Plug-in Hybrid

Gasoline-Electric
Hybrid Synergy Drive

ZVW35 Series
Foreword

This guide was developed to educate and assist dismantlers in the safe handling of Toyota Prius Plug-in
gasoline-electric hybrid vehicles. Prius Plug-in 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
Prius Plug-in hybrid, as they may not be familiar to dismantlers.
High voltage electricity powers the A/C compressor, electric motor, generator, and inverter/converter.
All other conventional automotive electrical devices such as the headlights, radio, and gauges are
powered from a separate 12 Volt auxiliary battery. Numerous safeguards have been designed into the
Prius Plug-in hybrid to help ensure the high voltage, approximately 346 Volt, Lithium-ion (Li-ion)
Hybrid Vehicle (HV) battery pack is kept safe and secure in an accident.
The Li-ion 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 Prius Plug-in hybrid identification.
• Major hybrid component locations and descriptions.

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

© 2010 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.

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Table of Contents

About the Prius Plug-in hybrid ................................................................................................................1

Prius Plug-in hybrid Identification ..........................................................................................................2

Exterior .........................................................................................................................................................3

Prius Plug-in hybrid Identification (Continued).....................................................................................4

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 ...........................................................................................................................34

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 About the Prius Plug-in hybrid
The Prius Plug-in hybrid contains a gasoline engine, an electric motor, and a newly developed large
capacity Li-ion battery. It is the first Toyota hybrid that allows the HV battery to be plugged-in and
charged by an external power source. Two power sources are stored on board the vehicle:

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

2. Electricity stored in a large capacity externally chargeable high voltage Hybrid Vehicle (HV) battery
assembly for the electric motor.

Depending on the driving conditions, one or both sources are used to power the vehicle. The following
illustration demonstrates how the Prius Plug-in hybrid operates in various driving modes.

Plug-in EV (Electric Vehicle) Mode:

Utilizing the charge cable assembly connected to a 120 Volt outlet, the vehicle’s HV battery can be
charged within 4 hours.

When the HV battery is sufficiently charged, the vehicle will basically run on the power of the
motor.

If the vehicle exceeds 100 km/h or accelerates suddenly when traveling in plug-in EV mode, the
gasoline engine and motor work together to power the vehicle.

HV (Hybrid Vehicle) Mode:

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 assembly.

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 the kinetic energy from the front
wheels to produce electricity that recharges the battery assembly.

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

Plug-in Charging Normal Driving Hard Acceleration

Plug-in charging Electricity Electricity and gasoline Electricity Electricity and gasoline Electricity and gasoline Charging batteries Engine
(additional electricity automatically
extracted from batteries) stopped

Plug-in EV Mode HV (Hybrid Vehicle) Mode

1
Prius Plug-in hybrid Identification
In appearance, the 2010 model year Prius Plug-in hybrid is a 5-door hatchback. 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 left side door pillar.

Example VIN: JTDKN3DPA82020211 or JTDKN36PA82020211

A Prius Plug-in hybrid is identified by the first 8 alphanumeric characters JTDKN3DP or JTDKN36P.

Driver Side Windshield and Left Side Door Pillar

2
Prius Plug-in hybrid Identification (Continued)
Exterior
logo on the front right fender.

Charge inlet door with logo, located on driver side front fender.
Plug-in Hybrid decals located on the sides of the vehicle.

Exterior Driver Side View

Exterior Front and Rear View

Exterior Rear and Driver Side View

3
Prius Plug-in hybrid Identification (Continued)
Interior
Instrument cluster (speedometer, READY light, shift position indicators, warning lights) located in
center of the dash and near the base of the windshield.

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

Interior View

Instrument Cluster View

4
Prius Plug-in hybrid Identification (Continued)
Engine Compartment

1.8-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 Right Side of A lead-acid battery that supplies power to the low voltage
Battery Cargo Area devices.
Hybrid Vehicle (HV) Cargo Area 346 Volt Lithium-ion (Li-ion) battery pack consisting of
Battery Assembly 3.6 Volt cells connected in a series-parallel circuit.
Power Cables Undercarriage Orange colored power cables carry high voltage Direct
and Engine Current (DC) between the HV battery assembly,
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
Converter Compartment HV battery assembly 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 charges the HV
battery assembly.
Gasoline Engine Provides two functions:
Engine Compartment 1) Powers vehicle.
2) Powers generator to charge the HV battery assembly.
The engine is started and stopped under control of the
vehicle computer.
Electric Engine 3-phase high voltage AC permanent magnet electric motor
Motor Compartment contained in the front transaxle. It is used to power the
front wheels.
Electric Generator Engine 3-phase high voltage AC generator that is contained in the
Compartment transaxle and charges the HV battery assembly.

*Numbers in the component column apply to the illustrations on the following page.

6
Hybrid Component Locations & Descriptions (Continued)

Specifications
Gasoline Engine: 98 hp (73 kW), 1.8-liter Aluminum Alloy Engine
Electric Motors 80 hp (60 kW), Permanent Magnet Motor
Transmission: Automatic Only (electrically controlled continuously variable transaxle)
HV Battery: 346 Volt Sealed Li-ion Battery
Curb Weight: 3,362 lbs/1,525 kg
Fuel Tank: 11.9 gals/45.0 liters
Frame Material: Steel Unibody
Body Material: Steel Panels except for Aluminum Hood and Back Door
Seating Capacity: 5 standard

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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 illuminated, 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 Prius Plug-in 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. The gasoline engine only.
3. 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 Prius Plug-in hybrid features a high voltage Hybrid Vehicle (HV) battery pack that contains sealed
Lithium-ion (Li-ion) battery cells.

HV Battery Pack
• The HV battery pack is enclosed in a metal case and is rigidly mounted to the cargo area floor pan
cross member behind the rear seat. The metal case is isolated from high voltage and concealed by
carpet in the cabin area.

• The HV battery pack consists of 96 low voltage (3.6 Volt) Li-ion battery cells connected in series to
produce approximately 346 Volts. Each Li-ion battery cell is non-spillable and in a sealed case.

• The electrolyte used in the Li-ion battery cell is an organic solvent containing lithium-ion. The
electrolyte is absorbed into the electrode and will not normally leak, even in a collision.

• In the unlikely event that the battery pack is overcharged, the cells vent gases directly outside the
vehicle through a vent hose.

HV Battery Assembly
Battery assembly voltage 346 V
Number of Li-ion battery cells in the battery 288 cells
Li-ion battery cell voltage 3.6 V
Li-ion battery cell dimensions 4.42 x 4.35 x 0.56 in.
(112.2 x 110.6 x 14.1 mm)
Li-ion cell weight 0.54 lbs (245 g)
Li-ion battery assembly dimensions 32.4 x 38.1 x 14.9 in.
(822.4 x 967.8 x 378.4 mm)
Li-ion battery assembly weight 333 lbs (151.1 kg)

Components Powered by the HV Battery Pack

• Electric Motor • Inverter/Converter Motor
• Power Cables • A/C Compressor
• Electric Generator

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 35) or the nearest Toyota dealer.

Auxiliary Battery
• The Prius Plug-in hybrid also contains a 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 auxiliary battery is grounded to the metal chassis of the vehicle.

• The auxiliary battery is located in the cargo area. It is concealed by a fabric cover on the
passenger side in the rear quarter panel well.

346 Volt HV Battery Pack Mounted in Cargo Area 12 Volt Auxiliary Battery Mounted in Cargo Area

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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 346 to 650 Volts DC. The inverter/converter creates 3-phase AC to power the motors.
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
electricity 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 chassis, so there is no
possibility of electric shock when touching the metal chassis.

• A ground-fault monitor 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 16).

Volts DC 12 Volts
Hybrid Vehicle Computer Auxiliary
Battery

A/C
Compressor

Electric
Generator
Inverter/
Converter
Electric
Volts DC
Motor

AC
3-Phase HV Battery Pack

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

12 Volts
Volts DC Hybrid Vehicle Computer Auxiliary
Battery

A/C
Compressor

Electric
Generator Inverter/
Converter
Electric
Volts DC
Motor

AC
3-Phase HV Battery Pack

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 Prius Plug-in hybrid contains the same common automotive fluids used in other non-hybrid Toyota
vehicles, with the exception of the Li-ion electrolyte used in the HV battery assembly. The electrolyte
used in the Li-ion battery cells is a flammable organic electrolyte containing carbonic acid esters. As
the electrolyte is absorbed into the electrode, even if the battery cells crack, there is very little chance of
liquid electrolyte leaking out. However, the electrolyte may react with moisture in the air and generate a
acidic vapor. Some flammable gases may be produced as a byproduct.

NOTE:
Leakage of liquid electrolyte from the HV battery assembly is extremely unlikely due to its construction
and the amount of available electrolyte contained within the Li-ion cells. Any liquid electrolyte that
leaks from a Li-ion battery cell quickly evaporates. Any spillage would not warrant a declaration as a
hazardous material incident. Responders should follow the recommendations as outlined in this
emergency response guide.

• Handle Li-ion electrolyte spills using the following Personal Protective Equipment (PPE):
Splash shield or safety goggles. Fold down helmet shields are not acceptable for acid or
electrolyte spills.
Rubber gloves.
Apron suitable for acid.
Rubber boots.
SCBA

14
Dismantling the vehicle

The following 2 pages contain general instructions for use when working on a Prius Plug-in hybrid.
Read these instructions before proceeding to the HV battery removal instructions on page 19.

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 auxiliary battery cover.
(2) Remove the tire repair kit and styrofoam insert.
(3) Disconnect the battery negative terminal.

15
2. Remove the 3 service plug grips.
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.

16
3. Carry the removed service plug grip in your pocket to prevent other staff from accidentally
reinstalling it while you are dismantling the vehicle.
4. 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).
5. If the service plug grip cannot be removed due to damage to the vehicle, remove the IGCT
fuse (30A) and AM2 fuse (7.5A).
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.

AM2 fuse

IGCT fuse

6. 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.
7. 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.
8. 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.
9. 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.
10. 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 the ignition (READY indicator is off).

2. Remove the tonneau cover assembly.
3. Remove the 12volt auxiliary battery.
(1) Remove the auxiliary battery cover.

(2) Remove the tire repair kit.

(3) Remove the styrofoam insert.
(4) Disconnect the cable from the auxiliary battery
negative (-) terminal.
(5) Disconnect the cable from the auxiliary battery
positive (+) terminal.
(6) Remove the 12volt auxiliary battery.

19
4. Remove the rear No. 4 floor board.
(1) Using a clip remover, disengage the 3 clips and
remove the rear No. 4 floor board.

5. Remove the rear No. 1 floor board.

(1) Using a clip remover, disengage the 8 clips.

(2) Disangage the 3 fasteners and disconnect the

rear No. 1 floor board from the rear seat
assembly LH.

(3) Disangage the 3 fasteners and disconnect the

rear No. 1 floor board from the rear seat
assembly RH and remove the rear No. 1 floor
board.

20
6. Remove the rear deck trim cover.
(1) Remove the bolt.
(2) Using a clip remover, disengage the 4 clips.
(3) Disengage the 4 claws and 4 guides, and
remove the rear deck trim cover.

7. Remove the hybrid battery carrier bracket.

(1) Remove the bolt.
(2) Disengage the 2 pins and remove the hybrid
battery carrier bracket.

21
8. Remove the 3 service plug grips.
Caution:
• Wear insulated gloves.
• Before inspecting or servicing the high-voltage system or disconnecting the low
voltage connector of the inverter with converter assembly, be sure to follow all
safety measures, such as wearing insulated gloves and removing the 3 service
plug grips to prevent electrocution. After removing the 3 service plug grips, carry
one of the 3 service plug grips in your pocket to prevent other technicians from
accidentally reconnecting it while you are servicing the vehicle. Keep the other 2
service plug grips in a secure place.
• High voltage wiring connectors are colored in orange.
(1) Slide the handle of the service plug grip to the right.
(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.

22
9. Remove the 9 bolts and inverter terminal cover.
Caution:
Wear insulated gloves.

10. Check the voltage at the terminals in the

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 DC 750 Volts measure the
voltage.
This inspection is performed to verify that it is safe to remove the HV battery.

11. Cut the rear center seatbelt.

12. Remove the rear seat cushion assembly.
(1) Disengage the 2 front hooks of the seat cushion
from the vehicle body as shown in the
illustration.
(2) Disengage the 2 guides of the seat cushion
from the seatback.
(3) Remove the rear seat cushion assembly.

23
13. Remove the rear side seatback assembly RH.
(4) Remove the bolt.

(5) Disengage the 2 guides and remove the rear

side seatback assembly RH.

14. Remove the rear side seatback assembly LH.

(1) Remove the bolt.

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 (2) Disengage the 2 guides and remove the rear
side seatback assembly LH.

15. Disconnect the rear center seat belt assembly.

(1) Remove the bolt and disconnect the anchor part
of the rear center seat belt assembly.

16. Remove the rear seatback assembly LH.

(1) Remove the 2 bolts and rear seatback assembly
LH.

17. Remove the rear seatback assembly RH.

(1) Remove the 2 bolts and rear seatback assembly
RH.

25
18. Remove the battery cooling blower bracket.
Notice:
• Be sure not to touch the fan part of the
battery cooling blower assemblies.
• Do not lift the battery cooling blower
assemblies using the wire harness.
(1) Disconnect the battery cooling blower assembly
connectors.

(2) Remove the 4 bolts and battery cooling blower

bracket.

19. Remove the No. 5 hybrid battery intake duct.

(1) Remove the 2 clips and No. 5 hybrid battery
intake duct (sub2).

(2) Remove the 2 clips and No. 5 hybrid battery

intake duct (sub1).

26
 (3) Remove the 2 clips and No. 5 hybrid battery
intake duct (main).

20. Remove the battery cooling blower assembly.

Notice:
• Be sure not to touch the fan part of the battery cooling blower assemblies.
• Do not lift the battery cooling blower assemblies using the wire harness.

(1) Remove the 9 nuts and 3 battery cooling blower

assemblies.

21. Disconnect the wire harness.

(1) Disconnect the 3 connectors and 4 clamps.

27
22. Remove converter cooling blower bracket.
(1) Remove the 2 bolts and converter cooling
blower bracket.

23. Remove the No. 2 converter cooling exhaust

duct.
(1) Remove the 4 clips and No. 2 converter cooling
exhaust duct.

24. Remove the No. 3 converter cooling exhaust

duct.
(1) Remove the 3 clips and No. 3 converter cooling
exhaust duct.

25. Remove battery cooling blower assembly (for

hybrid vehicle converter).
Notice:
• Be sure not to touch the fan part of the
battery cooling blower assemblies.
• Do not lift the battery cooling blower
assemblies using the wire harness.
(1) Remove the 3 nuts, clamp and battery cooling
blower assembly.

28
26. Remove the child restraint seat anchor bracket
assembly RH.
(1) Remove the 2 bolts and child restraint seat
anchor bracket sub-assembly RH.

27. Remove the No. 1 hybrid battery intake duct.

(1) Remove the clip and No. 1 hybrid battery
intake duct (main).

(2) Remove the clip and No. 1 hybrid battery

intake duct (sub1).

(3) Remove the clip and No. 1 hybrid battery

intake duct (sub2).

28. Remove the front hybrid cover panel.

(1) Remove the 2 nuts and front hybrid battery
cover panel.

29
29. Remove the HV battery cover sub-assembly.
Caution:
Be sure to wear insulated gloves and
protective goggles.
(1) Separate the 2 claws and 3 clamps, and remove
the indoor electrical key oscillator.

(2) Remove the 18 nuts and HV battery cover

Front
sub-assembly.

30. Disconnect the frame wire.

Caution:
Be sure to wear insulated gloves and protective goggles.
Notice:
Insulate the terminals of the removed frame wire with insulating tape.
(1) Remove the 5 nuts and disconnect the frame
wire from the hybrid junction block assembly.
(2) Disengage the clamp, remove the nut and
disconnect the frame wire from the hybrid
vehicle converter.
(3) Disconnect the connector to disconnect the
frame wire from the hybrid battery charge
relay.

(4) Remove the 2 nuts and frame wire from the

hybrid battery.

30
31. Remove the hybrid vehicle converter.
Caution:
Be sure to wear insulated gloves and protective goggles.
Notice:
Insulate the terminals of the removed frame wire with insulating tape.
(1) Disengage the clamp and disconnect the
connector.

(2) Disconnect the 2 connectors.

(3) Remove the 4 nuts and hybrid vehicle

converter.

32. Remove the converter cooling exhaust duct.

Caution:
Be sure to wear insulated gloves and
protective goggles.
(1) Remove the 2 clips, guide and converter
cooling exhaust duct.

31
33. Install HV battery cover sub-assembly.
Front
Caution:
Be sure to wear insulated gloves and
protective goggles.
(1) Temporarily install the HV battery cover
sub-assembly with the 18 nuts to prevent any
foreign objects or water from entering the HV
battery.

34. Remove the HV battery.

Caution:
Be sure to wear insulated gloves and protective goggles.
Notice:
Insulate the terminals of the removed frame wire with insulating tape.
(1) Remove the 2 bolts from each back door damper stay bracket UPR.
Hint:
Have an assistant support the back door.
(2) Rotate each back door damper stay bracket UPR upside-down as shown in the illustration and
install them with the 2 bolts.

Hint:
This step is performed to provide additional clearance and prevent interference between the
vehicle body and mini crane when removing or installing the HV battery.

32
 (3) Disconnect the 4 connectors and 2 clamps.

(4) Install the 4 eyebolts in the locations shown in

the illustration. Front
Hint:
Make sure to use the eyebolts supplied with the HV
battery.

(5) Set the hooks and straps as shown in the

illustration.
Notice:
Make sure to use hooks and straps that are
strong enough to support the weight of the HV
battery.

(6) Using a couple of pieces of cloth, protect the

surfaces of the HV battery where it contacts the
straps.

33
(7) Remove the 6 bolts and 2 nuts.
Hint:
• Attach tape to the feet and edges of the
battery to protect tools and the vehicle body.
• Use cardboard or other similar material to
protect the HV battery and vehicle body from
damage.

(8) Using a suitable adaptor such as straps, remove

the HV battery.
Caution:
To prevent any accidents and injuries due to
the weight of the HV battery, follow all
specified procedures and be careful to
balance the HV battery when removing or
installing it.
Notice:
Make sure that the HV battery does not
interfere with the vehicle body during removal
or installation.

34
HV Battery Caution Label
1. For U.S.A.

2. For CANADA

3. For Europe

35