HV Battery: Removal

PRECAUTION
(See REPAIR INSTRUCTION )
READ OUTPUT DTC
1. Check the DTC.
NOTE: Check the DTC, and confirm that P0AA6 (High voltage insulation is unusual) is not output before doing removal or installation work inside the battery. If the DTC is output, perform troubleshooting procedures first.
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
REMOVE SERVICE PLUG GRIP
CAUTION:
- Remove the service plug to interrupt a high voltage circuit at the time of the check.
- Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle.
- All the high voltage wiring connectors are colored in orange.
1. Remove the 2 clips, then open the battery service hole cover.
2. Wear insulation glove, and remove the service plug grip, after sliding up the lever of the service plug grip.
CAUTION:
- Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle.
- After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes.
NOTE: After removing the service plug grip, do not operate the ignition switch as it may damage the hybrid vehicle control ECU.

Fig 1: Removing Service Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR SEAT TRACK BRACKET COVER (See REMOVAL )
REMOVE REAR SEAT ASSEMBLY LH (See REMOVAL )
REMOVE REAR SEAT TRACK BRACKET COVER (See REMOVAL )
REMOVE REAR SEAT ASSEMBLY RH (See REMOVAL )
REMOVE AIR INTAKE COVER
1. Remove the air intake cover LH.
  1. Release the claw by using the screwdriver with the tip taped, and remove the 2 hole covers.
    
    Fig 2: Releasing Claw By Using Screwdriver
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Remove the 2 screws, then release the 2 claws and remove air intake cover LH.
  Fig 3: Locating Air Intake Cover Screws LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the air intake cover RH.
  1. Release the claw by using the screwdriver with the tip taped, and remove the 2 hole covers.
    
    Fig 4: Releasing Claw By Using Screwdriver
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Remove the 2 screws, then release the 2 claws and remove air intake cover RH.
  Fig 5: Locating Air Intake Cover Screws RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR INTAKE COVER CENTER
1. Release the claw by using the screwdriver with the tip taped, and remove the 2 hole covers.
  
  Fig 6: Removing Claw Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 screws, then release the 2 claws and remove air intake cover center.
SEPARATE FLOOR CARPET ASSEMBLY FRONT
1. Turn back the front floor carpet assembly.
REMOVE REAR CENTER SEAT INNER BELT ASSEMBLY (See REMOVAL )
REMOVE BATTERY CARRIER BRACKET
1. Remove the 2 bolts and battery carrier bracket.
Fig 8: Locating Battery Carrier Bracket Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BATTERY CARRIER DUCT
1. Remove the 2 bolts and battery carrier duct (LH).
  
  Fig 9: Locating Battery Carrier Duct Bolts (LH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 bolts and battery carrier duct (CTR).
  
  Fig 10: Locating Battery Carrier Duct Bolts (CTR)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 bolts and battery carrier duct (RH).
Fig 11: Locating Battery Carrier Duct Bolts (RH)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HV BATTERY SERVICE HOLE COVER
1. Using the service plug grip, remove the battery cover lock striker.
  HINT:
  
  Insert the projection part of the service plug grip, and turn the button of the battery cover lock striker counterclockwise, and release the lock.
  
  Fig 12: Removing Battery Service Hole Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 bolts and battery service hole cover.
REMOVE BATTERY COVER SUB-ASSEMBLY
CAUTION: Wear insulating gloves.
1. Remove the bolt, then disconnect the No.3 wire frame.
  
  Fig 13: Locating No 3 Wire Frame Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using the service plug grip, remove the battery cover lock striker.
  
  Fig 14: Locating Battery Cover Lock Striker Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Insert the projection part of the service plug grip, and turn the button of the battery cover lock striker counterclockwise, and release the lock.
3. Remove the 28 bolts, 6 nuts and battery cover.
REMOVE BATTERY SMART UNIT (See REMOVAL )
REMOVE HV BATTERY
CAUTION: Wear insulating gloves and protective glasses.

NOTE: Insulate the removed terminals with insulating tape.
1. Remove the HV battery LH.
  1. Remove the battery room ventilation hose between the HV batteries LH and CTR.
    
    Fig 15: Locating Battery Room Ventilation Hose
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Disconnect the wire harness clamp of the battery thermo sensor.
    
    Fig 16: Locating Wire Harness Clamp
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Remove the nut and main battery cable from the HV battery LH.
    NOTE:
    Insulate the tool with insulating tape.
    
    Do not use the universal joint.
    Fig 17: Removing Main Battery Cable From HV Battery
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Remove the nut, then disconnect the EV battery plug from the HV battery.
    NOTE:
    Insulate the tool with insulating tape.
    
    Do not use the universal joint.
    Fig 18: Disconnecting EV Battery Plug From HV Battery
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Remove the HV battery LH.
  Fig 19: Removing HV Battery LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the HV battery CTR.
  1. Disconnect the 2 connectors from the HV relay assembly.
    
    Fig 20: Locating HV Relay Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Disconnect the 2 connectors and clamp.
    
    Fig 21: Locating Connectors And Clamp
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Remove the battery room ventilation hose between the HV batteries CTR and RH.
    
    Fig 22: Locating Battery Room Ventilation Hose
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Remove the HV battery CTR.
  Fig 23: Removing HV Battery CTR
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the HV battery RH
  1. Disconnect the 2 clamps.
    
    Fig 24: Locating Connector And Clamps
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Remove the nut, then disconnect the main battery cable connector.
    
    Fig 25: Locating Main Battery Cable Connector And Nut
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Disconnect the clamp.
    
    Fig 26: Locating Clamp
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Remove the battery room ventilation hose.
    
    Fig 27: Locating Battery Room Ventilation Hose
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Remove the HV battery RH.
    
    Fig 28: Removing HV Battery RH
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Remove the nut and main battery cable No.2 from the HV battery RH.
    
    Fig 29: Locating Main Battery Cable No 2 Nut
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Remove the nut and main battery cable from the HV battery RH.
REMOVE BATTERY COOLING BLOWER ASSEMBLY
HINT:

Exchange the HV battery lower case as a set when liquids collect at the HV battery lower case and powder sticks.
1. Disconnect each battery cooling blower assembly connector and clamp.
  
  Fig 31: Locating Battery Cooling Blower Assembly Connector And Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 9 nuts and 3 battery cooling blower assemblies.
Fig 32: Identifying Battery Cooling Blower Assemblies With Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ELECTRIC VEHICLE BATTERY PLUG ASSEMBLY
1. Disconnect the connector and clamps.
  
  Fig 33: Locating Connector And Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 bolts, nut and EV battery plug.
REMOVE HYBRID VEHICLE RELAY ASSEMBLY (See REMOVAL )
REMOVE HV BATTERY SERVICE HOLE COVER
1. Disconnect the connector and clamp, then remove the HV battery lower case.
Fig 35: Identifying HV Battery Service Hole Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BATTERY COVER
1. Remove the battery cover from the HV battery lower case.
Fig 36: Locating Battery Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BATTERY PACKING NO.2
1. Remove the battery packing No.2 from the HV battery lower case.
Fig 37: Removing Battery Packing No 2 From HV Battery Lower Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BATTERY PACK WIRE
1. Disconnect the clamp, then remove the battery pack wire from the HV battery lower case.
  
  Fig 38: Locating Battery Pack Wire Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the 2 clamps, then remove the battery pack wire from the HV battery lower case.
Fig 39: Locating Battery Pack Wire Clamps
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002