AVALON Hybrid

Gasoline-Electric
Hybrid Synergy Drive

AVX40 Series
Foreword

This guide was developed to educate and assist dismantlers in the safe handling of Toyota
AVALON Hybrid gasoline-electric hybrid vehicles. AVALON Hybrid dismantling procedures are
similar to other non-hybrid Toyota vehicles with the exception of the high voltage electrical system.
It is important to recognize and understand the high voltage electrical system features and
specifications of the Toyota AVALON Hybrid, as they may not be familiar to dismantlers.
High voltage electricity powers the electric motor, generator, air conditioning (A/C) compressor and
inverter/converter. All other automotive electrical devices such as the head lights, radio, and
gauges are powered from a separate 12 Volt auxiliary battery. Numerous safeguards have been
designed into the AVALON Hybrid to help ensure the high voltage, approximately 244.8 Volt, Nickel
Metal Hydride (NiMH) Hybrid Vehicle (HV) battery pack is kept safe and secure in an accident.
The NiMH HV battery pack contains sealed batteries that are similar to rechargeable batteries used
in some battery operated power tools and other consumer products. The electrolyte is absorbed in
the cell plates and will not normally leak out even if the battery is cracked. In the unlikely event
the electrolyte does leak, it can be easily neutralized with a dilute boric acid solution or vinegar.
High voltage cables, identifiable by orange insulation and connectors, are isolated from the metal
chassis of the vehicle.

Additional topics contained in the guide include:

 Toyota AVALON Hybrid identification.
 Major hybrid component locations and descriptions.

By following the information in this guide, dismantlers will be able to handle AVALON Hybrid
hybrid-electric vehicles as safely as the dismantling of a conventional non-hybrid automobile.

 2012 Toyota Motor Corporation

All rights reserved. This book may not be reproduced or
copied, in whole or in part, without the written permission
of Toyota Motor Corporation.

ii
 Table of Contents

About the AVALON Hybrid.........................................................................................................................1

AVALON Hybrid Identification ..................................................................................................................2

Exterior .........................................................................................................................................................3
Interior...........................................................................................................................................................4
Engine Compartment ....................................................................................................................................5

Hybrid Component Locations & Descriptions...........................................................................................6

Specifications ................................................................................................................................................7

Hybrid Synergy Drive Operation................................................................................................................8

Vehicle Operation..........................................................................................................................................8

Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery........................................................................9

HV Battery Pack............................................................................................................................................9
Components Powered by the HV Battery Pack.............................................................................................9
HV Battery Pack Recycling .........................................................................................................................10
Auxiliary Battery ..........................................................................................................................................10

High Voltage Safety .................................................................................................................................... 11

High Voltage Safety System........................................................................................................................ 11
Service Plug Grip ........................................................................................................................................12

Precaution to be observed when dismantling the vehicle........................................................................13

Necessary Items .........................................................................................................................................13

Spills.............................................................................................................................................................14

Dismantling the vehicle ..............................................................................................................................15

Removal of HV battery ..............................................................................................................................19

HV Battery Caution Label.........................................................................................................................29

iii
About the AVALON Hybrid
The AVALON Hybrid 4-door sedan joins the hybrid model lineup for Toyota. Hybrid
Synergy Drive means that the vehicle contains a gasoline engine and an electric motor for
power. The two hybrid power sources are stored on board the vehicle:

1. Gasoline stored in the fuel tank for the gasoline engine.

2. Electricity stored in a high voltage Hybrid Vehicle (HV) battery pack for the electric motor.

The result of combining these two power sources is improved fuel economy and reduced
emissions. The gasoline engine also powers an electric generator to recharge the battery
pack; unlike a pure all electric vehicle, the AVALON Hybrid never needs to be recharged
from an external electric power source.

Depending on the driving conditions one or both sources are used to power the vehicle. The
following illustration demonstrates how the AVALON Hybrid operates in various driving
modes.

 During light acceleration at low speeds, the vehicle is powered by the electric motor.
The gasoline engine is shut off.

 During normal driving, the vehicle is powered mainly by the gasoline engine. The
gasoline engine also powers the generator to recharge the battery pack and to drive the
motor.

 During full acceleration, such as climbing a hill, both the gasoline engine and the electric
motor power the vehicle.

 During deceleration, such as when braking, the vehicle regenerates kinetic energy from
the front wheels to produce electricity that recharges the battery pack.

 While the vehicle is stopped, the gasoline engine and electric motor are off, however the
vehicle remains on and operational.

 Starting  Normal Driving  Acceleration  Deceleration  Stopping

Electricity Electricity and gasoline Electricity and gasoline Charging batteries Engine automatically
(additional electricity stopped
extracted from batteries)

1
AVALON Hybrid Identification
In appearance, the 2013 model year AVALON Hybrid is nearly identical to the conventional,
non-hybrid Toyota AVALON. The AVALON Hybrid is a 4-door sedan. Exterior, interior,
and engine compartment illustrations are provided to assist in identification.

The alphanumeric 17 character Vehicle Identification Number (VIN) is provided in the front
windshield cowl and on the driver side B pillar.

Example VIN: 4T1BD1EB0E2000101

An AVALON Hybrid is identified by the first 8 alphanumeric characters

4T1BD1EB.

Driver Side Windshield Cowl

Driver Side B Pillar

2
AVALON Hybrid Identification (Continued)
Exterior

 and logos on the trunk.

 logo on the driver and front passenger door.
 Gasoline fuel filler door located on the driver side rear quarter panel.

Exterior Driver Side View

 

Exterior Front and Rear View

  

Exterior Rear and Driver Side View

3
AVALON Hybrid Identification (Continued)
Interior
 The instrument cluster (READY indicator, and warning lights) located in the dash behind the
steering wheel, is different than the one on the conventional, non-hybrid AVALON.

 Instead of a tachometer, a hybrid system indicator is used.

Hint:
If the vehicle is shut off, the instrument cluster gauges will be “blacked out”, not illuminated.

Interior View

 READY Indicator

Instrument Cluster View

4
AVALON Hybrid Identification (Continued)
Engine Compartment
 2.5-liter aluminum alloy gasoline engine.
 Logo on the plastic engine cover.
 Orange colored high voltage power cables.

Engine Compartment View

Power Cables

5
Hybrid Component Locations & Descriptions

Component Location Description

12 Volt Auxiliary Passenger Side of A lead-acid battery that supplies power to the low voltage
Battery  Trunk devices.
Hybrid Vehicle Trunk Area, 244.8 Volt Nickel Metal Hydride (NiMH) battery pack
(HV) Battery Mounted behind consisting of 34 low voltage (7.2 Volt) modules connected
Pack  Rear Seat in series.
Power Cables  Undercarriage Orange colored power cables carry high voltage Direct
and Engine Current (DC) between the HV battery pack,
Compartment inverter/converter, and A/C compressor. These cables also
carry 3-phase Alternating Current (AC) between the
inverter/converter, electric motor, and generator.
Inverter/ Engine Boosts and inverts the high voltage electricity from the HV
Converter  Compartment battery pack to 3-phase AC electricity that drives the
electric motor. The inverter/converter also converts AC
electricity from the electric generator and electric motor
(regenerative braking) to DC that recharges the HV battery
pack.
DC-DC Inverter/ Converts 244.8 Volts from the HV battery pack to 12 Volts
Converter Converter for low voltage vehicle power.
for 12 Volt
Auxiliary
Battery 
Gasoline Engine Provides two functions:
Engine  Compartment 1) Powers vehicle.
2) Powers generator to recharge the HV battery pack.
The engine is started and stopped under control of the
vehicle computer.
Electric Engine 3-phase high voltage AC motor contained in the transaxle. It
Motor  Compartment is used to power the front wheels.

Electric Generator Engine 3-phase high voltage AC generator that is contained in the
 Compartment transaxle and recharges the HV battery pack.

A/C Compressor Engine 3-phase high voltage AC electrically driven motor

(with Inverter)  Compartment compressor.

Fuel Tank and Undercarriage The fuel tank provides gasoline via a fuel line to the engine.
Fuel Line and Driver Side The fuel line is routed along the driver side and center
 and Center tunnel under the floor pan.
*Numbers in the component column apply to the illustrations on the following page.

6
Hybrid Component Locations & Descriptions (Continued)
Specifications

Gasoline Engine: 156 hp (116 kW), 2.5-liter Aluminum Alloy Engine

Electric Motor: 141 hp (105 kW), Permanent Magnet Motor
Transmission: Automatic Only
HV Battery: 244.8 Volt Sealed NiMH Battery
Curb Weight: 3,594 - 3,638 lbs/1,630 - 1,650 kg
Fuel Tank: 17 gals/64 liters
Frame Material: Steel Unibody
Body Material: Steel Panels
Seating Capacity: 5 passenger





  


 
  

 
 

7
Hybrid Synergy Drive Operation
Once the READY indicator is illuminated in the instrument cluster, the vehicle may be driven.
However, the gasoline engine does not idle like a typical automobile and will start and stop
automatically. It is important to recognize and understand the READY indicator provided in
the instrument cluster. When lit, it informs the driver that the vehicle is on and operational
even though the gasoline engine may be off and the engine compartment is silent.

Vehicle Operation
 With the AVALON Hybrid, the gasoline engine may stop and start at any time while the READY
indicator is on.

 Never assume that the vehicle is shut off just because the engine is off. Always look for the
READY indicator status. The vehicle is shut off when the READY indicator is off.

 The vehicle may be powered by:

1. The electric motor only.
2. A combination of both the electric motor and the gasoline engine.

Instrument Cluster READY Indicator

8
Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery
The AVALON Hybrid features a high voltage Hybrid Vehicle (HV) battery pack that contains
sealed Nickel Metal Hydride (NiMH) battery modules.

HV Battery Pack
 The HV battery pack is enclosed in a metal case and is rigidly mounted to the trunk area behind
the rear seat. The metal case is isolated from high voltage and concealed by fabric covers in the
trunk.
 The HV battery pack consists of 34 low voltage (7.2 Volt) NiMH battery modules connected in
series to produce approximately 244.8 Volts. Each NiMH battery module is non-spillable and
sealed in a metal case.
 The electrolyte used in the NiMH battery module is an alkaline mixture of potassium and sodium
hydroxide. The electrolyte is absorbed into the battery cell plates and will not normally leak,
even in a collision.

HV Battery Pack
Battery pack voltage 244.8 V
Number of NiMH battery modules in the pack 34
NiMH battery module voltage 7.2 V
NiMH battery module dimensions 10.9 x 0.8 x 4.2 in
(Width x Length x Height) (276 x 19.6 x 106 mm)
NiMH module weight 2.2 lbs (1 kg)
NiMH battery pack dimensions 32.1 x 17.5 x 12.9 in
(Width x Length x Height) (817 x 445 x 325 mm)
NiMH battery pack weight 102.5 lbs (46.5 kg)
Note: Values in inches have been rounded

Components Powered by the HV Battery Pack

 Electric Motor  Power Cables
 Electric Generator  A/C Compressor
 Inverter/Converter
- DC-DC Converter for 12 Volt Auxiliary Battery

9
Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (Continued)
HV Battery Pack Recycling
 The HV battery pack is recyclable. Contact either your Toyota Distributor as mentioned on HV
battery Caution Label (see page 29) or the nearest Toyota dealer.

Auxiliary Battery
 The AVALON Hybrid contains a sealed lead-acid 12 Volt battery. This 12 Volt auxiliary battery
powers the vehicle electrical system similar to a conventional vehicle. As with other
conventional vehicles, the negative terminal of the auxiliary battery is grounded to the metal
chassis of the vehicle.
 The auxiliary battery is located in the trunk. It is concealed by a plastic resin cover on the
passenger side in the rear quarter panel well.

12 Volt Auxiliary Battery Mounted in the Trunk

244.8 Volt HV Battery Pack
(Passenger Side)

HV Battery Pack (Viewed from the Trunk)

10
High Voltage Safety
The HV battery pack powers the high voltage electrical system with DC electricity. Positive
and negative orange colored high voltage power cables are routed from the battery pack,
under the vehicle floor pan, to the inverter/converter. The inverter/converter contains a
circuit that boosts the HV battery voltage from 244.8 to 650 Volts DC. The
inverter/converter creates 3-phase AC to power the motor. Power cables are routed from the
inverter/converter to each high voltage motor (electric motor, electric generator, and A/C
compressor). The following systems are intended to help keep occupants in the vehicle and
emergency responders safe from high voltage electricity:

High Voltage Safety System

 A high voltage fuse * provides short circuit protection in the HV battery pack.

 Positive and negative high voltage power cables * connected to the HV battery pack are
controlled by 12 Volt normally open relays *. When the vehicle is shut off, the relays stop
electrical flow from leaving the HV battery pack.

WARNING:
・ The high voltage system may remain powered for up to 10
minutes after the vehicle is shut off or disabled. To prevent
serious injury or death from severe burns or electric shock,
avoid touching, cutting, or opening any orange high voltage
power cable or high voltage component.

 Both positive and negative power cables * are insulated from the metal body. High voltage
electricity flows through these cables and not through the metal vehicle body. The metal vehicle
body is safe to touch because it is insulated from the high voltage components.

 A ground fault monitor in the hybrid vehicle computer * continuously monitors for high voltage
leakage to the metal chassis while the vehicle is running. If a malfunction is detected, the hybrid
vehicle computer * will illuminate the master warning light in the instrument cluster and
indicate “Check Hybrid System” on the multi-information display.

 The HV battery pack relays will automatically open to stop electricity flow in a collision sufficient
to activate the SRS.

*Numbers apply to the illustration on the following page.

11
High Voltage Safety (Continued)
Service Plug Grip
 The high-voltage circuit is cut by removing the service plug grip (see page 15).

00

12 Volt
Volt DC Hybrid Vehicle Computer Auxiliary
Battery

A/C 
Compressor

Electric
Generator
Inverter/  
Converter
Electric 00
Motor Volt DC

0 Volts AC
3-Phase
HV Battery Assembly

High Voltage Safety System – Vehicle Shut Off (READY-OFF)

244.8
12 Volt
Volt DC Auxiliary
Hybrid Vehicle Computer
Battery

A/C
Compressor

Electric Inverter/
Generator Converter
244.8
Electric
Motor Volt DC

650 Volts
AC Max.
3-Phase HV Battery Assembly

High Voltage Safety System – Vehicle On and Operational (READY-ON)

12
Precaution to be observed when dismantling the vehicle

WARNING:
・ The high voltage system may remain powered for up to 10
minutes after the vehicle is shut off or disabled. To prevent
serious injury or death from severe burns or electric shock,
avoid touching, cutting, or opening any orange high voltage
power cable or high voltage component.

Necessary Items
 Protective clothing such as insulated gloves (electrically insulated), rubber gloves, safety goggles,
and safety shoes.
 Insulating tape such as electrical tape that has a suitable electrical insulation rating.
 Before wearing insulated gloves, make sure that they are not cracked, ruptured, torn, or damaged in
any way. Do not wear wet insulated gloves.
 An electrical tester that is capable of measuring DC 750 Volts or more.

13
Spills
The AVALON Hybrid contains the same common automotive fluids used in other non-hybrid
Toyota vehicles, with the exception of the NiMH electrolyte used in the HV battery pack. The
NiMH battery electrolyte is a caustic alkaline (pH 13.5) that is damaging to human tissues.
The electrolyte, however, is absorbed in the cell plates and will not normally spill or leak out
even if a battery module is cracked. A catastrophic crash that would breach both the metal
battery pack case and a metal battery module would be a rare occurrence.

A caustic alkaline is at the opposite end of the pH scale from a strong acid. A safe (neutral)
substance is approximately in the middle of this scale. Adding a weak acidic mixture, such as
a dilute boric acid solution or vinegar, to the caustic alkaline electrolyte will cause the
electrolyte to be neutralized. This is similar but opposite to the use of baking soda to
neutralize a lead-acid battery electrolyte spill.

A Toyota Product Safety Data Sheets (PSDS) is attached to this document.

 Handle NiMH electrolyte spills using the following Personal Protective Equipment (PPE):
• Splash shield or safety goggles. A fold down face shield is not acceptable for acid
or electrolyte spills.
• Rubber, latex or nitrile gloves.
• Apron suitable for alkaline.
• Rubber boots.

 Neutralize NiMH electrolyte.

• Use a boric acid solution or vinegar.
• Boric acid solution - 800 grams boric acid to 20 liters water or 5.5 ounces boric
acid to 1 gallon of water.

14
Dismantling the vehicle

The following 3 pages contain general instructions for use when working on an AVALON Hybrid.
Read these instructions before proceeding to the HV battery removal instructions on page 18.

WARNING:
・ The high voltage system may remain powered for up to 10
minutes after the vehicle is shut off or disabled. To prevent
serious injury or death from severe burns or electric shock, avoid
touching, cutting, or opening any orange high voltage power
cable or any high voltage component.

1. Shut off the ignition (READY indicator is off).

Then disconnect the cable from the auxiliary
battery negative (-) terminal.
(1) Remove the 3 deck boards.
(2) Remove the auxiliary boxes.
(3) Disconnect the battery negative terminal.

2. Remove luggage compartment front trim cover.

(1) Disengage the 8 fasteners to remove the
luggage compartment front trim cover.

3. Remove No. 8 hybrid vehicle battery shield

panel.
(1) Remove the 2 nuts and No. 8 hybrid vehicle
battery shield panel.

15
4. Remove the service plug grip.
Caution:
Wear insulated gloves for the following 3 steps.
(1) Slide the handle of the service plug grip to the right.
(2) Raise the release handle of the service plug grip.
(3) Remove the service plug grip.
(4) Apply insulating tape to the socket of the service plug grip to insulate it.

5. Carry the removed service plug grip in your pocket to prevent other staff from accidentally
reinstalling it while you are dismantling the vehicle.
6. Make other staff aware that a high-voltage system is being dismantled by using the
following sign: CAUTION: HIGH-VOLTAGE. DO NOT TOUCH. (see page 18).
7. If the service plug grip cannot be removed due to damage to the vehicle, remove the IG2
MAIN fuse (25A).
Caution:
This operation shuts off the HV system. Be sure to wear insulated gloves because
high voltage is not shut off inside the HV battery. When it is possible to remove
the service plug grip, remove it and continue the procedure.

IG2 MAIN
Fuse

16
8. After disconnecting or exposing a high-voltage
connector or terminal, insulate it immediately
using insulating tape. Before disconnecting or
touching a bare high-voltage terminal, wear
insulated gloves.
9. Check the HV battery and nearby area for
leakage. If you find any liquid, it may be
strong alkaline electrolyte. Wear rubber
gloves and goggles and neutralize the liquid using a saturated boric acid solution or
vinegar. Then wipe up the liquid using waste rags etc.
10. If the electrolyte comes into contact with your skin, wash the skin immediately using a
saturated boric acid solution or a large amount of water. If the electrolyte adheres to any
article of clothing, take the clothing off immediately.
11. If the electrolyte comes into contact with your eye(s), call out loudly for help. Do not rub
your eye(s). Instead, wash the eye(s) with a dilute boric acid solution or a large amount
of water and seek medical care.
12. With the exception of the HV battery, remove parts by following procedures which are
similar to conventional Toyota vehicles. For the removal of the HV battery, refer to the
following pages.

17
18
Removal of HV battery

WARNING:
・ Be sure to wear insulated gloves when handling high-voltage
parts.
・ Even if the vehicle is shut off and the relays are off, be sure to
remove the service plug grip before performing any further
work.
・ Power remains in the high voltage electrical system for 10
minutes even after the HV battery pack is shut off because the
circuit has a condenser that stores power.
・ Make sure that the tester reading is 0 V before touching any
high-voltage terminals which are not insulated.
・ The SRS may remain powered for up to 90 seconds after the
vehicle is shut off or disabled. To prevent serious injury or
death from unintentional SRS deployment, avoid cutting the
SRS components.

1. SHUT OFF IGNITION (READY indicator is off)

2. REMOVE LUGGAGE TRIM SERVICE
HOLE COVER

3. REMOVE 12 V AUXILIARY BATTERY

(1) Open the auxiliary battery terminal cap.
(2) Loosen the nut, and disconnect the cable from
the positive (+) auxiliary battery terminal.
(3) Disconnect the auxiliary battery hose.
(4) Loosen the nut and remove the bolt.
(5) Remove the auxiliary battery clamp.
(6) Remove the auxiliary battery.
4. REMOVE LUGGAGE COMPARTMENT FLOOR MAT

19
5. REMOVE LUGGAGE COMPARTMENT
FRONT TRIM COVER
(1) Disengage the 8 fasteners to remove the
luggage compartment front trim cover.

6. REMOVE NO. 8 HYBRID VEHICLE

BATTERY SHIELD PANEL
(1) Remove the 2 nuts and No. 8 hybrid vehicle
battery shield panel.

7. REMOVE SERVICE PLUG GRIP

Caution:
Wear insulated gloves for the following 3 steps.
(1) Slide the handle of the service plug grip.
(2) Raise the release handle of the service plug grip as shown in the illustration below.
(3) Remove the service plug grip.
(4) Apply insulating tape to the socket of the service plug grip to insulate it.

20
8. REMOVE CONNECTOR COVER
ASSEMBLY
Caution:
Wear insulated gloves.
(1) Remove the 2 bolts and connector cover
assembly.

9. CHECK TERMINAL VOLTAGE

(1) Check voltage at the terminals in inspection
point in the power control unit.
Caution:
Wear insulated gloves.
To prevent serious injury or death, do not
proceed with dismantling of the HV system
until the voltage at the terminals in the
inspection point is 0 V.
Standard voltage: 0 V

Hint:
Set the tester to the DC 750 Volts range to measure the voltage.
This inspection is performed to verify that it is safe to remove the HV battery.

10. REMOVE NO. 1 LUGGAGE

COMPARTMENT TRIM HOOK
(1) Push the 2 pins and remove the 2 No. 1
luggage compartment trim hooks.

21
11. REMOVE REAR FLOOR FINISH PLATE
(1) Using a clip remover, remove the 2 clips.

(2) Disengage the 4 clips and 3 guides to Clip

remove the rear floor finish plate as sown
in the illustration.

Guide

12. REMOVE LUGGAGE COMPARTMENT

INNER TRIM COVER LH
(1) Using a clip remover, remove the 2 clips.
(2) Disengage the 2 fasteners to remove the
luggage compartment inner trim cover LH.

13. REMOVE LUGGAGE COMPARTMENT

INNER TRIM COVER RH Clip
(1) Using a clip remover, remove the 2 clips.
(2) Disengage the 2 fasteners to remove the
luggage compartment inner trim cover RH.

14. REMOVE REAR SEAT HEADREST

ASSEMBLY

22
15. REMOVE REAR SEAT CUSHION
ASSEMBLY *1

(1) Disengage the 2 hooks on the front side of the

*2
rear seat cushion assembly from the vehicle
body as shown in the illustration.
a) Choose a hook to disengage first. Place
your hands near the hook as shown in the
illustration. Then lift the rear seat cushion
to disengage the hook.
b) Repeat the step above for the other hook. a

(2) Pass the buckle of the rear seat inner with *1: Rear Seat Inner with Center Belt Assembly LH
center belt assembly LH and buckle of the rear *2: Rear Seat Inner with Center Belt Assembly RH
seat inner with center belt assembly RH a: 100 mm (3.94 in.) or less

through the slit of the rear seat cushion assembly.

(3) w/ Seat Heater System:
a) Disconnect the 2 seat heater assembly connectors.
(4) Remove the rear seat cushion assembly.

16. REMOVE REAR SEATBACK ASSEMBLY

(1) Disconnect the rear seat outer belt assembly
LH from the rear seat shoulder belt guide LH.

(2) Disconnect the rear seat outer belt assembly

RH from the rear seat shoulder belt guide RH.

23
 (3) Disconnect the rear seat inner with center
belt assembly LH from the rear seat shoulder
belt guide LH.

(4) Disconnect the 2 rear seat airbag assembly connectors.

(5) w/ Seat Heater System:
a) Disconnect the 2 seat heater assembly connectors.
(6) Disengage the 2 clamps.
Text in Illustration *4 *5
*1 Clamp *3
*2 *2 *2
*2 Hook
*3 Rear Seat Outer Belt Assembly LH
*4 Rear Seat Outer Belt Assembly RH
*5 Rear Seat Inner with Center Belt
Assembly LH
(7) Remove the 4 bolts.
(8) Disconnect the rear seat outer belt assembly
LH, rear seat inner with center belt assembly
LH and rear seat outer belt assembly RH
from the rear seatback assembly.
*1
(9) Disengage the 3 hooks and remove the rear *1
seatback assembly.
17. REMOVE REAR DOOR SCUFF PLATE LH
(1) Disengage the 8 claws and remove the rear
door scuff plate LH.
18. DISCONNECT REAR DOOR OPENING
TRIM WEATHERSTRIP LH
(1) Disconnect the rear door opening trim
weatherstrip LH.

24
19. REMOVE REAR SEAT SIDE GARNISH LH
(1) Disengage the 2 claws and 5 clamps, and
remove the rear seat side garnish LH.

20. REMOVE NO. 1 HYBRID BATTERY

INTAKE DUCT
(1) Remove the 3 clips and No. 1 hybrid battery
intake duct.

21. REMOVE NO. 4 HYBRID BATTERY Service Plug Grip

SHIELD PANEL
Caution:
Turn
Wear insulated gloves for the following 2
steps. Button
Projection
(1) Using the service plug grip, remove the battery
cover lock striker.
Hint:
Insert the projection of the service plug grip, and Buttery Coven Lock Striker

turn the button of the battery cover lock striker

counterclockwise to release the lock.
(2) Remove the bolt, 2 nuts and No. 4 hybrid
battery shield panel.

25
22. DISCONNECT NO. 4 FLOOR WIRE
Caution:
Wear insulated gloves.
Notice:
Insulate the terminals of the removed frame
wire with insulating tape.
(1) Disconnect the 2 connectors shown in the
illustration.
(2) Disconnect the shielded wire ground and
disconnect the No. 4 floor wire.

23. REMOVE HV BATTERY

Caution:
Wear insulated gloves.
(1) Disconnect the connector and wire harness
clamp.

(2) Disconnect the 2 connectors.

(3) Remove the 6 bolts from the HV battery.

26
(4) Place a piece of cardboard in the luggage Cardboard
compartment.

(5) Cut and shape a piece of cardboard so that it

fits the area between the HV battery bolt
attachment positions, and then insert it as
shown in the illustration.
(6) Using a tire lever to hold up the HV battery,
insert the cardboard until it cannot be inserted
Cardboard
any further.
Notice: Hold Up
Insert
Secure the frame wire with electrical tape to
prevent it from getting caught when moving
the HV battery or other parts.

HV Battery Bolt Attachment

Position

Cardboard

(7) Pull the cardboard and HV battery together to

the middle of the luggage compartment.

Pull

Cardboard

27
(8) Remove the 2 nuts and No. 2 hybrid vehicle
battery upper cover bracket.

(9) Remove the clip.

(10) Disengage the 2 claws and remove the No. 2
hybrid battery intake duct.

(11) Disconnect the connector from the battery

cooling blower assembly.
(12) Remove the 3 nuts and battery cooling
blower assembly.

(13) Turn the cardboard and HV battery 180°

Turn 180°
together.
(14) Pull the HV battery together with the
cardboard toward the rear of the vehicle.

Pull

(15) Using a suitable adaptor such as a rope,

remove the HV battery while tilting the HV
battery.

28
24. The HV battery pack is recyclable. Contact your Toyota distributor (if included on the HV
battery caution label) or contact the nearest Toyota dealer (see below for samples of the
HV battery caution label).
Caution:
After removing the HV battery, do not reinstall the service plug grip to the HV
battery.

HV Battery Caution Label

29