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Removal [10/2018 - 07/2022]: Procedure

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  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.

      Refer to PRECAUTION [10/2018 - 07/2022]

    • When the cable is disconnected from the negative (-) auxiliary battery terminal, some systems need to be initialized after the cable is reconnected.

      Refer to INITIALIZATION [10/2018 - 07/2022]

    • 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.
      GTY551800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    • Do not allow foreign matter, such as grease or oil, to adhere to the bolts or nuts of the HV battery.
    • Do not put your hands into the openings of the HV battery.
      GTY554551Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Opening
    • 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.
  2. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [10/2018 - 07/2022] 

  3. DISCONNECT ENGINE WIRE 

    See step  3

  4. REMOVE CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 12

  5. CHECK TERMINAL VOLTAGE 

    Refer to PROCEDURE - Step 13

  6. INSTALL CONNECTOR COVER ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. 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.

      GTY587646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt (A)
      *b Bolt (B)
    2. Install the bolt (B).

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

  7. CONNECT ENGINE WIRE 

    See step  29

  8. REMOVE BENCH TYPE REAR SEAT CUSHION ASSEMBLY 

    Refer to PROCEDURE - Step 6

  9. REMOVE REAR SEAT CUSHION LOCK HOOK 

    Refer to PROCEDURE - Step 9

  10. REMOVE REAR DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 28 [10/2018 - 10/2020] Refer to PROCEDURE - Step 28 [10/2020 - 07/2022]

  11. REMOVE REAR UNDER SIDE COVER LH 

    Refer to PROCEDURE - Step 30 [10/2018 - 10/2020] Refer to PROCEDURE - Step 30 [10/2020 - 07/2022]

  12. REMOVE REAR DOOR SCUFF PLATE RH 

    HINT: 

    Use the same procedure as for the LH side.

    Refer to PROCEDURE - Step 29 [10/2018 - 10/2020] Refer to PROCEDURE - Step 29 [10/2020 - 07/2022]

  13. REMOVE REAR UNDER SIDE COVER RH 

    HINT: 

    Use the same procedure as for the LH side.

    Refer to PROCEDURE - Step 31 [10/2018 - 10/2020] Refer to PROCEDURE - Step 31 [10/2020 - 07/2022]

  14. REMOVE REAR UNDER COVER 
    1. Disengage the 2 clips.
      GTY778699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 guides to remove the rear under cover from the rear seat cushion leg sub-assembly.
  15. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY 
    1. Remove the 6 bolts and rear seat cushion leg sub-assembly.
      GTY780012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE BATTERY COOLING BLOWER ASSEMBLY 

    See step  9

  17. REMOVE NO. 1 HV BATTERY COVER PANEL RH 
    WARNING:

    Wear insulated gloves.

    1. Using the service plug grip, remove the battery cover lock striker.
      GTY601981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Service Plug Grip
      *2 Battery Cover Lock Striker
      *a Projection
      *b Turn
      *c Button

      HINT: 

      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 3 bolts, 2 nuts and No. 1 HV battery cover panel RH from the HV battery.
  18. DISCONNECT FLOOR UNDER WIRE 
    WARNING:

    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. Disconnect the 2 HV battery junction block assembly connectors.
      GTY584848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Shield Ground
    2. Disconnect the shield ground from the HV battery.
  19. DISCONNECT FLOOR WIRE 
    WARNING:

    Wear insulated gloves.

    1. Disengage the clamp.
      GTY551784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the electric vehicle battery plug assembly connector.
    3. Disconnect the HV battery junction block assembly connector.
  20. REMOVE NO. 1 HV BATTERY PROTECTOR 
    1. Remove the clip and No. 1 HV battery protector from the HV battery.
      GTY778689Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. DISCONNECT FLOOR WIRE 
    WARNING:

    Wear insulated gloves.

    1. Disengage the clamp.
      GTY828066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the battery voltage sensor connector.
  22. REMOVE HV BATTERY 
    WARNING:

    Wear insulated gloves.

    1. Remove the 3 bolts and rear floor side rail sub-assembly LH.
      GTY781923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
      • If the HV battery has been struck or dropped, replace it.
    2. Remove the 4 bolts and HV battery from the vehicle.
      GTY781925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
  23. REMOVE UPPER HV BATTERY COVER SUB-ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    1. Remove the 7 bolts, 6 nuts and upper HV battery cover sub-assembly from the HV battery.
      GTY803568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt
      *b Nut
  24. REMOVE NO. 1 HV BATTERY SHIELD PANEL 

    Refer to PROCEDURE - Step 23

  25. REMOVE BATTERY VOLTAGE SENSOR 

    Refer to PROCEDURE - Step 24

  26. REMOVE HYBRID BATTERY TERMINAL BLOCK 

    See step  24

  27. REMOVE NO. 1 HYBRID BATTERY PACKING 
    1. Disengage the 2 claws and remove the No. 1hybrid battery packing from the HV battery.
      GTY808889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY 

    See step  24

  29. REMOVE NO. 1 HYBRID BATTERY SHIELD SUB-ASSEMBLY 

    See step  3

  30. REMOVE NO. 1 HV BATTERY COVER INTAKE DUCT 

    See step  4

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