HV BATTERY REMOVAL

Info Added 2017-10-06

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during HV battery removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure	Necessary Procedures	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Disconnect cable from negative auxiliary battery terminal	Memorize steering angle neutral point	Lane departure alert system (w/ Steering Control)	Click here
		Simple intelligent parking assist system*1
		Toyota parking assist-sensor system*1
		Pre-collision system
	Initialize back door lock	Power door lock control system	Click here
Replacement of HV battery	Battery status info update	HV battery status information cannot be updated	Click here
Replacement of hybrid battery terminal block	Perform high voltage fuse accumulated load history reset	DTCs are stored	Click here

*1: When performing learning using the GTS.
Click here Click here

CAUTION:

This vehicle has contains high voltage circuits standardized with orange colored wiring and connectors, so follow the instructions in this manual to perform the procedures correctly.

Click here
If the correct procedures are not followed according to the instructions in this manual, there is a danger of electric shock from the high voltage circuits.
Be sure to wear insulating gloves when working on high voltage wiring or components.
If work is performed without wearing insulating gloves, there is a danger of electric shock.

Tech Tips

When disposing of an HV battery, make sure to return it through an authorized collection agent who is capable of handling it safely. If the HV battery is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.

PROCEDURE

PRECAUTION
Note
- After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.
  
  Click here
- When the cable is disconnected from the negative (-) auxiliary battery terminal, some systems need to be initialized after the cable is reconnected.
  
  Click here
- If the HV battery has been struck or dropped, replace it.
- When connecting a connector to the HV battery, confirm that the connector is securely connected through the following:
  
  - Push the connector until a click sound is heard.
  
  - Visually check and confirm that the connector is securely connected by pulling on it.
- Make sure to insulate the high-voltage connectors and terminals of the HV battery with insulating tape after removing it.
  
  If the HV battery stored without insulating the connectors and terminals, electric shock or fire may result.
- When performing repairs around the HV battery, such as using a tap, do not allow metal shavings to enter the HV battery.
- Do not touch any high voltage wire harnesses, connectors or parts with bare hands.
- Hold the areas shown in the illustration and lift the HV battery.
- Do not allow foreign matter, such as grease or oil, to adhere to the bolts or nuts of the HV battery.
- *a Opening
  
  Do not put your hands into the openings of the HV battery.
- When removing/installing/moving the HV battery assembly, make sure not to tilt it more than 80°.
- Do not climb on top of or stand on the HV battery.
- Do not allow any foreign matter or water to enter the HV battery.
- If any bolts, nuts or clips are dropped into the HV battery, make sure to remove them.
REMOVE SERVICE PLUG GRIP

Click here
DISCONNECT ENGINE WIRE

Click here
REMOVE CONNECTOR COVER ASSEMBLY

Click here
CHECK TERMINAL VOLTAGE

Click here
INSTALL CONNECTOR COVER ASSEMBLY

CAUTION:

Wear insulated gloves.
1. *a Bolt (A)
  
  *b Bolt (B)
  
  Using a T25 "TORX" socket wrench, install the connector cover assembly to the inverter with converter assembly with the bolt (A).
  
  Torque:
  
  4.5 N*m { 46 kgf*cm, 40 in.*lbf }
  
  Note
  
  Do not touch the waterproof seal of the connector cover assembly.
2. Install the bolt (B).
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
CONNECT ENGINE WIRE

Click here
REMOVE BENCH TYPE REAR SEAT CUSHION ASSEMBLY

Click here
REMOVE REAR SEAT CUSHION LOCK HOOK

Click here
REMOVE REAR DOOR SCUFF PLATE LH

Click here
REMOVE REAR UNDER SIDE COVER LH

Click here
REMOVE REAR DOOR SCUFF PLATE RH

Tech Tips

Use the same procedure as for the LH side.

Click here
REMOVE REAR UNDER SIDE COVER RH

Tech Tips

Use the same procedure as for the LH side.

Click here
REMOVE REAR UNDER COVER
1. Disengage the 2 clips.
2. Disengage the 2 guides to remove the rear under cover from the rear seat cushion leg sub-assembly.
REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY
1. Remove the 6 bolts and rear seat cushion leg sub-assembly.
REMOVE BATTERY COOLING BLOWER ASSEMBLY

Click here

REMOVE NO. 1 HV BATTERY COVER PANEL RH

CAUTION:

Wear insulated gloves.

*1	Service Plug Grip
*2	Battery Cover Lock Striker
*a	Projection
*b	Turn
*c	Button

Using the service plug grip, remove the battery cover lock striker.

Tech Tips

Insert the projection of the service plug grip and turn the button of the battery cover lock striker counterclockwise to release the lock.

Remove the 3 bolts, 2 nuts and No. 1 HV battery cover panel RH from the HV battery.

DISCONNECT HV FLOOR UNDER WIRE

CAUTION:

Wear insulated gloves.

Note

Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.
1. *a Shield Ground
  
  Disconnect the 2 HV battery junction block assembly connectors.
2. Disconnect the shield ground from the HV battery.
DISCONNECT FLOOR WIRE
CAUTION:

Wear insulated gloves.
1. Disengage the clamp.
2. Disconnect the electric vehicle battery plug assembly connector.
3. Disconnect the HV battery junction block assembly connector.
REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT
1. Remove the clip.
2. Disengage the claw to remove the No. 1 hybrid battery exhaust duct from the HV battery.
DISCONNECT FLOOR WIRE
CAUTION:

Wear insulated gloves.
1. Disengage the clamp.
2. Disconnect the battery voltage sensor connector.
REMOVE HV BATTERY
CAUTION:

Wear insulated gloves.
1. Remove the 5 bolts and HV battery from the vehicle.
  Note
  
  Do not allow foreign matter, such as grease or oil, to adhere to the bolts of the HV battery.
  
  To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.
  
  Use cardboard or another similar material to protect the HV battery and vehicle body from damage.
  
  Since the HV battery is very heavy, 2 people are needed to remove it. When removing the HV battery, be careful not to damage the parts around it.
  
  When removing the HV battery from the vehicle, do not allow it to contact the vehicle.
  
  When removing/installing/moving the HV battery, make sure not to tilt it more than 80°.
  
  Insulate the disconnected terminals or connectors with insulating tape.
  
  If the HV battery has been struck or dropped, replace it.
REMOVE UPPER NO. 1 HYBRID BATTERY COVER SUB-ASSEMBLY
CAUTION:

Be sure to wear insulated gloves and protective goggles.
1. Remove the 6 bolts, 5 nuts and upper No. 1 hybrid battery cover sub-assembly from the HV battery.
REMOVE NO. 1 HV BATTERY SHIELD PANEL

Click here
REMOVE BATTERY VOLTAGE SENSOR

Click here
REMOVE HYBRID BATTERY TERMINAL BLOCK

Click here
REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY

Click here
REMOVE NO. 1 HYBRID BATTERY SHIELD SUB-ASSEMBLY

Click here
REMOVE NO. 1 HYBRID BATTERY INTAKE DUCT

Click here

*a	Bolt (A)
*b	Bolt (B)