HV Battery: Removal

CAUTION:

When working on the high voltage systems, always wear insulating gloves.
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 power switch as it may damage the hybrid vehicle control ECU.

PRECAUTION
CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/removal, inspection and replacement of parts), be sure to follow the procedures (see PRECAUTION ).
REMOVE REAR NO. 2 FLOOR BOARD (See REMOVAL )
REMOVE REAR DECK FLOOR BOX (See REMOVAL )
REMOVE REAR NO. 3 FLOOR BOARD (See REMOVAL )
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
REMOVE SERVICE PLUG GRIP (See REMOVAL )
REMOVE REAR DECK TRIM COVER
1. Detach the 4 clips shown in the illustration, then remove the deck trim cover.
  
  Fig 1: Detaching Deck Trim Cover Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TONNEAU COVER
1. Remove the tonneau cover from the vehicle.
  
  Fig 2: Removing Tonneau Cover From Vehicle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR SEAT CUSHION ASSEMBLY
1. Undo the 2 joints shown in the illustration, then remove the rear seat cushion.
  
  Fig 3: Removing Rear Seat Cushion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR NO. 1 FLOOR BOARD
1. Remove the 2 bolts and luggage hold belt strikers.
2. Remove the 5 clips shown in the illustration and the rear floor board.
  
  Fig 4: Removing Rear Floor Board And Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR SIDE SEAT BACK FRAME LH
1. Remove the bolt from the rear side seat back frame LH.
2. Undo the 3 joints, then remove the rear side seat back frame LH.
  
  Fig 5: Removing Rear Side Seat Back Frame LH And Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR SIDE SEAT BACK FRAME RH
1. Remove the bolt from the rear side seat back frame RH.
2. Undo the 4 joints, then remove the rear side seat back frame RH.
  
  Fig 6: Removing Rear Side Seat Back Frame RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR NO. 4 FLOOR BOARD
1. While lifting up the rear floor board as shown in the illustration, undo the 2 joints and remove the rear floor board.
  
  Fig 7: Lifting Up Rear Floor Board
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DECK FLOOR BOX LH
1. Remove the clip and deck floor box LH.
REMOVE DECK TRIM SIDE PANEL LH
1. Remove the bolt and luggage hold belt striker.
  
  Fig 8: Removing Clip And Deck Floor Box LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 bolts from the deck trim side panel LH.
3. Remove the clip from the deck trim side panel LH.
4. Undo the 8 clips, then pull out a part of the weather strip and remove the deck trim side panel LH.
5. Disconnect the lighting connector.
REMOVE DECK TRIM SIDE PANEL RH
1. Remove the bolt and luggage hold belt striker.
  
  Fig 9: Removing Clip From Deck Trim Side Panel LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 bolts from the deck trim side panel RH.
3. Remove the clip from the deck trim side panel RH.
4. Undo the 7 clips, then pull out a part of the weather strip and remove the deck trim side panel RH.
  
  Fig 10: Removing Clip From Deck Trim Side Panel RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BATTERY CARRIER BRACKET
1. Remove the 7 bolts and battery carrier bracket.
  
  Fig 11: Removing Battery Carrier Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 QUARTER VENT DUCT INNER
1. Disconnect the clamp and No. 1 battery blower relay.
2. Remove the 2 clips.
3. Slide the vent duct to the battery side, then remove it.
  
  Fig 12: Removing Quarter Vent Duct Inner
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BATTERY BRACKET REINFORCEMENT
1. Remove the 7 bolts and battery bracket reinforcement.
  
  Fig 13: Removing Battery Bracket Reinforcement
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE QUARTER VENT DUCT
1. Disconnect the connector.
2. Remove the clamp, then disconnect the wire harness.
3. Remove the bolt, clip and quarter vent duct.
  
  Fig 14: Removing Quarter Vent Duct
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 6 BATTERY CARRIER PANEL
1. Remove the 3 bolts, 2 nuts and battery carrier panel.
  
  Fig 15: Removing Battery Carrier Panel
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE JUNCTION TERMINAL
CAUTION: Wear insulating gloves.

Fig 16: Removing Junction Terminal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRAME WIRE
CAUTION:
- Wear insulating gloves.
- Insulate the removed terminals with insulating tape.
1. Remove the 2 nuts, then disconnect the frame wire from the No. 2 and No. 3 system main relay.
  
  Fig 17: Removing Frame Wire
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE HV BATTERY ASSEMBLY
1. Remove the earth bolt and 4 bolts shown in the illustration.
  
  Fig 18: Removing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the system main relay connector.
  CAUTION: Wear insulating gloves.
3. Disconnect the interlock connector.
  CAUTION: Wear insulating gloves.
4. Remove the clamp, then disconnect the battery ECU connector.
  CAUTION: Wear insulating gloves.
  
  Fig 19: Disconnecting System Main Relay Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Disconnect the battery room ventilation hose from the floor panel.
  CAUTION: Wear insulating gloves.
6. Remove the HV battery.
  CAUTION: Wear insulating gloves.
  
  Fig 20: Disconnecting Battery Room Ventilation Hose From Floor Panel
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002