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Home >> Toyota >> 2025 >> Prius Plug-In Hybrid SE >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Electric Motor Systems >> Hybrid Battery Control System - Service Information (3 Of 3) >> HV BATTERY (for PHEV Model) >> Removal [03/2023 - ] >> Procedure

Removal [03/2023 - ]: Procedure

  1. PRECAUTION 
    Refer to PRECAUTION [03/2023 - ]
  2. READ VALUE USING GTS 
    1. GTY1075510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Read the Data List.

        Enter the following menus: Powertrain / HV supply battery assembly / Data List / Hybrid/EV Battery Temperature 1 to 20.

        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
        Hybrid/EV Battery Temperature 7
        Hybrid/EV Battery Temperature 8
        Hybrid/EV Battery Temperature 9
        Hybrid/EV Battery Temperature 10
        Hybrid/EV Battery Temperature 11
        Hybrid/EV Battery Temperature 12
        Hybrid/EV Battery Temperature 13
        Hybrid/EV Battery Temperature 14
        Hybrid/EV Battery Temperature 15
        Hybrid/EV Battery Temperature 16
        Hybrid/EV Battery Temperature 17
        Hybrid/EV Battery Temperature 18
        Hybrid/EV Battery Temperature 19
        Hybrid/EV Battery Temperature 20
        NOTE:

        If any of the temperatures listed in "Hybrid/EV Battery Temperature 1 to 20" are 50°C or more, leave the vehicle until the temperature drops to less than 50°C.

  3. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 

    Refer to PROCEDURE - Step 2

  4. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    Refer to REMOVAL [03/2023 - ]

  5. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [03/2023 - ]

  6. REMOVE FRONT WIPER ARM HEAD CAP 
    Refer to PROCEDURE - Step 1
  7. REMOVE SHIELD CAP 
    Refer to PROCEDURE - Step 2
  8. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH 

    Refer to PROCEDURE - Step 3

  9. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH 

    Refer to PROCEDURE - Step 4

  10. REMOVE WINDSHIELD LOWER OUTSIDE MOULDING LH 
    Refer to PROCEDURE - Step 1
  11. REMOVE WINDSHIELD LOWER OUTSIDE MOULDING RH 
    1. Use the same procedure as for the LH side.
  12. REMOVE COWL WATER EXTRACT SHIELD LH 

    Refer to PROCEDURE - Step 7

  13. REMOVE COWL WATER EXTRACT SHIELD RH 
    1. Use the same procedure as for the LH side.
  14. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 9

  15. CHECK TERMINAL VOLTAGE 
    Refer to PROCEDURE - Step 13
  16. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 4
  17. INSTALL COWL WATER EXTRACT SHIELD RH 
  18. INSTALL COWL WATER EXTRACT SHIELD LH 
  19. INSTALL WINDSHIELD LOWER OUTSIDE MOULDING LH 
    Refer to PROCEDURE - Step 4
  20. INSTALL WINDSHIELD LOWER OUTSIDE MOULDING RH 
    1. Use the same procedure as for the LH side.
  21. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH 
    Refer to PROCEDURE - Step 9
  22. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH 
    Refer to PROCEDURE - Step 10
  23. INSTALL SHIELD CAP 
  24. INSTALL FRONT WIPER ARM HEAD CAP 
  25. REMOVE BATTERY BOX COVER 
    1. GTY1157727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE BATTERY BOX PANEL SUB-ASSEMBLY 
    1. GTY1139018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Service Plug Grip *2 No. 23 Traction Battery Bracket
      *a Projection *b Turn
      *c Button - -
      1. Insert the projection of the service plug grip and turn the button of the No. 23 traction battery bracket counterclockwise to release the lock to remove the No. 23 traction battery bracket.
      2. Remove the 4 bolts, 3 nuts and battery box panel sub-assembly.
  27. REMOVE NO. 1 CENTER FLOOR HEAT INSULATOR SUB-ASSEMBLY 
    1. GTY1157724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. DISCONNECT LIQUID TUBE SUB-ASSEMBLY C 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    NOTE:

    Seal the openings of the disconnected parts with vinyl tape to prevent entry of moisture and foreign matter.
    1. GTY1157725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. DISCONNECT NO. 8 DISCHARGE TUBE 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    NOTE:

    Seal the openings of the disconnected parts with vinyl tape to prevent entry of moisture and foreign matter.
    1. GTY1138990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. DISCONNECT FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    NOTE:

    Insulate the disconnected terminals and connector with insulating tape.
    1. GTY1157746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. GTY1157744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. GTY1151392Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Green-colored Lock - -
      Slide - -
      1. Disengage the rubber cap and slide it as shown in the illustration.
      2. Using a screwdriver, slide the green-colored lock of the connector as shown in the illustration to release it and disconnect the floor under wire.
    4. w/ Solar Charging System:
      GTY1151393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Service Plug Grip *2 No. 23 Traction Battery Bracket
      *a Projection *b Turn
      *c Button - -
      1. Insert the projection of the service plug grip and turn the button of the No. 23 traction battery bracket counterclockwise to release the lock to remove the No. 23 traction battery bracket.
      2. Remove the nut and No. 20 traction battery bracket.
    5. w/ Solar Charging System:
      GTY1154772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Green-colored Lock - -
      Slide - -
      1. Disengage the rubber cap and slide it as shown in the illustration.
      2. Using a screwdriver, slide the green-colored lock of the connector as shown in the illustration to release it and disconnect the floor under wire.
      3. Disengage the clamp.
  31. REMOVE HV SUPPLY BATTERY ASSEMBLY 
    WARNING:
    • Because the weight of the HV supply battery assembly is extremely heavy, make sure to follow the work procedures described in the repair information.
    • If work is not performed according to the procedures described in the repair information, there is a danger that the components could fall down.
    • Do not damage the HV supply battery assembly with the fork etc.
    • Be sure to wear insulated gloves and protective goggles.
    GTY563885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. GTY1141668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Area That Can Touch The Ground - -
      1. Using an engine lifter and 4 attachments or equivalent tools, support the HV supply battery assembly as shown in the illustration.
        NOTE:
        • Do not allow foreign matter, such as grease or oil, to adhere to the bolts of the HV supply battery assembly.
        • To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.
        • Since the HV supply battery assembly is very heavy, 2 people are needed to remove it. When removing the HV supply battery assembly, be careful not to damage the parts around it.
        • When removing/installing/moving the HV supply battery assembly, make sure not to tilt it more than 80°.
        • If the HV supply battery assembly has been struck or dropped, replace it.
        • Do not apply any load outside of the area that can touch the ground.
    2. GTY1157740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. GTY1149264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Area That Can Touch The Ground - -
      1. Slowly lower the engine lifter to remove the HV supply battery assembly.
        NOTE:

        Be careful not to drop the HV supply battery assembly.

      2. Follow the procedure below when moving the HV supply battery assembly from the engine lifter.
      3. Install the SST at the position shown in the illustration.
        • SST: 09893-42010 
      4. Using 4 hooks, 4 belt slings and a chain block, hoist the HV supply battery assembly.
        NOTE:

        When removing/installing/moving the HV supply battery assembly, make sure not to tilt it more than 80°.

      5. Using the height adjustable attachment, set so that the HV supply battery assembly is in contact with the position shown in the illustration, and place the HV supply battery assembly on the height adjustable attachment.
        NOTE:
        • To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.
        • When removing/installing/moving the HV supply battery assembly, make sure not to tilt it more than 80°.
        • If the HV supply battery assembly has been struck or dropped, replace it.
        • Do not apply any load outside of the area that can touch the ground.
        • Do not place the lower surface of the battery on the ground.
  32. REMOVE VALVE TO CONNECTOR TUBE 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    NOTE:
    • Insulate the disconnected terminals and connector with insulating tape.
    • Seal the openings of the disconnected parts with vinyl tape to prevent entry of moisture and foreign matter.
    1. GTY1138989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. PERFORM RECOVERY INSPECTION 
    1. Before returning the HV supply battery assembly, make sure to perform a recovery inspection.

      Refer to RECOVERY INSPECTION [03/2023 - ] 

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