attempted by “do-it-yourselfers,” and you should not assume this bulletin applies to your vehicle, or that your vehicle has
the condition described. To determine whether this information applies, contact an authorized Honda automobile dealer.
© 2015 American Honda Motor Co., Inc. – All Rights Reserved
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TOOL INFORMATION
Tool Name
Tool Number
Quantity
Hybrid Battery R&R Equipment Loan Kit
(A complete list of contents is in the crate)
07PHEVBATOLKIT
1
The kit is ordered automatically when the replacement unit is ordered; it is currently not sold separately.
RECEIVING/STAGING THE RACK
The equipment loan kit rack is 71 inches tall and has a footprint of 4 feet by 4 feet (fully assembled). AHM strongly
recommends that the vehicle be ready for service when the battery and special tool kit arrive.
It is important to stage the rack near the vehicle. A pallet jack is required to move the loaded rack. Place the rack on a flat,
even surface. Do not allow the rack to be exposed to moisture, as it can damage the contents.
Below are two diagrams showing recommended equipment layouts. Select the appropriate orientation based on available
space in your service bay. A vehicle lift is not required.
•
•
The rack should be placed at least 3 feet from behind the vehicle. When disassembled, the tables should be placed
2 feet apart.
When using a forklift or pallet jack, lift the rack only at the designated locations labeled “LIFT HERE.”
Layout Option 1
Table
Base
Vehicle
Table
Layout Option 2
Table
Base
Vehicle
Table
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UNLOADING THE RACK
1. Unlatch the two 4-inch-wide rack tie-down straps securing the rack assembly, and tuck them underneath the base.
NOTE: Do not remove the pins from the legs.
TABLE A
PIN
Do not remove.
CROSSBAR
TIE-DOWN STRAP
2. With assistance, use the black crossbars to lift and remove Table A. Place it in the desired location, referring to the
recommended equipment layouts shown in RECEIVING/STAGING THE RACK. Table A will be one of two work
surfaces used to do the battery replacement.
3. Remove the tie-down straps securing the battery carton to Table B. Keep the corner protectors for reassembly. With
assistance, move the battery carton to Table A.
CORNER PROTECTOR
Do not discard.
TIE-DOWN STRAP
TABLE B
4. With assistance, lift and remove Table B, and set it on the ground according to the recommended layout you chose.
This is a second work platform where the repair can be completed.
5. Remove the tie-down straps securing the second battery carton and the tool crate to the rack base.
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6. Keep the corner protectors for reassembly. With assistance, move the second battery carton to Table B.
CORNER PROTECTOR
Do not discard.
TIE-DOWN STRAPS
7. Cut and discard the green security tags from the crate latches.
GREEN SECURITY TAG
Cut and discard.
8. Lift and rotate the latches counterclockwise, then remove the crate lid and place it in a safe location. Using the
enclosed contents sheet, make sure that all items are accounted for and in good condition.
NOTE: The insulated rubber gloves are not in the crate. They are in the small FedEx box attached to the crossbars on
the other side of the document holder.
BOX CONTAINING
RUBBER INSULATED
GLOVES
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9. Inside the crate, undo the interior tie-down strap securing the battery carriers and table. Remove the items that you will
need for the replacement procedure as directed by the appropriate electronic service manual.
NOTE: Call the Special Tools Hotline at 800-346-6327 if any of the contents are damaged or missing.
INTERIOR TIE-DOWN STRAP
10. Undo the Honda cinch straps on the battery carton. DO NOT CUT THESE STRAPS; you will reuse them later.
CINCH STRAP
Undo at buckle; do not cut.
11. Open the battery carton(s) and remove the interior cardboard isolator panels. DO NOT DISCARD THE CARTON, THE
LINER, OR ANY OF THE PANELS. All the packaging materials will be used to repackage the old battery for return to
AHM.
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12. Attach the battery carrier to one of the battery packs using the supplied bolts in the Cementex pouch inside the tool
bag. Then, with assistance, lift the battery from the carton, move the carton off the table, and set the battery back down
on the table. Repeat this step for the other battery pack.
Place all packaging for each battery pack in an area where it will not get damaged, paying special attention to which
carton and inserts belong to which battery pack. The carton for the top battery is marked UPR, and the carton for the
bottom battery is marked LWR. Placing the old batteries in the wrong cartons will cause your dealership to be
out of compliance with hazardous material shipping regulations.
13. Do the battery replacement procedure as directed in the electronic service manual.
RELOADING THE RACK
IMPORTANT: If any battery core is leaking or appears damaged, or if you detect heat or an unusual smell,
DO NOT RETURN THE BATTERY! Call AHM Hybrid Support IMMEDIATELY at 909-664-9323.
1. With assistance, place the batteries into the plastic liners in their respective cartons. Repackage the battery according
to the Lithium Ion Battery Core Packing Instructions (in ISIS, select Search by Vehicle, then Technical Library, and
enter keywords LITHIUM PACKING).
Make sure to place each battery pack into the correct carton. The carton for the top battery is marked UPR, and the
carton for the bottom battery is marked LWR.
2. Place the battery table and carriers back into the tool crate.
Remove the battery carrier extension handle and clip it to the back of the table before placing the table back into the
crate.
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3. Secure the carriers with the interior tie-down strap as shown.
INTERIOR TIE-DOWN STRAP
4. Return the insulated tools to the canvas tool bag. Place the bolts, split tubes, and vinyl caps inside the Cementex
pouch, and remove the two yellow security tags (these tags are to be attached to two of the crate latches after the lid is
reinstalled). Then, close the pouch and place it in the canvas tool bag. Zip the tool bag shut and place it in the crate.
5. Return the leather outer gloves to their protective bag. Also place the rubber insulated gloves in the same bag; do not
put them back in the FedEx box. Place the bag in the crate as shown. Fold the fender covers twice and place them in
the crate. Make sure the yellow adapter (not used) is also in the crate.
BAG CONTAINING BOTH
LEATHER GLOVES AND
RUBBER GLOVES
Do not put the rubber gloves
back in the FedEx box.
YELLOW ADAPTER
(not used)
FENDER COVERS
6. Place the lid on the crate so the black stripes on the lid and crate line up. Secure all latches. Then, attach the two
yellow security tags to two latches on opposite ends.
BLACK
STRIPE
Use to align
lid with crate.
YELLOW
SECURITY
TAG
Attach to two
latches after
closing.
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7. Center the tool crate on the rack base, then go to Table B and transfer the battery carton to the top of the crate.
CORNER
PROTECTOR
Position on
battery carton,
underneath
each tie-down
strap, before
tightening
the straps.
8. Secure the crate to the rack base with the tie-down straps as shown.
Place the corner protectors on the battery carton as shown, before tightening the tie-down straps. They should be tight
enough to keep the items from sliding, but not so tight that they dent the carton.
9. With assistance, install Table B onto the rack base. Make sure all four legs are set properly onto the ball receivers.
NOTE: Make sure you are installing Table B, not Table A (with the black crossbars).
10. With assistance, place the (other) battery on Table B. Place the corner protectors on the carton, then secure the carton
to the table with the tie-down straps as shown. The straps should be tight enough to keep the battery from sliding, but
not so tight that they dent the carton.
Make sure the battery packs are oriented so the UPR and LWR markings are on the same side.
CORNER PROTECTOR
Position on battery carton,
underneath each tie-down
strap, before tightening
the straps.
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11. With assistance, install Table A onto Table B. Then, secure the rack assembly as shown with the two 4-inch-wide
tie-down straps. The straps must be tight enough to prevent the rack from disassembling if toppled.
12. Make sure the following documents are completed and inserted into the document holder on the side of the crate:
• Hazmat Bill of Lading
• Core Return Update Acknowledgement – Battery
• Core Return Acknowledgement – Special Tool Kit
NOTE: See PIB (A13-0003 for Accord Plug-In) for detailed instructions. Failure to include properly completed
paperwork may result in additional processing fees.
FEES AND CORE LOSS CHARGES
A loan fee of $300.00 will be applied to each order for the use of the special tool kit.
If any of the following occurs to the failed battery core, your warranty claim will be debited and your dealership will be
issued a core loss charge of $9,000.00:
•
•
•
Any part of the core is physically damaged while at your dealership or in transit due to improper re-packaging.
The core is not received at AHM within 45 calendar days from the order date of the replacement assembly.
The core is returned disassembled, or one of the battery packs is missing.
If any of the following occurs to the special tool kit, your warranty claim will be debited and your dealership will be issued a
core loss charge of $3,000.00:
•
•
The crate and its contents are heavily damaged while at your dealership or in transit due to improper re-packaging.
The kit is not received at AHM within 45 calendar days from the order date of the replacement assembly.
If the special tool kit is returned with minor damage or missing components, you may be assessed a repair or replacement
fee by AHM Service Operations; however, you will not be subjected to the $3,000.00 core loss charge.
If one or both Core Return Update Acknowledgements are missing from your return, you will be charged a $50.00
processing fee for each missing printout.
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