PRIUS

Gasoline-Electric
Hybrid Synergy Drive

ZVW50/ZVW51 Series
Foreword

This guide was developed to educate and assist dismantlers in the safe handling of Toyota PRIUS
gasoline-electric hybrid vehicles. PRIUS 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, 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 head lights, radio, and gauges are
powered from a separate 12 Volt auxiliary battery. Numerous safeguards have been designed into the
PRIUS to help ensure the high voltage, approximately 201.6 Volt, Nickel Metal Hydride (NiMH) Hybrid
Vehicle (HV) battery pack*1 or Lithium-ion (Li-ion) Hybrid Vehicle (HV) battery pack*2 is kept safe
and secure in an accident.
The NiMH HV battery pack*1 or the Lithium-ion (Li-ion) HV battery pack*2 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.

*1: for Nickel-Metal hydride battery

*2: for Lithium-ion battery

Additional topics contained in the guide include:

 Toyota PRIUS identification.
 Major hybrid component locations and descriptions.

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

 2015 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.
Table of Contents

About the PRIUS ........................................................................................................................................ 1

PRIUS 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 ............................................................................................................................ 16

Removal of HV battery ............................................................................................................................ 21

About the PRIUS
The PRIUS 5-door hatchback joins the hybrid model for Toyota. Hybrid Synergy Drive
means that the vehicle contains a gasoline engine and 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 PRIUS 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 PRIUS 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 electric 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 the 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
PRIUS Identification
In appearance, the PRIUS is a 5-door hatchback. Exterior, interior, and engine
compartment illustrations are provided to assist in identification.

The alphanumeric 15 character Vehicle Identification Number (VIN) is provided on the

floor under the right side front seat, left side windshield cowl and left side B pillar.

Example VIN:
JTDKARFU3000101, JTDKBRFU3000101 or JTDKB3FU3000101

A PRIUS is identified by the first 8 alphanumeric characters JTDKARFU, JTDKBRFU

or JTDKB3FU.

Left Side Windshield Cowl, Under the Right Side Front Seat and Left Side B Pillar

2
PRIUS Identification (Continued)
Exterior

 logos on the luggage compartment door and each front fender.

 Gasoline fuel filler door located on the left side rear quarter panel.




Exterior Front and Left Side View


 

Exterior Rear and Left Side View

3
PRIUS Identification (Continued)
Interior

 The instrument cluster (READY indicator, shift state indicators and warning lights)
located in center of the dash and near the base of the windshield.

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

This illustration is for an LHD model

Interior View

READY Indicator READY Indicator

for LHD for RHD

Combination Meter View

4
PRIUS Identification (Continued)
Engine Compartment

 1.8-liter aluminum alloy gasoline engine.

 Logo on the engine cover.

 Orange colored high voltage power cables.

Engine Compartment View

for Nickel-Metal hydride battery:

 for Lithium-ion
battery:

Power Cables

5
Hybrid Component Locations & Descriptions

Component Description
12 Volt Auxiliary Battery Supplies electricity to the electrical components.

Hybrid Vehicle (HV)  Supplies electrical power to MG1 and MG2 in accordance with the
Battery Pack  driving conditions of the vehicle.
 Recharged by MG1 and MG2 in accordance with the SOC and the
driving conditions of the vehicle.
Power Cables  Connects the HV battery, inverter with converter assembly, hybrid
vehicle transaxle assembly and compressor with motor assembly.
Inverter/ DC-DC Steps down the HV battery nominal voltage of DC 201.6 V*1 / DC
Converter Converter  207.2 V*2 to approximately DC 14 V in order to supply electricity to
 for 12 Volt the electrical components, as well as to recharge the auxiliary battery.
Auxiliary
Battery
Motor Controls the inverter and boost converter in accordance with the
Generator signals received from the hybrid vehicle control ECU, thus operating
ECU MG1 and MG2 as either a generator or motor.
Boost Boosts the HV battery nominal voltage of DC 201.6 V*1 / DC 207.2
Converter V*2 up to a maximum voltage of DC 600 V and vice versa (steps
down DC 600 V to DC 201.6 V*1 / DC 207.2 V*2).
Inverter Converts the direct current from the boost converter into alternating
current for MG1 and MG2, and vice versa (from AC to DC).
Gasoline Engine  Is a high-expansion ratio Atkinson cycle engine which is compatible
with the hybrid system and which generates drive force for driving and
energy for electricity generation.
Electric Motor  MG2, which is driven by electrical power from MG1 and the HV
 battery, generates motive force for the drive wheels.
 During braking, or when the accelerator pedal is not depressed, it
generates high-voltage electricity to recharge the HV battery.
Electric Generator  MG1, which is driven by the engine, generates high-voltage electricity
in order to operate MG2 and charge the HV battery. Also, it functions
as a starter to start the engine.
A/C Compressor Is driven at a speed calculated by the air conditioning amplifier
(with inverter)  assembly, receives drive requests from the hybrid vehicle control ECU
and takes in, compresses and discharges refrigerant.
Fuel Tank and Fuel Line The fuel tank provides gasoline via a fuel line to the engine. The fuel
 line is routed along the left side under the floor pan.
*Numbers in the component column apply to the illustrations on the following page.

*1: for Nickel-Metal hydride battery

*2: for Lithium-ion battery

6
Hybrid Component Locations & Descriptions (Continued)
Specifications

Gasoline Engine: 71 kW*1 / 72 kW*2, 1.8-liter Aluminum Alloy Engine

Electric Motor: 53 kW (71 HP), Permanent Magnet Motor
Transmission: Automatic Only
HV Battery: 201.6 Volt Sealed NiMH Battery*3
207.2 Volt Sealed Li-ion- Battery*4
Curb Weight: 1,775 kg / 3,915 lbs*5
1,790 kg / 3,946 lbs*6
Fuel Tank: 43 liters /11.4 gals
Frame Material: Steel Unibody
Body Material: Steel Panels
Seating Capacity: 5 passenger

*1: for North America, South Korea

*2: except North America, South Korea
*3: for Nickel-Metal hydride battery
*4: for Lithium-ion battery
*5: except Europe
*6: for Europe

for Nickel-Metal hydride battery:


 
 for Lithium-ion battery:
 



for Nickel-Metal hydride battery:


 for Lithium-ion
 battery: 




7
Hybrid Synergy Drive Operation
Once the READY indicator is illuminated in the combination meter, 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, 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.

for LHD for RHD

Combination Meter READY Indicator

8
Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery
The PRIUS features a high voltage Hybrid Vehicle (HV) battery pack that contains
sealed Nickel Metal Hydride (NiMH) battery modules*1 or Lithium-ion (Li-ion) battery
cells*2.

*1: for Nickel-Metal hydride battery

*2: for Lithium-ion battery

HV Battery Pack
for Nickel-Metal hydride battery:
 The HV battery pack is enclosed in a metal case and is rigidly mounted to the cabin area
under the right side front seat. The metal case is isolated from high voltage and concealed
by fabric covers in the cabin area.

 The HV battery pack consists of 28 low voltage (7.2 Volt) NiMH battery modules
connected in series to produce approximately 201.6 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 201.6 V
Number of NiMH battery modules in the pack 28
NiMH battery module voltage 7.2 V

for Lithium-ion battery:

 The HV battery pack is enclosed in a metal case and is rigidly mounted to the cabin area
under the right side front seat. The metal case is isolated from high voltage and concealed
by fabric covers in the cabin area.

 The HV battery pack consists of 56 low voltage (3.6 Volt) Li-ion battery cells connected in
series to produce approximately 207.2 Volts. Each Li-ion battery cell is non-spillable and in
a sealed case.

 The electrolyte used in the Li-ion battery cells is a flammable organic electrolyte. The
electrolyte is absorbed into the battery cell separator and will not normally leak, even in a
collision.

HV Battery Pack
Battery pack voltage 207.2 V
Number of Li-ion battery cells in the pack 56
Li-ion battery cell voltage 3.6 V

Components Powered by the HV Battery Pack

 Electric Motor
 Power Cables
 A/C Compressor
 Electric Generator
 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 or the nearest Toyota dealer.

Auxiliary Battery
 The PRIUS also 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 auxiliary battery is grounded to the metal chassis of the vehicle.
 The auxiliary battery is located in the luggage compartment area. It is concealed by a plastic
resin cover on the right side in the battery compartment.

for Nickel-Metal hydride battery:

for Lithium-ion battery:

12 Volt Auxiliary Battery Mounted in

201.6*1 / 207.2*2 Volt HV Battery Pack
Engine Compartment Area

for Nickel-Metal hydride battery: for Lithium-ion battery:

HV Battery Pack Mounted in Cabin Area

*1: for Nickel-Metal hydride battery

*2: for Lithium-ion battery

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 201.6*1, 207.2*2 to 600 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 motors (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:

*1: for Nickel-Metal hydride battery

*2: for Lithium-ion battery

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 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 * 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 a
message indicating that the hybrid system is malfunctioning will be displayed 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).

Hybrid Vehicle Computer

0.0
➍
Volts DC

A/C
➋
Compressor
➋
Electric Inverter/ ❸ ❸
Generator Converter

12 Volts 0.0
Auxiliary Electric Volts DC
Battery Motor
➊

0 Volts AC HV Battery Pack

3-Phase

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

Hybrid Vehicle Computer

201.6*1
207.2*2
Volts DC

A/C
Compressor

Electric Inverter/
Generator Converter

12 Volts 201.6*1
Auxiliary Electric 207.2*2
Battery Motor Volts DC

600 Volts
HV Battery Pack
AC Max
3-Phase

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

*1: for Nickel-Metal hydride battery

*2: for Lithium-ion battery

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

for Nickel-Metal hydride battery:

The PRIUS 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 metal 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
for Lithium-ion battery:
The PRIUS 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 pack. The electrolyte used
in the Li-ion battery cells is a flammable organic electrolyte. The electrolyte is absorbed into the battery
cell separators, even if the battery cells are crushed or cracked, it is unlikely that liquid electrolyte will
leak. Any liquid electrolyte that leaks from a Li-ion battery cell quickly evaporates.

WARNING:
・ The Li-ion battery contains organic electrolyte. Only a small
amount may leak from the batteries which may irritate the eyes,
nose, throat, and skin.
・ Contact with the vapor produced by the electrolyte may irritate
the nose and throat.
・ To avoid injury by coming in contact with the electrolyte or vapor,
wear personal protective equipment for organic electrolyte
including SCBA or protective mask for organic gases.

 Handle Li-ion 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 gloves or gloves suitable for organic solvents.
• Apron suitable for organic solvents.
• Rubber boots or boots suitable for organic solvents.
• Protective mask for organic gases or SCBA.

15
Dismantling the vehicle

The following 4 pages contain general instructions for use when working on a PRIUS.
Read these instructions before proceeding to the HV battery removal instructions on page 21.

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) Loosen the nut, and disconnect the cable from
the negative (-) auxiliary battery terminal.

2. Remove the battery service hole cover.

(1) Remove the clip.
(2) Disengage the 5 claws and remove the
battery service hole cover.
.

16
3. Remove the service plug grip.
Caution:
・Wear insulated gloves.
・Do not inspect or service the high voltage
system with the service plug grip installed.

・To reduce the risk of electric shock, make sure to remove the service plug grip to
cut off the high voltage circuit before servicing the vehicle..
・To reduce the risk of electric shock, make sure
to wait at least 10 minutes after removing the
service plug grip to fully discharge the high
voltage capacitor inside the inverter with
converter assembly.

・Keep the removed service plug grip in your pocket to prevent other technicians from
accidentally installing it while you are servicing the vehicle.
・Place a "HIGH VOLTAGE WORK IN PROGRESS. DO NOT TOUCH." sign, in order to
prevent other technicians from accidentally reconnecting the power while work is in
progress.
Notice:
・After removing the service plug grip, turning the power switch on (READY) may cause a
malfunction. Do not turn the power switch on (READY) unless instructed by the repair manual.
・Do not touch the terminals of the service plug grip.
Hint:
Waiting for at least 10 minutes is required to discharge the high voltage capacitor inside the
inverter with converter assembly.

17
 (1) While wearing insulated gloves, rotate the handle of the service plug grip and remove the
service plug grip as indicated by the arrows, in the order shown in the illustration.

for NICKEL METAL HYDRIDE BATTERY:

for LITHIUM-ION BATTERY:

4. Carry the removed service plug grip in your pocket to prevent other staff from
accidentally reinstalling it while you are dismantling the vehicle.
5. 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 20).
6. If the service plug grip cannot be removed due IG2-MAIN fuse
to damage to the vehicle, remove the
IG2-MAIN fuse (25 A).
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.

18
7. 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.

8. 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.
9. 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.
10. 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.
11. 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.

19
20
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 IGINITION (READY indicator is off)

2. REMOVE AUXILIARY BATTERY
(1) Loosen the nut and disconnect the cable from the
negative (-) auxiliary battery terminal.

(2) Disengage the 2 claws and open the battery terminal

cap.
(3) Loosen the nut and disconnect the cable from the
positive (+) auxiliary battery terminal.

21
 (4) Remove the bolt.

(5) Remove the No. 2 battery clamp as shown in the

illustration..
(6) Remove the auxiliary battery.

3. REMOVE BATTERY SERVICE HOLE COVER

(1) Remove the clip.
(2) Disengage the 5 claws and remove the battery
service hole cover.

22
4. REMOVE SERVICE PLUG GRIP
Caution:
・Wear insulated gloves.
・Do not inspect or service the high voltage
system with the service plug grip installed.

・To reduce the risk of electric shock, make sure to remove the service plug grip to
cut off the high voltage circuit before servicing the vehicle..
・To reduce the risk of electric shock, make sure
to wait at least 10 minutes after removing the
service plug grip to fully discharge the high
voltage capacitor inside the inverter with
converter assembly.

・Keep the removed service plug grip in your pocket to prevent other technicians from
accidentally installing it while you are servicing the vehicle.
・Place a "HIGH VOLTAGE WORK IN PROGRESS. DO NOT TOUCH." sign, in order to
prevent other technicians from accidentally reconnecting the power while work is in
progress.
Notice:
・After removing the service plug grip, turning the power switch on (READY) may cause a
malfunction. Do not turn the power switch on (READY) unless instructed by the repair manual.
・Do not touch the terminals of the service plug grip.
Hint:
Waiting for at least 10 minutes is required to discharge the high voltage capacitor inside the
inverter with converter assembly.

23
 (1) While wearing insulated gloves, rotate the handle of the service plug grip and remove the
service plug grip as indicated by the arrows, in the order shown in the illustration..
for NICKEL METAL HYDRIDE BATTERY:

for LITHIUM-ION BATTERY:

5. REMOVE WINDSHIELD OUTSIDE MOULDING

LH
(1) Using a moulding remover, disengage the 12 claws
and remove the windshield outside moulding.

6. REMOVE WINDSHIELD OUTSIDE MOULDING

RH
Hint:
Use the same procedure as for the LH side.

24
7. REMOVE FRONT WIPER ARM HEAD CAP
(1) Using a screwdriver, disengage the 3 claws to
remove the front wiper arm head cap.
Hint:
Use the same procedure for the RH side and LH side.

8. REMOVE FRONT WIPER ARM AND BLADE

ASSEMBLY LH
(1) Remove the nut and front wiper arm and blade
assembly LH.

9. REMOVE FRONT WIPER ARM AND BLADE

ASSEMBLY RH
(1) Remove the nut and front wiper arm and blade
assembly RH.

10. REMOVE COWL WATER EXTRACT SHIELD LH

(1) Disengage the 2 claws and 2 guides to remove the
cowl water extract shield LH as shown in the
illustration.

11. REMOVE COWL WATER EXTRACT SHIELD RH

Hint:
Use the same procedure as for the LH side.

25
12. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
(1) Remove the 2 clips.

(2) Disengage the guide as shown in the illustration.

26
 (3) Disengage the 3 guides and remove the cowl top ventilator louver sub-assembly as shown in
the illustration.

Notice:
When removing the cowl top ventilator louver sub-assembly, it may contact the brake master
cylinder reservoir filler cap assembly and cause it to fall off. Check the installation condition of
the brake master cylinder reservoir filler cap assembly after removing the cowl top ventilator
louver sub-assembly.

13. REMOVE WINDSHIELD WIPER MOTOR AND for LHD:

LINK ASSEMBLY
(1) Remove the 2 bolts.

for RHD:

27
(2) Disengage the motor grommet as shown in the for LHD:
illustration.

Motor Grommet

for RHD:

Motor Grommet

(3) Disconnect the connector to remove the windshield for LHD:

wiper motor and link assembly.

for RHD:

28
14. REMOVE NO. 1 HEATER AIR DUCT SPLASH
SHIELD SEAL (for LHD)
(1) Disengage the 2 claws and remove the No. 1 heater
air duct splash shield seal from the outer cowl top
panel sub-assembly.

15. REMOVE NO. 2 HEATER AIR DUCT SPLASH

SHIELD SEAL (for RHD)
(2) Disengage the 2 claws and remove the No. 2 heater
air duct splash shield seal from the outer cowl top
panel sub-assembly.

16. REMOVE WATER GUARD PLATE LH for LHD:

(1) Disengage the claw and remove the water guard
plate LH.

for RHD:

17. REMOVE COWL BODY MOUNTING for LHD:

REINFORCEMENT LH
(1) Remove the 4 bolts and cowl body mounting
reinforcement LH from the outer cowl top panel
sub-assembly and vehicle body.

for RHD:

29
18. REMOVE OUTER COWL TOP PANEL for LHD:
SUB-ASSEMBLY
(1) Disengage the 2 clamps and separate the wire harness
from the outer cowl top panel subassembly.

for RHD:

(2) Remove the 7 bolts, 4 nuts and outer cowl top panel for LHD:
sub-assembly.

for RHD:

19. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

(1) Disengage the 3 clips and remove the No. 1 engine
cover sub-assembly.
Notice:
Pull the No. 1 engine cover sub-assembly straight up to
remove. Attempting to pull the No. 1 engine cover
sub-assembly forward or attempting to pull it up by
holding the left and right sides may cause the No. 1
engine cover sub-assembly to break.

30
20. DISCONNECT ENGINE WIRE
Caution:
Wear insulated gloves.
Notice:
Do not allow any foreign matter or water to enter
the inverter with converter assembly.
(1) Move each lock lever as shown in the illustration
and disconnect the 2 inverter with converter
assembly connectors.
Notice:
・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.
(2) Remove the bolt.
(3) Disengage the 2 clamps and disconnect the engine
wire.

21. REMOVE CONNECTOR COVER ASSEMBLY

Caution: (B)
Wear insulated gloves.
(1) Remove the bolt (B).
(2) Using a T25 "TORX" socket wrench, remove the (A)
bolt (A) and connector cover assembly from the
inverter with converter assembly.
Notice:
Do not allow any foreign matter or water to enter
the inverter with converter assembly.

31
22. CHECK TERMINAL VOLTAGE
Caution:
Wear insulated gloves.
Notice:
Do not allow any foreign matter or water to enter the inverter with converter assembly.
(1) Using a voltmeter, measure the voltage between the
terminals of the 2 phase connectors.
Standard Voltage: 0 V
Hint:
Use a measuring range of DC 750 V or more on the
voltmeter.

23. REMOVE REAR SEAT CUSHION ASSEMBLY Frame Hook Rear Side
Caution: Place Hand Here
Wear protective gloves. Sharp areas on the seat
frame may injure your hands. Place Hand Here
(1) Lift the front edge of the rear seat cushion assembly
as shown in the illustration and disengage the 2 rear
seat cushion frame hooks on the front side of the
rear seat cushion assembly from the rear seat cushion
A A
lock hooks.
Frame Hook Frame Hook
Notice:
Front Side Front Side
Be sure to hold the parts of the seat cushion assembly
directly next to the rear seat cushion frame hooks
when lifting it. Lifting a different part of the cushion may
deform the rear seat cushion frame.
Standard Measurement:
Area Measurement
A 135 mm (5.31 in.)
(2) Disengage the rear seat cushion frame hook on
the rear side of the rear seat cushion assembly as
shown in the illustration.

24. REMOVE REAR SEAT CUSHION LOCK HOOK

(1) Disengage the 2 claws to remove the rear seat
cushion lock hook as shown in the illustration.
Hint:
Use the same procedure for the RH side and LH side.

32
25. REMOVE REAR DOOR SCUFF PLATE LH Place Hand Here
(1) Disengage the claw as shown in the illustration.

(2) Disengage the 6 claws and 3 guides to remove the

rear door scuff plate LH as shown in the illustration.

26. REMOVE REAR UNDER SIDE COVER LH

(1) Remove the 2 clips.
(2) Disengage the claw, 4 clips and guide to
remove the rear under side cover LH as shown
in the illustration.

27. REMOVE REAR DOOR SCUFF PLATE RH

Hint:
Use the same procedure as for the LH side.

28. REMOVE REAR UNDER SIDE COVER RH

Hint:
Use the same procedure as for the LH side.

33
29. REMOVE REAR UNDER COVER for NICKEL METAL
(1) Disengage the 2 clips. HYDRIDE BATTERY:
(2) Disengage the 2 guides to remove the rear
under cover from the rear seat cushion leg
sub-assembly.

for LITHIUM-ION BATTERY:

30. REMOVE REAR SEAT CUSHION LEG

SUB-ASSEMBLY
(1) for NICKEL METAL HYDRIDE BATTERY:
a) Remove the 6 bolts and rear seat cushion leg
sub-assembly.

(2) for LITHIUM-ION BATTERY:

a) Remove the 9 bolts and rear seat cushion leg
sub-assembly.

31. REMOVE BATTERY COOLING BLOWER for NICKEL METAL

ASSEMBLY HYDRIDE BATTERY:
(1) Disconnect the battery cooling blower assembly
connector.
(2) Disengage the 2 clamps.

for LITHIUM-ION BATTERY:

34
 (3) Remove the 3 bolts.
for NICKEL METAL for LITHIUM-ION
HYDRIDE BATTERY: BATTERY:

(4) Disengage the 2 claws to remove the battery cooling blower assembly.
Notice:
・Be sure not to touch the fan part of the battery cooling blower assembly.
・Do not lift the battery cooling blower assembly using the wire harness.

32. REMOVE NO. 1 HV BATTERY COVER PANEL RH Service Plug Grip

Caution:
Wear insulated gloves. Turn Button
(1) for NICKEL METAL HYDRIDE BATTERY: Lock Striker
a) Using the service plug grip, remove the battery
cover lock striker. Projection

Hint:
Insert the projection of the service plug grip and
turn the button of the battery cover lock striker
counterclockwise to release the lock.
b) Remove the 3 bolts, 2 nuts and No. 1 HV battery
cover panel RH from the HV battery.
(2) for LITHIUM-ION BATTERY: Service Plug Grip
a) Using the service plug grip, remove the battery
cover lock striker. Turn Button
Hint: Lock Striker
Insert the projection of the service plug grip and
turn the button of the battery cover lock striker Projection
counterclockwise to release the lock.
b) Remove the 2 bolts, 3 nuts and No. 1 HV battery
cover panel RH from the HV battery.

35
33. DISCONNECT HV FLOOR UNDER WIRE for NICKEL METAL HYDRIDE
Caution: BATTERY:
Wear insulated gloves.
Notice:
Insulate each disconnected high-voltage connector
with insulating tape. Wrap the connector from the Shield Ground
wire harness side to the end of the connector.
for LITHIUM-ION BATTERY:
(1) Disconnect the 2 HV battery junction block
assembly connectors.
(2) Disconnect the shield ground from the HV
battery.

Shield Ground

34. DISCONNECT FLOOR WIRE for NICKEL METAL HYDRIDE

Caution: BATTERY:
Wear insulated gloves.
(1) Disengage the clamp.
(2) Disconnect the electric vehicle battery plug assembly
connector.
(3) Disconnect the HV battery junction block assembly
for LITHIUM-ION BATTERY:
connector.

35. REMOVE NO. 1 HYBRID BATTERY EXHAUST

DUCT (for NICKEL METAL HYDRIDE BATTERY)
(1) Remove the clip.
(2) Disengage the claw to remove the No. 1 hybrid
battery exhaust duct from the HV battery.

36
36. REMOVE HYBRID BATTERY HOSE ASSEMBLY
(for LITHIUM-ION BATTERY)
(1) Disconnect the hybrid battery hose assembly from
the vehicle.
(2) Disengage the 2 claws to remove the hybrid battery
hose assembly from the HV battery.

37. REMOVE NO. 4 HV BATTERY PROTECTOR

(for LITHIUM-ION BATTERY)
(1) Disengage the 2 claws to remove the No. 4 HV
battery protector from the HV battery.

38. DISCONNECT FLOOR WIRE for NICKEL METAL

Caution: HYDRIDE BATTERY:
Wear insulated gloves.
(1) Disengage the clamp.
(2) Disconnect the connector.

for LITHIUM-ION BATTERY:

39. REMOVE HV BATTERY

Caution:
Wear insulated gloves.
(1) for NICKEL METAL HYDRIDE BATTERY:
a) Remove the 5 bolts and HV battery from the
vehicle.

37
(2) for LITHIUM-ION BATTERY:
a) Remove the 4 bolts and HV battery from the
vehicle.
Notice:
・To prevent the wire harness from being caught,
make sure to bundle the wire harness using
insulating tape or equivalent.
・Since the HV battery is very heavy, 2 people are needed to remove it.
・When removing/ moving the HV battery, make sure not to tilt it more than 80°.
・Insulate the disconnected terminals or connectors with insulating tape.
・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 for NICKEL METAL
battery. HYDRIDE BATTERY:

for LITHIUM-ION BATTERY:

: Hold Area

・Do not put your hands into the openings of the HV for NICKEL METAL HYDRIDE
battery. BATTERY:

for LITHIUM-ION BATTERY:

38
: Opening