LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2022 >> Corolla Cross L, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 50 (Hybrid Battery Control System - Service Information) >> HV Battery >> Removal [11/2022 - ] >> Procedure

Removal [11/2022 - ]: Procedure

WARNING: This page is about a different car, the 2025 Toyota Corolla Cross, 2024 Toyota Corolla Cross, and 2023 Toyota Corolla Cross. However, it is still accessible from the selected car via links, so may be relevant.
  1. PRECAUTION 
    NOTE:
    • After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal.

      Refer to BEFORE DISCONNECTING BATTERY [11/2022 - 11/2023] , or refer to BEFORE DISCONNECTING BATTERY [11/2023 - ]

    • 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.
      GTY1108974Courtesy 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.
      GTY1108161Courtesy 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 GTS 
    1. GTY1104650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Connect the GTS to the DLC3.
      2. Turn the ignition switch on (IG).
      3. Enter the following menus: Powertrain / HV Battery / Data List / Hybrid/EV Battery Temperature 1 to 6.

        Powertrain > HV Battery > Data List 

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

        If any of the temperatures listed in "Hybrid/EV 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 [11/2022 - ] 

  4. REMOVE CONNECTOR COVER ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 See step  4 [11/2022 - 12/2024], or see step  4 [12/2024 - ]
  5. CHECK TERMINAL VOLTAGE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 See step  5 [11/2022 - 12/2024], or see step  5 [12/2024 - ]
  6. INSTALL CONNECTOR COVER ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. GTY1106121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt (A) *b Bolt (B)
      1. Using a T30 "TORX" socket wrench, install the connector cover assembly to the inverter with converter assembly with the bolt (A).

        Torque: 2.0 N.m (20 kgf/cm, 18 in.lbf) 

        NOTE:

        Do not touch the waterproof seal of the connector cover assembly.

      2. Install the bolt (B).

        Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

  7. DISCONNECT REAR CENTER SEAT OUTER BELT ASSEMBLY 

    Refer to PROCEDURE - Step 1

  8. REMOVE BENCH TYPE REAR SEAT CUSHION ASSEMBLY 

    Refer to PROCEDURE - Step 3

  9. REMOVE REAR SEAT CUSHION LOCK HOOK 

    Refer to PROCEDURE - Step 6

  10. REMOVE REAR DOOR SCUFF PLATE RH 

    Refer to PROCEDURE - Step 16

  11. REMOVE REAR UNDER SIDE COVER RH 
    1. GTY1103734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
  12. REMOVE REAR DOOR SCUFF PLATE LH 
    1. Use the same procedure as for the RH side.
  13. REMOVE REAR UNDER SIDE COVER LH 
    1. GTY1104825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
  14. REMOVE REAR UNDER COVER 
    1. GTY1104304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY 
    1. GTY1104430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE NO. 1 EV BATTERY INTAKE DUCT 

    See step  10

  17. REMOVE BATTERY COOLING BLOWER ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 See step  11
  18. REMOVE HYBRID BATTERY HOSE ASSEMBLY 
    1. GTY1106159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE NO. 2 HYBRID BATTERY INTAKE DUCT 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. GTY1108969Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE NO. 3 HV BATTERY PACK WIRE 
    1. GTY1106161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE NO. 1 HYBRID BATTERY SHIELD SUB-ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. GTY1109407Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Service Plug Grip *2 Battery Cover Lock Striker
      *a Projection *b Turn
      *c Button - -
      1. Using the service plug grip, remove the battery cover lock striker.

        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 5 nuts and HV battery upper cover panel from the HV battery.
  22. DISCONNECT FLOOR UNDER WIRE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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. GTY1105386Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Shield Ground - -
      1. Disconnect the 2 HV battery junction block assembly connectors.
      2. Disconnect the shield ground from the HV battery.
  23. DISCONNECT FLOOR WIRE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. GTY1106158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE HV SUPPLY BATTERY ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.

    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.
    1. GTY1106157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE NO. 1 HV BATTERY CARRIER BRACKET SUB-ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. GTY1106155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE NO. 2 HYBRID BATTERY CARRIER BRACKET 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. GTY1106152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE NO. 3 HV BATTERY CARRIER BRACKET 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. GTY1106151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE NO. 4 HV BATTERY CARRIER BRACKET 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    WARNING:

    Wear insulated gloves.
    1. GTY1106154Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. PERFORM RECOVERY INSPECTION 
    1. GTY1103342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Before returning the HV battery, make sure to perform a recovery inspection.

        Refer to RECOVERY INSPECTION [11/2022 - ] 

scientia non olet · About LEMON Manuals