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Removal [10/2023 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. PRECAUTION 
    NOTE:

    After turning the ignition 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.

  2. REMOVE NO. 1 FLOOR UNDER COVER (w/ NO. 1 FLOOR UNDER COVER) 

    Refer to PROCEDURE - Step 1

  3. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [10/2023 - ]

  4. DISCONNECT ENGINE ROOM MAIN WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    NOTE:

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

    1. Move the lock lever while pushing the lock on the connector, and disconnect the inverter with converter assembly connector.
      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.
      GTY940571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 9

  6. CHECK TERMINAL VOLTAGE 

    Refer to PROCEDURE - Step 10

  7. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 11

  8. DISCONNECT FLOOR UNDER WIRE 

    Refer to PROCEDURE - Step 12

  9. REMOVE BENCH TYPE REAR SEAT CUSHION ASSEMBLY 

    Refer to PROCEDURE - Step 1

  10. REMOVE REAR SEAT CUSHION LOCK HOOK 

    Refer to PROCEDURE - Step 2

  11. REMOVE REAR DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 9

  12. REMOVE NO. 3 BATTERY SERVICE COVER BOARD 

    Refer to PROCEDURE - Step 4

  13. REMOVE REAR DOOR SCUFF PLATE RH 

    HINT: 

    Use the same procedure as for the LH side.

  14. REMOVE NO. 2 BATTERY SERVICE COVER BOARD 

    Refer to PROCEDURE - Step 6

  15. REMOVE BATTERY SERVICE COVER BOARD 

    Refer to PROCEDURE - Step 7

  16. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8

  17. REMOVE NO. 1 HV BATTERY COVER PANEL RH 

    Refer to PROCEDURE - Step 9

  18. DISCONNECT FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Disconnect the 2 HV battery junction block assembly connectors.
      NOTE:

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

      GTY933129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Shield Ground
    2. Disconnect the shield ground from the HV battery.
    3. Disengage the 3 claws to remove the No. 4 relay block cover.
      GTY910937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the nut.
      GTY910945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disengage the clamp.
    6. Disengage the clamp and disconnect HV floor under wire.
      GTY942224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE FRONT FENDER FRONT SPLASH SHIELD LH 

    Refer to PROCEDURE - Step 13

  20. REMOVE FRONT FENDER FRONT SPLASH SHIELD RH 

    Refer to PROCEDURE - Step 14

  21. REMOVE NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 15

  22. REMOVE NO. 2 ENGINE UNDER COVER ASSEMBLY 

    Refer to PROCEDURE - Step 16

  23. REMOVE ENGINE UNDER COVER HEAT INSULATOR 

    Refer to PROCEDURE - Step 42

  24. REMOVE FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 43

  25. REMOVE FRONT FLOOR COVER RH 

    Refer to PROCEDURE - Step 44

  26. REMOVE FRONT CENTER FLOOR COVER 
    1. Remove the 2 clips and front center floor cover.
      GTY927320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE FRONT NO. 2 FLOOR HEAT INSULATOR 
    1. Remove the 2 nuts, clip and front No. 2 floor heat insulator.
      GTY920051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE FRONT LOWER NO. 1 FLOOR HEAT INSULATOR 
    1. Remove the nut, bolt, clip and front lower No. 1 floor heat insulator.
      GTY903982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR 
    1. GTY925920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the 2 nuts and front No. 1 floor heat insulator.

  30. REMOVE NO. 2 ENGINE SERVICE COVER CUSHION 
    1. Remove the 2 nuts and No. 2 engine service cover cushion.
      GTY908345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE ENGINE SERVICE COVER CUSHION 
    1. Remove the 2 nuts and engine service cover cushion.
      GTY908346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Remove the nut and disconnect the transmission control cable assembly.
      GTY856862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 3

  34. REMOVE EXHAUST MANIFOLD 

    Refer to PROCEDURE - Step 9

  35. REMOVE FUEL TANK ASSEMBLY 

    Refer to REMOVAL [10/2023 - ]

  36. REMOVE FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    NOTE:

    Insulate the disconnected connectors with insulating tape.

    1. Remove the 2 nuts and 2 bolts.
      GTY1002243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    2. Disengage the grommet and pull out the HV floor under wire from the floor panel hole.
      GTY892708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 3 bolts and nut.
      GTY892732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 stud clamps.
      NOTE:

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

    5. Remove the 2 nuts, bolt and 2 stud clamps.
      GTY934904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      If the stud clamps is removed forcibly, the stud bolt may be damaged.

    6. Disengage the 2 claws.
      GTY938180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    7. Disengage the guide and disconnect the No. 1 terminal cap.
    8. Remove the nut and disconnect the engine room main wire.
      GTY919435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the 2 nuts and HV floor under wire.
      GTY919434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Disengage the clamp.
      GTY842515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Remove the 2 bolts and HV floor under wire from the rear traction motor with transaxle assembly.
      NOTE:
      • Do not damage the terminals, interlock connector or rear traction motor with transaxle assembly during disconnection.
      • Do not touch the waterproof seal or terminals of the connector.
      • Do not allow any foreign matter or water to enter the rear traction motor with transaxle assembly.
      • Although the connector may feel loose, this is not due to a malfunction.
      GTY909024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
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