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HV Battery: Removal

  1. PRECAUTION 

    (See PRECAUTION )

  2. READ OUTPUT DTC 
    1. Check the DTC.
      NOTE: Check the DTC, and confirm that P0AA6 (High voltage insulation is unusual) is not output before doing removal or installation work inside the battery. If the DTC is output, perform troubleshooting procedures first.
  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  4. REMOVE SERVICE PLUG GRIP 
    CAUTION:
    • Remove the service plug to interrupt a high voltage circuit at the time of the check.
    • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle.
    • All the high voltage wiring connectors are colored in orange.
    1. Remove the 2 clips and door scuff plate LH.
    2. Remove the 2 clips and reclining hinge cover.
    3. Wear insulation glove, and remove the service plug grip, after sliding up the lever of the service plug grip.
      Fig 1: Identifying Clips On Service Plug Grip
      G05201983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      CAUTION:
      • 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 ignition switch as it may damage the hybrid vehicle control ECU.
  5. REMOVE RECLINING HINGE COVER LH (w/ Rear No. 2 Seat)  (See REMOVAL )
  6. REMOVE REAR SEAT TRACK BRACKET COVER OUTER (w/ Rear No. 2 Seat)  (See REMOVAL )
  7. REMOVE REAR SEAT TRACK COVER LH (w/ Rear No. 2 Seat)  (See REMOVAL )
  8. REMOVE REAR SEAT TRACK BRACKET COVER INNER LH (w/ Rear No. 2 Seat)  (See REMOVAL )
  9. REMOVE SEAT TRACK COVER INNER LH (w/ Rear No. 2 Seat)  (See REMOVAL )
  10. REMOVE REAR NO. 1 SEAT ASSEMBLY LH (w/ Rear No. 2 Seat)  (See REMOVAL )
  11. REMOVE REAR SEAT TRACK BRACKET COVER OUTER (w/ Rear No. 2 Seat)  (See REMOVAL )
  12. REMOVE REAR SEAT TRACK COVER RH (w/ Rear No. 2 Seat)  (See REMOVAL )
  13. REMOVE REAR SEAT TRACK BRACKET COVER INNER RH (w/ Rear No. 2 Seat)  (See REMOVAL )
  14. REMOVE SEAT TRACK INNER COVER RH (w/ Rear No. 2 Seat)  (See REMOVAL )
  15. REMOVE REAR NO. 1 SEAT ASSEMBLY RH (w/ Rear No. 2 Seat)  (See REMOVAL )
  16. REMOVE REAR SEAT TRACK BRACKET COVER OUTER (w/o Rear No. 2 Seat)  (See REMOVAL )
  17. REMOVE REAR SEAT TRACK BRACKET COVER OUTER (w/o Rear No. 2 Seat)  (See REMOVAL )
  18. REMOVE REAR NO. 1 SEAT ASSEMBLY RH (w/o Rear No. 2 Seat)  (See REMOVAL )
  19. REMOVE REAR SEAT TRACK BRACKET COVER OUTER (w/o Rear No. 2 Seat)  (See REMOVAL )
  20. REMOVE REAR SEAT TRACK BRACKET COVER OUTER (w/o Rear No. 2 Seat)  (See REMOVAL )
  21. REMOVE REAR NO. 1 SEAT ASSEMBLY LH (w/o Rear No. 2 Seat)  (See REMOVAL )
  22. REMOVE TONNEAU COVER ASSEMBLY 
  23. REMOVE DECK BOARD SUB-ASSEMBLY (w/ Rear No. 2 Seat)  (See REMOVAL )
  24. REMOVE DECK BOARD SUB-ASSEMBLY (w/o Rear No. 2 Seat)  (See REMOVAL )
  25. REMOVE DECK BOARD SUB-ASSEMBLY NO.3 
  26. REMOVE DECK BOARD SUB-ASSEMBLY NO.2 
  27. REMOVE DECK FLOOR BOX REAR  (See REMOVAL )
  28. REMOVE DECK FLOOR BOX FRONT (w/o Rear No. 2 Seat)  (See REMOVAL )
  29. REMOVE REAR FLOOR FINISH PLATE  (See REMOVAL )
  30. REMOVE BACK DOOR WEATHERSTRIP 
  31. REMOVE REAR SEAT RECLINING COVER NO.2 LH (w/ Rear No. 2 Seat)  (See REMOVAL )
  32. REMOVE REAR SEAT RECLINING COVER NO.2 RH (w/ Rear No. 2 Seat) 
  33. REMOVE JACK CARRIER ASSEMBLY  (See REMOVAL )
  34. REMOVE DECK SIDE TRIM BOX LH  (See REMOVAL )
  35. REMOVE DECK SIDE TRIM BOX RH 
  36. REMOVE REAR DOOR SCUFF PLATE LH (w/ Rear No. 2 Seat)  (See REMOVAL )
  37. REMOVE REAR DOOR SCUFF PLATE LH (w/o Rear No. 2 Seat)  (See REMOVAL )
  38. REMOVE REAR DOOR SCUFF PLATE RH 
  39. REMOVE DECK SIDE TRIM COVER LH (w/ Rear No. 2 Seat)  (See REMOVAL )
  40. REMOVE DECK SIDE TRIM COVER LH (w/o Rear No. 2 Seat)  (See REMOVAL )
  41. REMOVE DECK SIDE TRIM COVER RH 
  42. REMOVE REAR NO.1 SEAT BELT ASSEMBLY OUTER LH  (See REMOVAL )
  43. REMOVE REAR NO.1 SEAT BELT ASSEMBLY OUTER RH 
  44. REMOVE ROPE HOOK  (See REMOVAL )
  45. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH  (See REMOVAL )
  46. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH 
  47. REMOVE AIR INTAKE COVER 
    1. Remove the air intake cover LH.
      1. Release the claw by using the screwdriver with the tip taped, and remove the 2 hole covers.
        Fig 2: Releasing Claw By Using Screwdriver
        G05201984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Remove the 2 screws, then release the 2 claws and remove air intake cover LH.
        Fig 3: Identifying Air Intake Cover LH
        G05201985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the air intake cover RH.
      1. Release the claw by using the screwdriver with the tip taped, and remove the 2 hole covers.
        Fig 4: Releasing Claw By Using Screwdriver
        G05201986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Remove the 2 screws, then release the 2 claws and remove air intake cover RH.
        Fig 5: Identifying Air Intake Cover RH
        G05201987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE AIR INTAKE COVER CENTER 
    1. Release the claw by using the screwdriver with the tip taped, and remove the 2 hole covers.
      Fig 6: Removing Claw Using Screwdriver
      G05201988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 screws, then release the 2 claws and remove air intake cover center.
      3. Fig 7: Locating Air Intake Cover
      G05201989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. SEPARATE FLOOR CARPET ASSEMBLY FRONT 
    1. Turn back the front floor carpet assembly.
  50. REMOVE FLOOR BOARD NO.1 
    1. Remove the floor board No.1.
      Fig 8: Identifying Floor Board No.1
      G05201990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE FLOOR BOARD NO.2 
    1. Remove the floor board No.2.
      Fig 9: Identifying Floor Board No.2
      G05201991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. REMOVE FLOOR BOARD NO.3 
    1. Remove the floor board No.3.
      Fig 10: Identifying Floor Board No.3
      G05201992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE REAR CENTER SEAT INNER BELT ASSEMBLY  (See REMOVAL )
  54. REMOVE BATTERY CARRIER DUCT 
    1. Remove the 2 bolts and battery carrier duct (LH).
      Fig 11: Locating Battery Carrier Duct (LH)
      G05201993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and battery carrier duct (CTR).
      Fig 12: Locating Battery Carrier Duct With Bolts (CTR)
      G05201994Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and battery carrier duct (RH).
      Fig 13: Locating Battery Carrier Duct With Bolts (RH)
      G05201995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. REMOVE HV BATTERY SERVICE HOLE COVER 
    1. Using the service plug grip, remove the battery cover lock striker.

      HINT:

      Insert the projection part of the service plug grip, and turn the button of the battery cover lock striker counterclockwise, and release the lock.

    2. Remove the 2 bolts and battery service hole cover.
      3. Fig 14: Locating Battery Service Hole Cover Striker
      G05201996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. REMOVE BATTERY COVER SUB-ASSEMBLY 
    CAUTION: Wear insulating gloves.
    1. Remove the bolt, then disconnect the No.3 wire frame.
      Fig 15: Locating No 3 Wire Frame With Bolt
      G05201801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using the service plug grip, remove the battery cover lock striker.
      Fig 16: Locating Battery Cover Lock Striker With Bolts
      G05201998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Insert the projection part of the service plug grip, and turn the button of the battery cover lock striker counterclockwise, and release the lock.

    3. Remove the 28 bolts, 6 nuts and battery cover.
  57. REMOVE BATTERY SMART UNIT (See  REMOVAL  ) 
  58. REMOVE HV BATTERY 
    CAUTION: Wear insulating gloves and protective glasses.
    NOTE: Insulate the removed terminals with insulating tape.
    1. Remove the HV battery LH.
      1. Remove the battery room ventilation hose between the HV batteries LH and CTR.
        Fig 17: Locating Battery Room Ventilation Hose
        G05201999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disconnect the wire harness clamp of the battery thermo sensor.
        Fig 18: Locating Wire Harness Clamp
        G05202000Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Remove the nut and main battery cable from the HV battery LH.
        NOTE:
        • Insulate the tool with insulating tape.
        • Do not use the universal joint.
          Fig 19: Removing Main Battery Cable From HV Battery
          G05202001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Remove the nut, then disconnect the EV battery plug from the HV battery.
        NOTE:
        • Insulate the tool with insulating tape.
        • Do not use the universal joint.
          Fig 20: Locating EV Battery Plug
          G05202002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Remove the HV battery LH.
        Fig 21: Locating HV Battery LH
        G05202003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the HV battery CTR.
      1. Disconnect the 2 connectors from the HV relay assembly.
        Fig 22: Locating HV Relay Connector
        G05202004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disconnect the 2 connectors and clamp.
        Fig 23: Locating Connectors Clamp
        G05202005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Remove the battery room ventilation hose between the HV batteries CTR and RH.
        Fig 24: Locating Battery Room Ventilation Hose
        G05202006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Remove the HV battery CTR.
        Fig 25: Removing HV Battery CTR
        G05202007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the HV battery RH
      1. Disconnect the 2 clamps.
        Fig 26: Locating Clamps
        G05202008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Remove the nut, then disconnect the main battery cable connector.
        Fig 27: Locating Main Battery Cable
        G05202009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Disconnect the clamp.
        Fig 28: Locating Clamp
        G05202010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Remove the battery room ventilation hose.
        Fig 29: Locating Battery Room Ventilation Hose
        G05202011Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Remove the HV battery RH.
        Fig 30: Removing HV Battery RH
        G05202012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      6. Remove the nut and main battery cable No.2 from the HV battery RH.
        Fig 31: Locating Main Battery Cable No 2 Nut
        G05202013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      7. Remove the nut and main battery cable from the HV battery RH.
        Fig 32: Locating Main Battery Cable From HV Battery RH
        G05202014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE BATTERY COOLING BLOWER ASSEMBLY 

    HINT:

    Exchange the HV battery lower case as a set when liquids collect at the HV battery lower case and powder sticks.

    1. Disconnect each battery cooling blower assembly connector and clamp.
      Fig 33: Locating Battery Cooling Blower Assembly Connector And Clamp
      G05202015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 9nuts and 3 battery cooling blower assemblies.
      Fig 34: Identifying Battery Cooling Blower Assemblies With Nuts
      G05202016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. REMOVE ELECTRIC VEHICLE BATTERY PLUG ASSEMBLY 
    1. Disconnect the connector and clamps.
      Fig 35: Locating Connector And Clamps
      G05202017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts, nut and EV battery plug.
      Fig 36: Locating Electric Vehicle Battery Plug Assembly
      G05202018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. REMOVE HYBRID VEHICLE RELAY ASSEMBLY (See  REMOVAL  ) 
  62. REMOVE HV BATTERY SERVICE HOLE COVER 
    1. Disconnect the connector and clamp, then remove the HV battery lower case.
      Fig 37: Identifying HV Battery Service Hole Cover
      G05202019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. REMOVE BATTERY COVER 
    1. Remove the battery cover from the HV battery lower case.
      Fig 38: Locating Battery Cover
      G05202020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. REMOVE BATTERY PACKING NO.2 
    1. Remove the battery packing No.2 from the HV battery lower case.
      Fig 39: Removing Battery Packing No 2 From HV Battery Lower Case
      G05202021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. REMOVE BATTERY PACK WIRE 
    1. Disconnect the clamp, then remove the battery pack wire from the HV battery lower case.
      Fig 40: Locating Battery Pack Wire Connector
      G05202022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 2 clamps, then remove the battery pack wire from the HV battery lower case.
      Fig 41: Locating Battery Pack Wire Clamps
      G05202023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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