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Home >> Toyota >> 2016 >> Prius Two >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Battery Management Systems >> Hybrid Battery Control System - Service Information (2 Of 3) >> HV BATTERY (for LITHIUM-ION BATTERY) >> Removal [11/2015 - 12/2018] >> Procedure

Removal [11/2015 - 12/2018]: Procedure

  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 [11/2015 - 11/2017] , or refer to PRECAUTION [11/2017 - 12/2018]

    • 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 [11/2015 - 11/2017] , or refer to INITIALIZATION [11/2017 - 12/2018]

    • 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.
      GTY551799Courtesy 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.
      GTY546125Courtesy 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. READ VALUE USING TECHSTREAM 
    1. Connect the Techstream to the DLC3.
    2. Turn the power switch on (IG).
    3. Enter the following menus: Powertrain / HV Battery / Data List / Hybrid Battery Temperature 1 to 6.

      Powertrain > HV Battery > Data List 

      Tester Display
      Hybrid Battery Temperature 1
      Hybrid Battery Temperature 2
      Hybrid Battery Temperature 3
      Hybrid Battery Temperature 4
      Hybrid Battery Temperature 5
      Hybrid Battery Temperature 6
    4. Read the Data List.
      NOTE:

      If any of the temperatures listed in "Hybrid Battery Temperature 1 to 6" are 50°C or more, leave the vehicle until the temperature drops to less than 50°C.

  3. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [11/2015 - 12/2018]

  4. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [11/2015 - ]

  5. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL 

    Refer to PROCEDURE - Step 3

  6. REMOVE WATER GUARD PLATE LH 

    Refer to PROCEDURE - Step 4

  7. REMOVE COWL BODY MOUNTING REINFORCEMENT LH 

    Refer to PROCEDURE - Step 5

  8. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  9. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 13 [11/2015 - 08/2016] , or refer to PROCEDURE - Step 13 [08/2016 - 12/2018]

  10. DISCONNECT ENGINE WIRE 

    See step  9

  11. REMOVE CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 16

  12. CHECK TERMINAL VOLTAGE 

    Refer to PROCEDURE - Step 17

  13. 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.

      GTY608505Courtesy 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) 

  14. CONNECT ENGINE WIRE 

    Refer to PROCEDURE - Step 17

  15. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 72 [11/2015 - 08/2016] , or refer to PROCEDURE - Step 72 [08/2016 - 12/2018]

  16. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 14

  17. INSTALL COWL BODY MOUNTING REINFORCEMENT LH 

    Refer to PROCEDURE - Step 15

  18. INSTALL WATER GUARD PLATE LH 

    Refer to PROCEDURE - Step 16

  19. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL 

    Refer to PROCEDURE - Step 17

  20. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to INSTALLATION [11/2015 - ]

  21. REMOVE REAR SEAT CUSHION ASSEMBLY 

    Refer to PROCEDURE - Step 7

  22. REMOVE REAR SEAT CUSHION LOCK HOOK 

    Refer to PROCEDURE - Step 8

  23. REMOVE REAR DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 18

  24. REMOVE REAR UNDER SIDE COVER LH 

    Refer to PROCEDURE - Step 35

  25. REMOVE REAR DOOR SCUFF PLATE RH 

    HINT: 

    Use the same procedure as for the LH side.

  26. REMOVE REAR UNDER SIDE COVER RH 

    HINT: 

    Use the same procedure as for the LH side.

  27. REMOVE REAR UNDER COVER 
    1. Disengage the 2 clips.
      GTY551772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 guides to remove the rear under cover from the rear seat cushion leg sub-assembly.
  28. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY 
    1. Remove the 9 bolts and rear seat cushion leg sub-assembly.
      GTY551774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE BATTERY COOLING BLOWER ASSEMBLY 

    Refer to PROCEDURE - Step 9

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

    Wear insulated gloves.

    1. Using the service plug grip, remove the battery cover lock striker.
      GTY575331Courtesy 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 2 bolts, 3 nuts and No. 1 HV battery cover panel RH from the HV battery.
  31. DISCONNECT HV 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.
      GTY591779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Shield Ground
    2. Disconnect the shield ground from the HV battery.
  32. DISCONNECT FLOOR WIRE 
    WARNING:

    Wear insulated gloves.

    1. Disengage the clamp.
      GTY551785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the electric vehicle battery plug assembly connector.
    3. Disconnect the HV battery junction block assembly connector.
  33. REMOVE HYBRID BATTERY HOSE ASSEMBLY 
    1. Disconnect the hybrid battery hose assembly from the vehicle.
      GTY600446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 claws to remove the hybrid battery hose assembly from the HV battery.
  34. REMOVE NO. 4 HV BATTERY PROTECTOR 
    1. Disengage the 2 claws to remove the No. 4 HV battery protector from the HV battery.
      GTY551783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. DISCONNECT FLOOR WIRE 
    WARNING:

    Wear insulated gloves.

    1. Disengage the clamp.
      GTY551776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the HV battery connector.
  36. REMOVE HV BATTERY 
    WARNING:

    Wear insulated gloves.

    1. Remove the 4 bolts and HV battery from the vehicle.
      GTY563777Courtesy 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.
  37. PERFORM RECOVERY INSPECTION 
    1. Before returning the HV battery, make sure to perform a recovery inspection.

      Refer to RECOVERY INSPECTION [11/2015 - ] 

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