Precaution [08/2020 - 08/2021]

1. Before the following operations are conducted, take precautions to prevent electric shock by turning the power switch off, wearing insulated gloves, and removing the service plug grip from HV battery.
   • Inspecting the high-voltage system
   • Disconnecting the low voltage connector of the inverter with converter assembly
   • Disconnecting the low voltage connector of the HV battery
   Fig 1: Low Voltage Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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.

     Refer to INITIALIZATION [08/2020 - 08/2021]

   • After removing the service plug grip, turning the power switch on (READY) may cause a malfunction. Do not turn the power switch on (READY) unless instructed by the repair service information.
   Fig 2: Wear Insulated Gloves

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.
   Fig 3: Do Not Service The Vehicle Before Cutting Of The High-Voltage Circuit

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.
   Fig 4: Do Not Leave Service Plug Grip Accessible To Other Technicians

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. After removing the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals.

   HINT: 

   Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

   Fig 5: Do Not Service Vehicle Before Waiting At Least 10 Minutes After Discharging High Voltage Capacitor

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Without waiting for 10 minutes

5. Check the voltage at the terminals in the inspection point in the inverter with converter assembly.
   WARNING:

   Be sure to wear insulated gloves.

   1. Remove the connector cover assembly from the inverter with converter assembly.

      Refer to PROCEDURE - Step 10

      NOTE:

      • Do not touch the connector cover assembly waterproof seal.
      • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      Fig 6: Locating Connector Cover Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Measure the voltage according to the value(s) in the table below.

      Standard Voltage

      Tester Connection	Condition	Specified Condition
      Inspection point	At least 10 minutes after removing the service plug grip	0 V

      HINT: 

      Set the tester to DC750 V or more to measure the voltage.

      Fig 7: Testing Voltage

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Reinstall the connector cover assembly.
6. When turning the power switch on (IG) during an inspection, do not press the power switch with the brake pedal depressed.
   WARNING:

   Pressing the power switch with the brake pedal depressed causes the system to enter the READY-on state. This is very dangerous because high voltage may be applied to the inspection area.

   Fig 8: Do Not Service The Vehicle Before Disconnecting The Negative Battery Terminal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Turn the power switch off, wear insulated gloves, and disconnect the cable from the negative (-) terminal of the auxiliary battery before touching any of the orange-colored wires of the high-voltage system.
   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.

   Refer to INITIALIZATION [08/2020 - 08/2021]

8. Turn the power switch off before performing any resistance checks.
9. Turn the power switch off before disconnecting or reconnecting any connectors.
10. When performing work involving high-voltage wires, use either a tool wrapped with vinyl insulation tape or an insulated tool.
11. When high-voltage connectors are removed, wrap the connectors with insulation tape to prevent them from contacting foreign matter.

1. When the warning light is illuminated, or the auxiliary battery has been disconnected and reconnected, attempting to turn the power switch on (READY) may not start the system (the system may not enter the READY-on state) on the first attempt. If so, turn the power switch off and reattempt to start the hybrid system.
   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.

   Refer to INITIALIZATION [08/2020 - 08/2021]

HINT: 

The AMD terminal is connected to the positive terminal of the auxiliary battery. To prevent damage when the AMD terminal is being disconnected, use the following procedure.

1. Be sure to disconnect the cable from the negative (-) auxiliary battery terminal before disconnecting the AMD terminal from the No. 1 engine room relay block and No. 1 junction block assembly.
   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.

   Refer to INITIALIZATION [08/2020 - 08/2021]

   Fig 9: AMD Terminals

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	AMD Terminal (Inverter with Converter Assembly Side)
   *2	AMD Terminal (No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly Side)

2. After disconnecting the AMD terminal, wrap the terminal with insulation tape.
3. Be sure to reconnect the AMD terminal to the engine room relay block and junction block assembly before reconnecting the cable to the negative (-) auxiliary battery terminal.
   NOTE:

   A short circuit to ground may occur if the AMD terminal is disconnected before the cable is disconnected from the negative (-) terminal of the auxiliary battery. If a short circuit to ground occurs, it can result in an open circuit in a fusible link or fuse.

1. When disposing of HV batteries and HV supply stack sub-assemblies, make sure to return them through an authorized collection agent who is capable of handling them safely. If they are returned via the manufacturer specified route, they will be returned properly and in a safe manner by an authorized collection agent.
   WARNING:

   • After removing the HV battery, keep it away from water. Exposure to water may cause the HV battery to produce heat, resulting in a fire.
     Fig 10: Do Not Expose HV Battery To Moisture

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • Accidents such as electric shock may result if the HV battery is disposed of improperly or abandoned.

     Therefore, make sure to return HV battery through an authorized collection agent.

     Fig 11: Properly Dispose Of HV Battery Through An Authorized Collection Agent

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

     *a	Dealer
     *b	Battery Collection Agent

   • To reduce the risk of fire, HV battery must not be stored in an area where they will be exposed to fire or high temperatures.
   • If the temperature of the HV battery is high, leave the vehicle until the temperature drops.
   • 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.

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

     Refer to RECOVERY INSPECTION [08/2020 - ]

   • Before returning the HV supply stack sub-assembly, make sure to perform a recovery inspection

     Refer to RECOVERY INSPECTION [08/2020 - ]

HV battery learning values are stored in the battery ECU assembly and ECM to display "HAVE TRACTION BATTERY INSPECTED" on the multi-information display. When either of these ECUs is replaced, the new ECU receives the HV battery learning value data from the other ECU and updates the information.

1. Procedure when replacing both battery ECU assembly and ECM:
   1. Disconnect the cable from the negative (-) auxiliary battery terminal.
   2. Replace either of the ECUs.
   3. Connect the cable to the negative (-) auxiliary battery terminal.
   4. Turn the power switch on (READY) and wait for 5 minutes or more.
   5. Turn the power switch off and disconnect the cable from the negative (-) auxiliary battery terminal.
   6. Replace the other ECU.
   7. Connect the cable to the negative (-) auxiliary battery terminal.
   8. Check that the power switch can be turned on (READY).

HINT: 

If the battery ECU assembly and ECM are replaced at the same time without following the above procedure, replace either of the ECUs with its original one and then replace it again by following the above procedure. If the correct procedure is not followed, perform the procedure again from the beginning.

Fig 12: Disconnecting Cable From Negative (-) Battery Terminal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Before performing work on electronic components, disconnect the cable from the negative (-) auxiliary battery terminal to prevent damage to the electrical system or electrical components.
2. Before disconnecting and reconnecting the auxiliary battery cable, turn the power switch off and the headlight switch off. Then loosen the terminal nut completely. Do not damage the cable or terminal.
3. When the auxiliary battery cable is disconnected, the clock and radio settings and stored DTCs are cleared. Therefore, before disconnecting the auxiliary battery cable, make a note of them.
   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.

     Refer to INITIALIZATION [08/2020 - 08/2021]

   • When the cable is disconnected from the negative (-) auxiliary battery terminal, initialize the following systems after the cable is reconnected.

   System Name	See Procedure
   Lane Control System	Refer to INITIALIZATION [08/2020 - 08/2021]
   Pre-collision System
   Parking Support Brake System
   Lighting System
   Parking Assist Monitor System
   Panoramic View Monitor System
   Power Trunk Lid System