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Removal [07/2020 - ]: 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 [08/2019 - ]

  2. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [07/2020 - ] 

  3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [11/2015 - ]

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

    Refer to PROCEDURE - Step 3

  5. REMOVE WATER GUARD PLATE LH 

    Refer to PROCEDURE - Step 4

  6. REMOVE COWL BODY MOUNTING REINFORCEMENT LH 

    Refer to PROCEDURE - Step 5

  7. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  8. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 13

  9. DISCONNECT ENGINE WIRE 
    WARNING:

    Wear insulated gloves.

    NOTE:

    Do not allow any foreign matter or water to enter the inverter with converter assembly.

    1. Move each lock lever as shown in the illustration and disconnect the 2 inverter with converter assembly connectors.
      NOTE:
      • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
      • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
      • Insulate the disconnected terminals with insulating tape.
      • Do not touch the waterproof seal or terminals of the connector.
      GTY541775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt.
      GTY598509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the 2 clamps and disconnect the engine wire.
  10. REMOVE CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 16

  11. CHECK TERMINAL VOLTAGE 

    Refer to PROCEDURE - Step 17

  12. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 18

  13. DISCONNECT HV FLOOR UNDER WIRE 

    Refer to PROCEDURE - Step 19

  14. DISCONNECT REAR CENTER SEAT OUTER BELT ASSEMBLY 

    Refer to PROCEDURE - Step 4

  15. REMOVE REAR SEAT CUSHION ASSEMBLY 

    Refer to PROCEDURE - Step 7

  16. REMOVE REAR SEAT CUSHION LOCK HOOK 

    Refer to PROCEDURE - Step 8

  17. REMOVE REAR DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 23

  18. REMOVE REAR UNDER SIDE COVER LH 

    Refer to PROCEDURE - Step 40

  19. REMOVE REAR DOOR SCUFF PLATE RH 

    HINT: 

    Use the same procedure as for the LH side.

  20. REMOVE REAR UNDER SIDE COVER RH 

    HINT: 

    Use the same procedure as for the LH side.

  21. REMOVE REAR NO. 1 FLOOR BOARD (for NICKEL METAL HYDRIDE BATTERY) 

    Refer to PROCEDURE - Step 4

  22. REMOVE REAR DECK FLOOR BOX (for NICKEL METAL HYDRIDE BATTERY) 

    Refer to PROCEDURE - Step 13

  23. REMOVE INVERTER TERMINAL COVER (for NICKEL METAL HYDRIDE BATTERY) 

    Refer to PROCEDURE - Step 5

  24. CHECK TERMINAL VOLTAGE (for NICKEL METAL HYDRIDE BATTERY) 

    Refer to PROCEDURE - Step 6

  25. TEMPORARILY INSTALL INVERTER TERMINAL COVER (for NICKEL METAL HYDRIDE BATTERY) 

    Refer to PROCEDURE - Step 10

  26. REMOVE REAR SEAT HEADREST ASSEMBLY (for NICKEL METAL HYDRIDE BATTERY for RH Side) 

    HINT: 

    Use the same procedure as for the LH side.

    Refer to PROCEDURE - Step 2

  27. REMOVE REAR SEAT CENTER HEADREST ASSEMBLY (for NICKEL METAL HYDRIDE BATTERY) 

    Refer to PROCEDURE - Step 3

  28. REMOVE REAR SEATBACK ASSEMBLY RH (for NICKEL METAL HYDRIDE BATTERY) 

    Refer to PROCEDURE - Step 5

  29. REMOVE REAR SEATBACK HINGE SUB-ASSEMBLY RH (for NICKEL METAL HYDRIDE BATTERY) 

    HINT: 

    Use the same procedure as for the LH side.

    Refer to PROCEDURE - Step 41

  30. REMOVE REAR SEAT SIDE GARNISH RH (for NICKEL METAL HYDRIDE BATTERY) 

    HINT: 

    Use the same procedure as for the LH side.

    Refer to PROCEDURE - Step 43

  31. REMOVE REAR UNDER COVER 
  32. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY 
  33. REMOVE BATTERY COOLING BLOWER ASSEMBLY (for NICKEL METAL HYDRIDE BATTERY) 

    See step  9

  34. REMOVE NO. 1 HV BATTERY COVER PANEL RH 
  35. DISCONNECT WIRE HARNESS 
    WARNING:

    Wear insulated gloves.

    1. Disconnect the 2 HV battery junction block assembly connectors.
      GTY539027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for NICKEL METAL HYDRIDE BATTERY
      *B for LITHIUM-ION BATTERY
      *a Shield Ground
      NOTE:

      Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

    2. Disconnect the shield ground from the HV battery.
  36. REMOVE INVERTER TERMINAL COVER (for NICKEL METAL HYDRIDE BATTERY) 

    Refer to PROCEDURE - Step 5

  37. DISCONNECT HV FLOOR UNDER WIRE (for NICKEL METAL HYDRIDE BATTERY) 

    Refer to PROCEDURE - Step 7

  38. DISCONNECT HV BATTERY PACK WIRE (for NICKEL METAL HYDRIDE BATTERY) 

    Refer to PROCEDURE - Step 8

  39. TEMPORARILY INSTALL INVERTER TERMINAL COVER (for NICKEL METAL HYDRIDE BATTERY) 

    Refer to PROCEDURE - Step 10

  40. REMOVE NO. 1 FLOOR UNDER COVER ASSEMBLY 

    Refer to PROCEDURE - Step 4

  41. REMOVE FRONT FLOOR COVER RH 

    HINT: 

    Perform the same procedure as for the front floor cover LH.

    Refer to PROCEDURE - Step 6

  42. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 

    Refer to REMOVAL [12/2018 - ]

  43. DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY 
    1. Remove the 2 bolts and disconnect the No. 2 parking brake cable assembly.
      GTY543059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE HV FLOOR UNDER WIRE (for LITHIUM-ION BATTERY) 
    WARNING:

    Wear insulated gloves.

    NOTE:

    Insulate the disconnected connectors with insulating tape.

    1. Remove the 2 nuts.
      GTY563668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 clamps.
      GTY577269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      If the clamps are removed forcibly, the stud bolts may be damaged.

    3. Disengage the grommet and pull out the HV floor under wire from the floor panel hole.
      GTY563669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the clamp (A).
      GTY571723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disengage the clamp (B) to remove the HV floor under wire.
  45. REMOVE HV FLOOR UNDER WIRE (for NICKEL METAL HYDRIDE BATTERY) 
    WARNING:

    Wear insulated gloves.

    NOTE:

    Insulate the disconnected connectors with insulating tape.

    1. Disengage the 2 clamps.
      GTY834528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 5 clamps.
      GTY808236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the clamp.
      GTY796241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 nuts.
      GTY563668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 3 clamps.
      GTY577269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      If the clamps are removed forcibly, the stud bolts may be damaged.

    6. Disengage the grommet and pull out the HV floor under wire from the floor panel hole.
      GTY563669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the clamp (A).
      GTY571723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Disengage the clamp (B) to remove the HV floor under wire.
  46. REMOVE HV BATTERY PACK WIRE (for NICKEL METAL HYDRIDE BATTERY) 
    WARNING:

    Wear insulated gloves.

    1. Disengage the 7 clamps to remove the HV battery pack wire.
      GTY808241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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