Precaution [12/2023 - ]

1. Before the following operations are conducted, take precautions to prevent electric shock by turning the ignition switch off, wearing insulated gloves, and removing the service plug grip from HV battery.

   Refer to REMOVAL [12/2023 - ]

   Fig 1: Wear Insulated Gloves

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • Inspecting the high-voltage system
   • Disconnecting the low voltage connector of the hybrid motor control inverter assembly
   • Disconnecting the low voltage connector of the HV battery
   • Disconnecting the low voltage connector of the electric vehicle charger assembly
   • Disconnecting the low voltage connector of the voltage inverter

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   After removing the service plug grip, turning the ignition switch to ON (READY) may cause a malfunction. Do not turn the ignition switch to ON (READY) unless instructed by the repair Service Information.

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 2: 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 3: 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 hybrid motor control inverter assembly and the electric vehicle charger assembly.

   Fig 4: 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 of the hybrid motor control inverter assembly.
   WARNING:

   Be sure to wear insulated gloves.

   1. Remove the connector cover assembly from the hybrid motor control inverter assembly.

      Refer to REMOVAL [12/2023 - ]

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      NOTE:

      • Do not touch the connector cover assembly waterproof seal.
      • Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
   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: 

      Make sure to set the tester to DC750 V or more when measuring the voltage.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   3. Reinstall the connector cover assembly.
6. Check the voltage at the terminals in the inspection point of the rear transaxle with motor and inverter assembly.
   WARNING:

   Be sure to wear insulated gloves.

   1. Remove the upper inverter cover sub-assembly from the rear transaxle with motor and inverter assembly.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to REMOVAL [12/2023 - ]

      NOTE:

      • Pull up vertically because the upper inverter cover sub-assembly is equipped with an interlock connector.
      • Do not touch the upper inverter cover sub-assembly waterproof seal.
      • Do not allow any foreign matter or water to enter the rear transaxle with motor and inverter assembly.
   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.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

7. 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 5: Do Not Service The Vehicle Before Disconnecting The Negative Battery Terminal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Turn the ignition 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.
9. Turn the ignition switch off before performing any resistance checks.
10. Turn the ignition switch off before disconnecting or reconnecting any connectors.
11. When performing work involving high-voltage wires, use either a tool wrapped with vinyl insulating tape or an insulated tool.
12. When high-voltage connectors are removed, wrap the connectors with vinyl insulating tape to prevent foreign matter or water from entering them.

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

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 luggage room relay block and No. 1 junction block assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	AMD Terminal (DC/DC Converter Assembly Side)

2. After disconnecting the AMD terminal, wrap it with vinyl insulating tape.
3. Be sure to reconnect the AMD terminal to the No. 1 luggage room relay block and No. 1 junction block assembly before reconnecting the cable to the negative (-) terminal of the auxiliary battery.
   NOTE:

   A short to ground may occur if the AMD terminal is disconnected before the cable is disconnected from the negative (-) auxiliary battery terminal. If a short to ground occurs, a fusible link or fuse may break.

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:

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

     Refer to RECOVERY INSPECTION [12/2023 - ]

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

     Refer to RECOVERY INSPECTION [12/2023 - ]

   • After removing the HV battery or the HV supply stack sub-assembly, keep it away from water. Exposure to water may cause the HV battery or the HV supply stack sub-assembly to produce heat, resulting in a fire.
     Fig 6: Do Not Expose HV Battery To Moisture

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • Accidents such as electric shock may result if the HV battery or the HV supply stack sub-assembly is disposed of improperly or abandoned.
     Fig 7: HV Supply Stack Improper Disposal Warning

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

     *a	Dealer
     *b	Battery Collection Agent

     Therefore, make sure to return HV battery and all HV supply stack sub-assemblies through an authorized collection agent.

   • To reduce the risk of fire, HV battery or HV supply stack sub-assemblies must not be stored in an area where they will be exposed to fire or high temperatures.
   • If the temperature of the HV battery and HV supply stack sub-assembly is high, leave the vehicle until the temperature drops.
   • Make sure to insulate the high-voltage connectors and terminals of the HV battery or HV supply stack sub-assemblies with insulating tape after removing them.

     If the HV battery is stored without insulating the connectors and terminals, electric shock or fire may result.

1. When the hybrid vehicle control ECU assembly is replaced, perform the ECU configuration.

   Refer to ECU CONFIGURATION [09/2023 - ]

2. When the hybrid vehicle control ECU assembly is replaced, update the ECU security key.

   Refer to UPDATE ECU SECURITY KEY [09/2023 - ]

3. Before replacing the hybrid vehicle control ECU assembly, refer to Registration.

   Refer to REGISTRATION [09/2023 - ]

HV battery learning values are stored in the battery ECU assembly and ECM to display "Maintenance Required for Traction Battery at Your Dealer" 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 ignition switch to ON (READY) and wait for 5 minutes or more.
   5. Turn the ignition switch off and wait for 1 minute or more.
   6. Disconnect the cable from the negative (-) auxiliary battery terminal.
   7. Replace the other ECU.
   8. Connect the cable to the negative (-) auxiliary battery terminal.
   9. Check that the ignition switch can be turned to 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 8: 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 ignition 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:

   • To prevent the key from being locked in the vehicle, make sure to enter e-latch inspection mode and enable the manual release handle before disconnecting the cable from the negative (-) auxiliary battery terminal.

     Refer to INSPECTION MODE PROCEDURE [09/2023 - ]

   • After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

     Refer to BEFORE DISCONNECTING BATTERY [09/2023 - ]

   • When disconnecting and reconnecting the auxiliary battery.

     Refer to WORK PROCEDURE [09/2023 - ]

     HINT: 

     When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

     Refer to AUTOMATIC LEARNING CHART [09/2023 - ]