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Airtight Inspection [12/2023 - ]: Procedure

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  1. CHECK FOR AIRTIGHTNESS (COMPONENT) 
    1. Using SST, cover each of the connector portions.
      GTY1000742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09893-42020 

      Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

    2. Remove the No. 2 traction battery cover cap that was removed from the vehicle.
      GTY999209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install SST to the No. 2 traction battery cover with the wing bolt as shown in the illustration.
      GTY999669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wing Bolt
      • SST: 09893-10010 
    4. Install the No. 2 traction battery cover to the HV supply battery sub-assembly with the 4 bolts.

      Torque: 12.2 N.m (124 kgf/cm, 9 ft.lbf) 

      NOTE:
      • If the No. 1 hybrid battery seal is stuck to the No. 2 traction battery cover mounting surface, remove it cleanly and clean it.
      • Visually check the mounting surface of the No. 2 traction battery cover for foreign matter and dust before mounting.
      • Do not use compressed air or solvents to clean.

      HINT: 

      When checking airtightness, the No. 1 hybrid battery seal can be reused.

    5. Pump the pump as shown in the illustration until SST gauge pressure becomes 2.0 kPa.
      GTY999217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      The pressure should reach 2.0 kPa after approximately 20 pumps.

    6. Close the valve, wait 20 minutes, and then check that the gauge pressure has not decreased by more than the specified value.
      GTY999991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Valve Open
      *b Valve Close
      *c Power Button

      OK

      After waiting for 20 minutes, pressure has not decreased by 0.1 kPa or more.

      HINT: 

      • If the gauge pressure display has disappeared, press the power button and check the gauge pressure.
      • If the pressure has decreased, apply soapy water to the areas shown in the illustration to identify the location of the leak
        GTY1001042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Apply Area - -
    7. Remove the 4 bolts and No. 2 traction battery cover from the HV supply battery sub-assembly.
    8. Remove the wing bolt and SST from the No. 2 traction battery cover.
  2. CHECK FOR AIRTIGHTNESS (ON-VEHICLE) 
    1. Remove the service plug grip.

      Refer to REMOVAL [12/2023 - ]

    2. Check the terminal voltage.
      1. Remove the No. 2 inverter protector.

        Refer to PROCEDURE - Step 6

      2. Check the terminal voltage.

        Refer to PROCEDURE - Step 7

      3. Install the No. 2 inverter protector.

        Refer to PROCEDURE - Step 19

    3. Remove the rear engine under cover RH.

      Refer to PROCEDURE - Step 11

    4. Remove the front floor cover LH.

      Refer to PROCEDURE - Step 14

    5. Remove the No. 2 floor under cover.

      See step  10

    6. Remove the front floor cover RH.

      Refer to PROCEDURE - Step 15

    7. Remove the engine under cover heat insulator.

      See step  12

    8. Disconnect the floor under wire.

      See step  17

    9. Disconnect the No. 2 traction battery wire.

      See step  18

    10. Connect SST to the disconnected openings of the wire harness, HV floor under wire and HV battery charger wire, and cover them with SST.
      GTY1001217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09893-42020 

      Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

    11. Remove the No. 2 traction battery cover cap that was removed from the vehicle.
      GTY999209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Install SST to the No. 2 traction battery cover with the wing bolt as shown in the illustration.
      GTY999669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wing Bolt
      • SST: 09893-10010 
    13. Install the No. 2 traction battery cover to the HV supply battery sub-assembly with the 4 bolts.

      Torque: 12.2 N.m (124 kgf/cm, 9 ft.lbf) 

      NOTE:
      • If the No. 1 hybrid battery seal is stuck to the No. 2 traction battery cover mounting surface, remove it cleanly and clean it.
      • Visually check the mounting surface of the No. 2 traction battery cover for foreign matter and dust before mounting.
      • Do not use compressed air or solvents to clean.

      HINT: 

      When checking airtightness, the No. 1 hybrid battery seal can be reused.

    14. Pump the pump as shown in the illustration until SST gauge pressure becomes 2.0 kPa.
      GTY1080513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      The pressure should reach 2.0 kPa after approximately 20 pumps.

    15. When the gauge pressure reaches 2.0 kPa, close the valve.
      GTY999991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Valve Open
      *b Valve Close
    16. Leave the vehicle for 20 minutes, then check that the gauge pressure has not decreased by more than the specified value.

      OK

      After waiting for 20 minutes, pressure has not decreased by 0.1 kPa or more.

      HINT: 

      If the result is not as specified, replace the HV supply battery assembly.

    17. Remove the 4 bolts and No. 2 traction battery cover from the HV supply battery sub-assembly.
    18. Remove the wing bolt and SST from the No. 2 traction battery cover.
    19. Install the cap to the No. 2 traction battery cover.
    20. Connect the No. 2 traction battery wire.

      See step  3

    21. Connect the floor under wire.

      See step  4

    22. Install the engine under cover heat insulator.

      See step  9

    23. Install the front floor cover RH.

      Refer to PROCEDURE - Step 76

    24. Install the No. 2 floor under cover.

      See step  11

    25. Install the front floor cover LH.

      Refer to PROCEDURE - Step 75

    26. Install the rear engine under cover RH.

      Refer to PROCEDURE - Step 80

    27. Install the service plug grip.

      Refer to INSTALLATION [12/2023 - ]

    28. Install a new No. 2 traction battery cover with the 4 bolts.

      Torque: 12.2 N.m (124 kgf/cm, 9 ft.lbf) 

      NOTE:
      • If the No. 1 hybrid battery seal is stuck to the No. 2 traction battery cover mounting surface, remove it cleanly and clean it.
      • Visually check the mounting surface of the No. 2 traction battery cover for foreign matter and dust before mounting.
      • Do not use compressed air or solvents to clean.
    29. Install the rear floor service hole cover.

      Refer to PROCEDURE - Step 5

    30. Install the battery service hole cover.

      Refer to PROCEDURE - Step 6

    31. Connect cable to negative auxiliary battery terminal.

      Refer to PROCEDURE - Step 7

    32. Perform high voltage fuse accumulated load history reset.

      Refer to UTILITY [09/2023 - ]

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