HV BATTERY REMOVAL

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
Auxiliary battery terminal is disconnected/reconnected Memorize steering angle neutral point Lane departure alert system (w/ Steering Control)

Click here

Intelligent clearance sonar system*1
Simple intelligent parking assist system*1
Pre-crash safety system
Adaptive high beam system
Parking assist monitor system

Click here

Initialize back door lock Power door lock control system

Click here

Replacement of HV battery

  1. Battery diagnosis

  2. 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


  • Replacement of battery ECU assembly

  • Replacement of HV battery junction block assembly

 Current sensor offset learning

Click here

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

CAUTION:


  • B006HTF

    Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.

    Click here

  • B006HUP

    To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.

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


  1. 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.

    • Do not touch any high voltage wire harnesses, connectors or parts with bare hands.

    • Do not allow foreign matter, such as grease or oil, to adhere to the bolts or nuts of the HV battery.

    • B006IP6C01
      *a Opening

      Do not put your hands into the openings of the HV battery.

    • When removing/installing/moving the HV battery, 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.

  2. READ VALUE USING GTS


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / HV Battery / Data List / Hybrid Battery Temperature 1 to 15.


      Powertrain > HV Battery > Data List
      Tester Display
      Hybrid Battery Temperature 1
      Hybrid Battery Temperature 2
      Hybrid Battery Temperature 3
      Hybrid Battery Temperature 4
      Hybrid Battery Temperature 5
      Hybrid Battery Temperature 6
      Hybrid Battery Temperature 7
      Hybrid Battery Temperature 8
      Hybrid Battery Temperature 9
      Hybrid Battery Temperature 10
      Hybrid Battery Temperature 11
      Hybrid Battery Temperature 12
      Hybrid Battery Temperature 13
      Hybrid Battery Temperature 14
      Hybrid Battery Temperature 15

    4. Read the Data List.

      Note

      If any of the temperatures listed in "Hybrid Battery Temperature 1 to 15" are 50°C (122°F) or more, leave the vehicle until the temperature drops to less than 50°C (122°F).

  3. REMOVE SERVICE PLUG GRIP

    Click here

  4. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  5. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)

    Click here

  6. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

    Click here

  7. REMOVE WATER GUARD PLATE

    Click here

  8. REMOVE COWL BODY MOUNTING REINFORCEMENT LH

    Click here

  9. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

    Click here

  10. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (w/o Canister Pump Module)

    Click here

  11. DISCONNECT ENGINE WIRE (w/o Canister Pump Module)

    Click here

  12. DISCONNECT ENGINE WIRE (w/ Canister Pump Module)

    Click here

  13. REMOVE CONNECTOR COVER ASSEMBLY

    Click here

  14. CHECK TERMINAL VOLTAGE

    Click here

  15. INSTALL CONNECTOR COVER ASSEMBLY

    CAUTION:

    Wear insulated gloves.


    1. B006HKEC05
      *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 }

  16. CONNECT ENGINE WIRE (w/ Canister Pump Module)

    Click here

  17. CONNECT ENGINE WIRE (w/o Canister Pump Module)

    Click here

  18. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (w/o Canister Pump Module)

    Click here

  19. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

    Click here

  20. INSTALL COWL BODY MOUNTING REINFORCEMENT LH

    Click here

  21. INSTALL WATER GUARD PLATE

    Click here

  22. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)

    Click here

  23. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

    Click here

  24. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  25. REMOVE REAR NO. 3 FLOOR BOARD

    Click here

  26. REMOVE REAR NO. 4 FLOOR BOARD

    Click here

  27. REMOVE DECK FLOOR BOX LH

    Click here

  28. REMOVE DECK FLOOR BOX RH

    Click here

  29. REMOVE DECK TRIM SERVICE HOLE COVER

    Click here

  30. REMOVE REAR DECK TRIM COVER

    Click here

  31. REMOVE NO. 3 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY

    Click here

  32. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH

    Click here

  33. REMOVE REAR SEATBACK HINGE SUB-ASSEMBLY LH

    Click here

  34. REMOVE REAR SEAT SIDE GARNISH LH

    Click here

  35. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH

    Click here

  36. REMOVE REAR SEATBACK HINGE SUB-ASSEMBLY RH

    Click here

  37. REMOVE REAR SEAT SIDE GARNISH RH

    Click here

  38. REMOVE ROPE HOOK (for RH Side without Toyota Safety Sense)

    Click here

  39. REMOVE NO. 2 ROPE HOOK (for RH Side without Toyota Safety Sense)

    Click here

  40. REMOVE NO. 1 TONNEAU COVER HOLDER CAP (for RH Side with Toyota Safety Sense)

    Click here

  41. REMOVE TONNEAU COVER HOOK A (for RH Side with Toyota Safety Sense)

    Click here

  42. REMOVE NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY

    Click here

  43. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH

    Click here

  44. REMOVE NO. 3 HYBRID BATTERY INTAKE DUCT (for LH Side)

    Click here

  45. REMOVE NO. 3 HYBRID BATTERY INTAKE DUCT (for RH Side)

    Click here

  46. REMOVE HYBRID BATTERY HOSE ASSEMBLY


    1. B006J7R

      Disconnect the hybrid battery hose assembly from the vehicle.

    2. Remove the 2 clips and hybrid battery hose assembly from the HV battery.

  47. REMOVE NO. 1 HYBRID BATTERY INTAKE DUCT (for RH Side)

    Click here

  48. REMOVE NO. 2 HYBRID BATTERY INTAKE DUCT (for RH Side)

    Click here

  49. REMOVE CENTER REAR SEATBACK HINGE SUB-ASSEMBLY

    Click here

  50. REMOVE NO. 1 HV BATTERY SHIELD PANEL

    CAUTION:

    Wear insulated gloves.


    1. B006HLJC02
      *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.

    2. Remove the 8 nuts and No. 1 HV battery shield panel from the HV battery.

  51. REMOVE NO. 3 HV BATTERY SHIELD PANEL

    CAUTION:

    Wear insulated gloves.


    1. B006J80

      Remove the 4 nuts and No. 3 HV battery shield panel from the HV battery.

  52. REMOVE NO. 2 HV BATTERY SHIELD PANEL

    CAUTION:

    Wear insulated gloves.


    1. B006IH0

      Remove the 3 nuts and No. 2 HV battery shield panel from the HV battery.

  53. DISCONNECT WIRE HARNESS

    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. B006IX4C03
      *a Earth Terminal

      Disconnect the 2 HV battery junction block assembly connectors (A).

    2. Disconnect the 2 HV battery junction block assembly connectors (B).

    3. Remove the 2 nuts and disconnect the earth terminals.

    4. Remove the nut.

    5. Disengage the 3 clamps.

  54. DISCONNECT FLOOR WIRE

    CAUTION:

    Wear insulated gloves.


    1. B006IU2

      Disengage the clamp.

    2. Disconnect the 2 HV battery connectors.

  55. REMOVE HV BATTERY

    CAUTION:

    Wear insulated gloves.


    1. Remove the 4 bolts (A) and 6 bolts (B).

      B006J4FN01

      Note

      Do not allow foreign matter, such as grease or oil, to adhere to the bolts of the HV battery.

    2. Set the 4 hooks and 2 straps as shown in the illustration.

      B006I0CC02
      *a Hook - -

    3. Using a suitable adaptor such as straps, remove the HV battery while tilting it.

      Note


      • 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.

      • When removing the HV battery, make sure to cover the opening on the front of the HV battery with a piece of cloth.

  56. REMOVE NO. 4 HV BATTERY MOUNT BRACKET

    Tech Tips

    Perform this procedure only when replacement of the No. 4 HV battery mount bracket is necessary.


    1. B006HT7

      Remove the 3 bolts and No. 4 HV battery mount bracket.

  57. REMOVE NO. 3 HV BATTERY MOUNT BRACKET

    Tech Tips

    Perform this procedure only when replacement of the No. 3 HV battery mount bracket is necessary.


    1. B006IG8

      Remove the 3 bolts and No. 3 HV battery mount bracket.

  58. REMOVE NO. 2 HV BATTERY MOUNT BRACKET

    Tech Tips

    Perform this procedure only when replacement of the No. 2 HV battery mount bracket is necessary.


    1. B006IO8

      Remove the 2 bolts and No. 2 HV battery mount bracket.

  59. REMOVE NO. 1 HV BATTERY MOUNT BRACKET

    Tech Tips

    Perform this procedure only when replacement of the No. 1 HV battery mount bracket is necessary.


    1. B006I00

      Remove the 2 bolts and No. 1 HV battery mount bracket.

  60. PERFORM RECOVERY INSPECTION


    1. Before returning the HV battery, make sure to perform a recovery inspection.

      Click here