Repair Instruction: Precaution: Precaution

1. HINTS ON OPERATIONS
   Fig 1: Identifying Precaution For Basic Repair

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1	Attire	Always wear a clean uniform. A hat and safety shoes must be worn.
   2	Vehicle protection	Prepare a grille cover, fender cover, seat cover and floor mat before starting work.
   3	Safety procedures	When working with 2 or more persons, be sure to check the safety of one another. When working with the engine running, make sure to provide ventilation for exhaust fumes in the workshop. If working on high temperature, high pressure, rotating, moving or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others. When jacking up the vehicle, be sure to support the specified locations with safety stands. When lifting up the vehicle, use appropriate safety equipment.
   4	Preparation of tools and measuring equipment	Before starting work, prepare a tool stand, SST, measuring equipment, oil and any replacement parts required.
   5	Removal and installation, disassembly and assembly operations	Diagnose with a thorough understanding of proper procedures and of the reported problem. Before removing any parts, check the general condition of the assembly and for deformation and damage. If the procedure is complicated, take notes. For example, note the total number of electrical connections, bolts or hoses removed. Add matchmarks to ensure reassembly of components in the original positions. Temporarily mark hoses and their fittings if needed. Clean and wash the removed parts if necessary and assemble them after a thorough check.
   6	Removed parts	Place the removed parts in a separate box to avoid mixing them up with new parts or contaminating the new parts. For non-reusable parts such as gaskets, O-rings and self-locking nuts, replace them with new ones as instructed in this information. Retain the removed parts for customer inspection, if requested.
   7*	Checks to perform after work is finished	Make sure that removed and installed parts (oil filler cap, level dipstick, floor mat, etc.) are properly installed/tightened. Make sure that none of the cloths or tools that were used have been left in the engine compartment or within the vehicle. Check that there are no oil leaks.

   WARNING:

   *: Be sure to perform these checks properly, Not performing these checks properly after finishing work can lead to serious accident or injury.

2. JACKING UP AND SUPPORTING VEHICLE
   1. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations.
3. PRECOATED PARTS
   Fig 2: Identifying Seal Lock Adhesive

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *a	Seal Lock Adhesive

   1. Precoated parts are bolts and nuts that are coated with seal lock adhesive at the factory.
   2. If a precoated part is retightened, loosened or moved in any way, it must be recoated with the specified adhesive.
   3. When reusing a precoated part, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriately to that part.
   4. Some seal lock agents harden slowly. You may have to wait for the seal lock adhesive to harden.
4. GASKETS
   1. When necessary, use a sealer on gaskets to prevent leaks.
5. BOLTS, NUTS AND SCREWS
   1. Carefully follow all the specifications for tightening torque. Always use a torque wrench.
6. FUSES
   Fig 3: Identifying Incorrect/Correct Fuse Conditions

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *a	INCORRECT
   *b	CORRECT

   1. When inspecting a fuse, check that the wire of the fuse is not broken.
   2. If the wire of a fuse is broken, confirm that there are no shorts in its circuit.
   3. When a fuse is replaced, a fuse with the same amperage rating must be used.

      Illustration	Symbol	Part Name	Abbreviation
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	FUSE	FUSE
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	MEDIUM CURRENT FUSE	M-FUSE
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	HIGH CURRENT FUSE	H-FUSE
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	FUSIBLE LINK	FL
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	CIRCUIT BREAKER	CB

7. CLIPS
   1. The removal and installation methods of typical clips used for vehicle body parts are shown in the table below.

      HINT: 

      If clips are damaged during a procedure, always replace the damaged clips with new ones.

      Shape (Example)	Removal/Installation
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002 Remove the clips with a clip remover or pliers.
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002 Remove the clips with a clip remover or screwdriver.
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002 Remove the clips with a wide scraper to prevent panel damage.
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002 Remove the clips by pushing the center pin through and prying out the shell.
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002 Remove the clips by unscrewing the center pin and prying out the shell.
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002 Remove the clips by prying out the pin and then prying out the shell.

8. CLAWS
   1. The removal and installation methods of typical claws used for vehicle body parts are shown in the table below.

      HINT: 

      If claws are damaged during a procedure, always replace the cap or cover that has damaged claws with a new one.

      Shape (Example)	Illustration	Procedure
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Using a screwdriver, disengage the claws and remove the cap or cover.
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Using a screwdriver, disengage the claws and remove the cap or cover.
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Using a screwdriver, disengage the claws and remove the cap or cover.

9. HINGES, GUIDES, CLAMPS, PINS, ETC.
   1. The removal and installation methods of typical hinges, guides, clamps and pins used for vehicle body parts are shown in the table below.

      HINT: 

      If clamps are damaged during a procedure, always replace the cap or cover that has damaged clamps with a new one.

      Shape (Example)	Removal/Installation
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

10. REMOVAL AND INSTALLATION OF VACUUM HOSES
    1. To disconnect a vacuum hose, pull and twist it from the end of the hose. Do not pull it from the middle of the hose as this may damage the hose.
       Fig 4: Identifying Removal & Installation Of Vacuum Hoses

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       TEXT IN ILLUSTRATION
       
       

       *a	INCORRECT
       *b	CORRECT

    2. When disconnecting vacuum hoses, use tags to identify where they should be reconnected.
       Fig 5: Identifying Tags On Vacuum Hoses

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. After completing any hose related repairs, double-check that the vacuum hoses are properly connected. The label under the hood shows the proper layout.
    4. When using a vacuum gauge, never force the hose onto a connector that is too large. If a hose has been stretched, air may leak. Use a step-down adapter if necessary.
11. TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL
    Fig 6: Identifying Torque Wrench With Extension Tool (1 Of 2)

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with a torque wrench.
       Fig 7: Identifying Torque Wrench With Extension Tool (2 Of 2)

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       • Formula

         T' = (L2/(L1 + L2)*T

         T'	Reading of torque wrench {N*m (kgf*cm, ft.*lbf)}
         T	Torque {N*m (kgf*cm, ft.*lbf)}
         L1	Length of SST or extension tool {cm (in.)}
         L2	Length of torque wrench {cm (in.)}

       NOTE:

       If an extension tool or SST is combined with a torque wrench and used to tighten to a torque specification in this information, the actual torque will be excessive and parts will be damaged.

1. Technicians must undergo special training to be able to service and inspect the high-voltage system.
2. All high-voltage wire harnesses and connectors are colored orange. The HV battery and other high-voltage components have "High Voltage" caution labels. Do not carelessly touch these wires or components.
3. When there is a problem with the wire harness or connector of a high-voltage circuit, repairs to the harness or connector should not be attempted. Replace damaged or malfunctioning high voltage cables or connectors.
4. Before inspecting or servicing the high-voltage system, be sure to follow all safety measures, such as wearing insulated gloves and removing the service plug to prevent electrocution. Carry the removed service plug in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.
   Fig 8: Identifying Service Plug Grip

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

5. After removing the service plug grip, wait 10 minutes before touching any of the high-voltage connectors and terminals.

   HINT: 

   Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

6. Before using insulated gloves, be sure to check them for cracks, tears and other types of damage by performing the following procedure.
   Fig 9: Inspecting Insulated Gloves For Potential Hazardous Damages

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Place the glove on its side.
   2. Roll the opening up 2 or 3 times.
   3. Fold the opening in half to close it.
   4. Confirm that there are no air leaks.
7. When servicing the vehicle, do not carry metal objects like mechanical pencils or rulers that can be dropped accidentally and cause a short circuit.
8. Before touching a bare high-voltage terminal, wear insulated gloves and use a tester to make sure that the terminal voltage is 0 V.
9. After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulating tape.
   Fig 10: Insulating High Voltage Connectors & Terminals

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Bolts and nuts for high-voltage terminals should be tightened firmly to the specified torque. Both insufficient and excessive torque can cause failure.
11. Use the "CAUTION: HIGH VOLTAGE DO NOT TOUCH" sign to notify other technicians that the high-voltage system is being inspected and/or repaired.
    Fig 11: Identifying Caution: High Voltage Do Not Touch Sign

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. After servicing the high-voltage system and before reinstalling the service plug, check again that you have not left a part or tool inside, that the high-voltage terminals are firmly tightened, and that the connectors are correctly connected.
13. When installing hybrid system components such as the HV battery, make sure that the polarity of all connections is correct.

1. The vehicle automatically turns the engine on and off when the READY light on the instrument panel is illuminated. To avoid injury, make sure that both the indicator on the power switch and the READY light on the meter are off.

Fig 12: Identifying Ready Light, Master Warning Light, MIL & Charge Warning Light

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. If one of the warning lights (2) to (4) illuminates, connect the Techstream to the DLC3 to check the DTCs (Diagnostic Trouble Codes). Then, refer to the applicable troubleshooting steps in this information to inspect and repair the affected area. The foregoing actions are also required if the READY light does not illuminate when attempting to turn the power switch on (READY).

   Indicator Light	Vehicle Condition
   (1) READY (TO DRIVE)	Illuminates when the power switch is turned on (READY), indicating that the vehicle is ready to be driven.
   (2) Master Warning Light	Depending on the warning, the master warning light comes on or flashes to indicate that a warning is currently being displayed on the multi-information display. Depending on the warning, the buzzer may also sound. When any malfunction occurs in the hybrid system or hybrid battery system, the master warning light comes on or flashes along with a buzzer, and a warning, "CHECK HYBRID SYSTEM", is displayed on the multi-information display.
   (3) MIL	Illuminates when there is a malfunction in the engine control system. (Also illuminates when the power switch is turned on (IG) and on (READY).)
   (4) Charge Warning Light	Illuminates when there is a malfunction in the charging system. (Be sure to check the DTC (Diagnostic Trouble Code) if this light illuminates together with the master warning light.)

HINT: 

The vehicle uses a 12 V auxiliary and a 201.6 V HV battery. Therefore, there are 2 recharging methods when the batteries are discharged.

1. Perform this procedure when the auxiliary battery is fully discharged.

   HINT: 

   The following problems indicate that the auxiliary battery is discharged:

   • No display appears on the instrument panel when the power switch is turned on (IG).
   • The hybrid system does not start.
   • The headlights are dim.
   • The sound from the horn is weak.
   • Park (P) cannot be disengaged.
   NOTE:

   Never use a quick charger.

   1. Engage the parking brake.
   2. Turn the power switch off and remove the key from the interior detection area.
   3. Remove the No. 1 relay block cover.
   4. Using booster cables, connect the 12 V auxiliary battery of the rescue vehicle and the auxiliary battery of the stalled vehicle as shown in the illustration.

      HINT: 

      Use the booster terminal in the engine compartment.

      Fig 13: Connecting 12 V Auxiliary Battery Of Rescue Vehicle & Auxiliary Battery Of Stalled Vehicle

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Connecting Sequence	Connecting Location
      1	Positive booster terminal of stalled vehicle
      2	Positive auxiliary battery terminal of rescue vehicle
      3	Negative auxiliary battery terminal of rescue vehicle
      4	Position shown in the illustration on stalled vehicle

   5. Start the engine of the rescue vehicle and run the engine at a speed slightly higher than usual.
   6. Turn the power switch on (READY).
      NOTE:

      Immediately disconnect the booster cables in the reverse order of connection after the hybrid system has started. Do not leave the booster cables connected because they are not designed for recharging purposes.

      If the hybrid system fails to start and the HV battery warning is displayed, the HV battery may be discharged.

      Fig 14: Identifying Master Warning Light & Multi-information Display

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION
      
      

      *1

      Master Warning Light

      *2

      Multi-information Display

2. When the HV battery is discharged:
   1. Using the THS charger, charge the HV battery. Refer to CHARGING .

      HINT: 

      Perform this operation when the HV battery is discharged or low, or if Low Traction Battery is displayed and DTC P3000-388 or 389 is stored in the power management control ECU (HV CPU).

1. Items to be prepared for the accident site
   • Protective clothing (insulated gloves, rubber gloves, goggles and safety shoes)
   • Saturated boric acid solution 20 liter (21.1 US qts, 17.6 Imp.qts) (obtain 800 g (1.76 lb) of boric acid powder, put it into a container, and dissolve it in water)
   • Red litmus paper
   • ABC fire extinguisher (effective against both oil flames and electrical flames)
   • A shop rag or piece of cloth (for wiping off the electrolyte)
   • Insulating tape (for insulating cables)
   • Electrical tester
2. Actions to be taken at the accident site
   WARNING:

   • Do not touch any bare cables that may have high-voltage. If a cable must be touched or if accidental contact is possible, wear insulated gloves and insulate the cable using insulating tape.
   • If the vehicle catches on fire, use an ABC fire extinguisher to extinguish the fire. Trying to extinguish a fire using only a small amount of water can be more dangerous than effective. Use a substantial amount of water or wait for firefighters.
   • Visually check the HV battery and the immediate area for any electrolyte leakage. Do not touch any leaked liquid because it could be highly alkaline electrolyte.
   • Work on the vehicle only after the vehicle has been pulled out of the water.
   1. Check the vicinity of the HV battery for any leakage of the electrolyte.
      WARNING:

      Do not touch any leaked liquid because it could be highly alkaline electrolyte. Wear rubber gloves and goggles, neutralize the liquid with saturated boric acid solution, and then apply red litmus paper to the liquid. Check that the paper does not turn blue. Wipe up the neutralized liquid with a shop rag or piece of cloth.

   2. If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the following procedure.
      WARNING:

      Be sure to wear insulated gloves, goggles and safety shoes.

      Fig 15: Identifying High-Voltage Components & Cables

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION
      
      

      *1	Inverter with Converter Assembly	*2	Engine Room Junction Block Assembly
      *3	Auxiliary Battery	*4	HV battery
      *5	Frame Wire	*6	Hybrid Vehicle Transaxle Assembly
      *7	Inverter Water Pump Assembly	*8	Compressor with Motor Assembly

   3. Turn the power switch off.
      Fig 16: Identifying AM2 Fuse & IGCT Fuse On Engine Room Junction Block Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION
      
      

      *1	AM2 Fuse
      *2	IGCT Fuse
      *3	Engine Room Junction Block Assembly

      HINT: 

      If the power switch cannot be turned off, remove the IGCT fuse and AM2 fuse from the engine room junction block assembly. Confirm that the READY light is off.

   4. Disconnect the cable from the negative (-) terminal of the auxiliary battery.
   5. Wear insulated gloves and then remove the service plug.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

3. Moving the damaged vehicle

   If any of the following conditions is met, tow the vehicle away using a tow truck.

   • One or more of the high-voltage components and cables are damaged.
   • Components related to driving, the transaxle, or the fuel system are damaged.
   • The master warning light is on.
   • The READY light does not come on when attempting to turn the power switch on (READY).
   WARNING:

   Before towing the vehicle away using a tow truck, disconnect the cable from the negative (-) terminal of the auxiliary battery and remove the service plug.

   NOTE:

   Perform the procedure below if the READY light turns off, or there are abnormal noises, unusual smells, or strong vibrations while driving:

   1. Park the vehicle in a safe place.
   2. Apply the parking brake, and then push the P position switch.
   3. Turn the power switch off, and disconnect the cable from the negative (-) terminal of the auxiliary battery.
   4. Remove the service plug while wearing insulated gloves.
4. Actions required after moving the damaged vehicle
   1. Procedure

      If you see any liquid on the road surface, it could be highly alkaline electrolyte leakage.

      Wear rubber gloves and goggles, neutralize the liquid with saturated boric acid solution, and then apply red litmus paper to the liquid. Check that the paper does not turn blue. Wipe up the neutralized liquid with a shop rag or piece of cloth.

5. Items to be prepared (when repairing a damaged vehicle)
   • Protective clothing (insulated gloves, rubber gloves, goggles and safety shoes)
   • Saturated boric acid solution 20 liter (21.1 US qts, 17.6 Imp.qts) (obtain 800 g (1.76 lb) of boric acid powder, put it into a container, and dissolve it in water)
   • Red litmus paper
   • A shop rag or piece of cloth (for wiping off the electrolyte)
   • Insulating tape (for insulating cables)
   • Electrical tester
6. Precautions to be observed when servicing a damaged vehicle
   WARNING:

   Always follow instructions to ensure safety.

   1. Wear insulated or rubber gloves, goggles, and safety shoes.
   2. Check the HV battery and immediate area for any electrolyte leakage.
      WARNING:

      • Do not touch any leaked liquid because it could be highly alkaline electrolyte. Wear rubber gloves and goggles, neutralize the liquid with saturated boric acid solution and then apply red litmus paper to the liquid. Check that the paper does not turn blue. Wipe the neutralized liquid with a shop rag or piece of cloth.
      • If the electrolyte comes in contact with your skin, use a saturated boric acid solution or a large amount of water to wash it off. If the electrolyte comes in contact with an article of clothing, take it off immediately.
      • If the electrolyte comes in contact with your eyes, call out loudly for help. Do not rub your eyes. Wash them immediately with a large amount of water and seek medical care.
   3. Do not touch any bare cables that could be high voltage cables. If a cable must be touched or if accidental contact is possible, follow the following instructions: 1) wear insulated gloves and goggles, 2) measure the voltage between the cable and body ground using an electrical tester, and 3) insulate the cable using insulating tape.
   4. If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the procedure below.
      WARNING:

      Do not touch any bare cables that may have high-voltage. If a cable must be touched or if accidental contact is possible, wear insulated gloves and insulate the cable using insulating tape.

   5. Turn the power switch off.
      Fig 17: Identifying AM2 Fuse & IGCT Fuse On Engine Room Junction Block Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION
      
      

      *1	AM2 Fuse
      *2	IGCT Fuse
      *3	Engine Room Junction Block Assembly

      HINT: 

      If the power switch cannot be turned off, remove the IGCT fuse and AM2 fuse from the engine room junction block assembly. Confirm that the READY light is off.

   6. Disconnect the cable from the negative (-) terminal of the auxiliary battery.
   7. Wear insulated gloves, and then remove the service plug.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

7. Precautions to be taken when disposing of the vehicle
   1. Disposing of HV battery

      When scrapping the vehicle, remove the HV battery from the vehicle and return it to the location specified by the manufacturer. Any damaged HV battery should also be returned to the specified location.

      WARNING:

      • After removing the HV battery, keep it away from water. Water may heat the HV battery, resulting in a fire.
      • Accidents such as electric shocks could result if the vehicle and its HV battery are disposed of improperly or abandoned. Therefore, make sure to return any HV battery using the prescribed recovery route through an authorized dealer.
8. Precautions to be observed when towing
   1. Tow the damaged vehicle with its front and rear wheels lifted off the ground.
      WARNING:

      Towing the damaged vehicle with its front wheels on the ground will cause the motor to generate electricity. This electricity could, depending on the nature of the damage, leak and cause a fire.

9. Towing with the 4 wheels on the ground
   WARNING:

   • If the vehicle needs to be towed using a rope with all 4 wheels on the ground, do not exceed 30 km/h (19 mph) and tow only for a short distance and then have the vehicle towed by a truck.
   • Turn the power switch on (IG), move the shift lever to N and confirm that neutral (N) has been selected.
   • Make sure not to turn the power switch off while the vehicle is being towed. Park (P) may be selected, resulting in damage or an accident.
   • If any abnormality is present in the damaged vehicle during towing, stop towing immediately.

   HINT: 

   • Neutral (N) cannot be selected if the auxiliary battery is disconnected.
   • There is a possibility that neutral (N) cannot be selected when parts related to the transmission control ECU have a malfunction.

This vehicle is equipped with a Supplemental Restraint System (SRS).

1. GENERAL NOTICE
   1. As malfunctions of the SRS are difficult to confirm, the Diagnostic Trouble Codes (DTCs) become the most important source of information when troubleshooting. When troubleshooting the SRS, always check for DTCs before disconnecting the auxiliary battery.
   2. Work must be started at least 90 seconds after the power switch is turned off and after the cable is disconnected from the negative (-) auxiliary battery terminal.

      The SRS is equipped with a back-up power source. If work is started within 90 seconds after turning the power switch off and disconnecting the cable from the negative (-) auxiliary battery terminal, the SRS may deploy.

      When the cable is disconnected from the negative (-) auxiliary battery terminal, the clock and audio system memory will be cleared. Before starting work, make a note of the settings of each memory system. When work is finished, reset the clock and audio system as before.

      WARNING:

      Never use a back-up power source (battery or other) to avoid clearing the system memory. The back-up power source may inadvertently power the SRS and cause it to deploy.

   3. If the vehicle has been involved in a minor collision where the SRS does not deploy, the steering pad, front passenger airbag assembly, knee airbag assembly, seat side airbag assembly, curtain shield airbag assembly and seat outer belt assembly should be inspected before further use of the vehicle.
   4. Never use SRS parts from another vehicle. When replacing parts, use new ones.
   5. Before repairs, remove the airbag sensor assemblies if impacts are likely to be applied to the sensor during repairs.
   6. Never disassemble and attempt to repair any airbag sensor assemblies or airbag assemblies.
      1. Steering pad
      2. Front passenger airbag assembly
      3. Knee airbag assembly
      4. Front seat side airbag assembly
      5. Curtain shield airbag assembly
      6. Front seat outer belt assembly
   7. Replace the airbag sensor assemblies and the airbag assemblies if: 1) damage has occurred from being dropped, or 2) cracks, dents or other defects in the case, bracket or connector are present.
   8. Do not directly expose the airbag sensor assemblies or airbag assemblies to hot air or flames.
   9. Use a voltmeter/ohmmeter with high impedance (minimum = 10 kΩ) for troubleshooting electrical circuits.
   10. Information labels are attached to the SRS components. Follow the instructions on the labels.
   11. After work on the SRS is completed, check the SRS warning light.
2. SPIRAL CABLE
   Fig 18: Identifying Alignment Mark On Spiral Cable

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *a	Alignment Mark

   1. The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position. Otherwise, cable damage and other problems may occur. Refer to the information about correct installation of the steering wheel. Refer to INSTALLATION .
3. STEERING PAD
   1. Always place a removed or new steering pad with the surface facing upward as shown in the illustration. Placing the steering pad with the pad surface facing downward could cause a serious accident if the airbag deploys. Also, do not place anything on top of the steering pad.
      Fig 19: Identifying Correct/Incorrect Way To Place Steering Pad Surface

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION
      
      

      *a

      CORRECT

      *b

      INCORRECT

   2. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury.
      Fig 20: Precaution For Steering Pad Airbag Deployment Warning

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Grease or detergents of any kind should not be applied to the steering pad.
   4. Store the steering pad in an area where the ambient temperature is below 93°C (199°F), the humidity is not high and there is no electrical noise.
   5. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
   6. When disposing of the vehicle or the steering pad by itself, the airbag should be deployed using SST before disposal. Refer to DISPOSAL . Deploy the airbag in a safe place away from electrical noise.
4. FRONT PASSENGER AIRBAG ASSEMBLY
   1. Always place a removed or new front passenger airbag assembly with the pad surface facing upward as shown in the illustration. Placing the airbag assembly with the airbag deployment direction facing downward could cause a serious accident if the airbag deploys.
      Fig 21: Identifying Correct/Incorrect Placement Of Front Airbag Assembly With Pad

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION
      
      

      *a

      CORRECT

      *b

      INCORRECT

   2. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury.
      Fig 22: Precaution For Front Passenger Airbag Deployment Warning

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Grease or detergents of any kind should not be applied to the front passenger airbag assembly.
   4. Store the airbag assembly in an area where the ambient temperature is below 93°C (199°F), the humidity is not high and there is no electrical noise.
   5. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
   6. When disposing of the vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal. Refer to DISPOSAL . Deploy the airbag in a safe place away from electrical noise.
5. KNEE AIRBAG ASSEMBLY
   1. Always place a removed or new knee airbag assembly with the airbag deployment direction facing upward as shown in the illustration. Placing the airbag assembly with the airbag deployment direction facing downward could cause a serious accident if the airbag deploys.
      Fig 23: Identifying Correct/Incorrect Placement Of Knee Airbag Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION
      
      

      *a

      CORRECT

      *b

      INCORRECT

   2. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury.
      Fig 24: Precaution For Knee Airbag Deployment Warning

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Grease or detergents of any kind should not be applied to the knee airbag assembly.
   4. Store the knee airbag assembly in an area where the ambient temperature is below 93°C (199°F), the humidity is not high and there is no electrical noise.
   5. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
   6. When disposing of a vehicle or knee airbag assembly unit by itself, the airbag should be deployed using SST before disposal. Refer to DISPOSAL for driver side. Refer to DISPOSAL for passenger side). Deploy the airbag in a safe place away from electrical noise.
6. FRONT SEAT SIDE AIRBAG ASSEMBLY
   1. Always place a removed or new seat side airbag assembly with the airbag deployment direction facing upward.
   2. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury.
      Fig 25: Precaution For Seat Side Airbag Deployment Warning

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Grease or detergents of any kind should not be applied to the seat side airbag assembly.
   4. Store the airbag assembly in an area where the ambient temperature is below 93°C (199°F), the humidity is not high and there is no electrical noise.
   5. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
   6. When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal. Refer to DISPOSAL . Deploy the airbag in a safe place away from electrical noise.
7. CURTAIN SHIELD AIRBAG ASSEMBLY
   1. Always place a removed or new curtain shield airbag assembly in a clear plastic bag, and keep it in a safe place.
      Fig 26: Identifying Correct Placement Of Curtain Shield In Plastic Bag

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION
      
      

      *1	Clear Plastic Bag	*a	CORRECT
      *b	INCORRECT	-	-

      WARNING:

      The plastic bag should be disposed of after use.

      NOTE:

      Never disassemble the curtain shield airbag assembly.

   2. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury.
      Fig 27: Precaution For Measuring Resistance Of Airbag Squib

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Grease or detergents of any kind should not be applied to the curtain shield airbag assembly.
   4. Store the airbag assembly in an area where the ambient temperature is below 93°C (199°F), the humidity is not high and there is no electrical noise.
   5. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
   6. When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal. Refer to DISPOSAL . Deploy the airbag in a safe place away from electrical noise.
8. FRONT SEAT OUTER BELT ASSEMBLY (SEAT BELT PRETENSIONER)
   1. Never measure the resistance of the front seat outer belt assembly. This may cause the pretensioner of the front seat outer belt assembly to activate, which could cause serious injury.
      Fig 28: Precaution For Measuring Resistance Of Front Seat Outer Belt Assembly (Seat Belt Pretensioner)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Never disassemble the front seat outer belt assembly.
   3. Never install the front seat outer belt assembly on another vehicle.
   4. Store the front seat outer belt assembly in an area where the ambient temperature is below 80°C (176°F), the humidity is not high and there is no electrical noise.
   5. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
   6. When disposing of a vehicle or the front seat outer belt assembly unit by itself, the front seat outer belt assembly should be activated before disposal. Refer to DISPOSAL . Activate the front seat outer belt assembly in a safe place away from electrical noise.
   7. As the front seat outer belt assembly is hot after being activated, allow some time for it to cool down sufficiently before disposal. Never apply water to cool down the front seat outer belt assembly.
   8. Grease, detergents, oil or water should not be applied to the front seat outer belt assembly.
9. CENTER AIRBAG SENSOR ASSEMBLY
   1. Never reuse a center airbag sensor assembly that has been involved in a collision where the SRS has deployed.
   2. The connectors to the center airbag sensor assembly should be connected or disconnected with the sensor installed to the vehicle. If the connectors are connected or disconnected while the center airbag sensor assembly is not installed, the SRS may activate.
   3. Work must be started at least 90 seconds after the power switch is turned off and the cable is disconnected from the negative (-) auxiliary battery terminal, even if only loosening the bolts of the center airbag sensor assembly.
10. WIRE HARNESS AND CONNECTOR
    1. All the connectors in the system are a standard yellow color. If an SRS wire harness has an open circuit or a connector is broken, replace it.

Fig 29: Identifying Negative Auxiliary Battery Terminal & Cable

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. DISCONNECTING AND RECONNECTING NEGATIVE AUXILIARY BATTERY CABLE
   1. Before performing work on electronic components, disconnect the cable from the negative (-) auxiliary battery terminal to prevent damage to the electrical system or components.
   2. When disconnecting the cable, turn the power switch and headlight switch off and loosen the cable nut completely. Perform these operations without twisting or prying the cable. Then, disconnect the cable.
   3. Clock settings, radio settings, audio system memory, DTCs and other data will be cleared when the cable is disconnected from the negative (-) auxiliary battery terminal. Write down any necessary data before disconnecting the cable.
2. HANDLING OF ELECTRONIC PARTS
   Fig 30: Precaution For Handling Electronic Parts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *a

   INCORRECT

   1. Do not open the cover or case of the ECU unless absolutely necessary. If the IC terminals are touched, the IC may be rendered inoperative by static electricity.
   2. Do not pull on the wires when disconnecting electronic connectors. Pull on the connector itself.
   3. Do not drop electronic components, such as sensors or relays. If they are dropped on a hard surface, they should be replaced.
   4. When cleaning the engine compartment with steam, protect the electronic components, air filter and emission-related components from water.
   5. Never use an impact wrench to remove or install temperature switches or temperature sensors.
   6. When measuring the resistance between terminals of a wire connector, insert the tester probe carefully to prevent the terminals from bending.

HINT: 

• If all of the following are met for a certain period of time during a few minutes immediately before the power switch is turned off, the cooling fans will continue to operate for a maximum of 3 minutes after the engine is stopped. This is performed to ensure restartability.
  • The Techstream indicates a very high coolant temperature.
  • The Techstream indicates a high outside air temperature.

1. PLACE FOR REMOVING AND INSTALLING FUEL SYSTEM PARTS
   1. Work in a location with good air ventilation that does not have welders, grinders, drills, electric motors, stoves or any other ignition sources nearby.
   2. Never work in a pit or near a pit as fuel vapors will collect there.
2. REMOVING AND INSTALLING FUEL SYSTEM PARTS
   1. Prepare a fire extinguisher before starting work.
   2. To prevent static electricity, install a ground wire between the fuel changer and vehicle, and do not spray the surrounding area with water. Be careful when performing work in this area, as the floor surface will become slippery. Do not clean up gasoline spills with water, as this may cause the gasoline to spread, and possibly create a fire hazard.
   3. Avoid using electric motors, work lights and other electric equipment that can cause sparks or high temperatures.
   4. Avoid using iron hammers as they may create sparks.
   5. Dispose of fuel-contaminated cloth separately using a fire resistant container.

1. If any metal particles enter intake system parts, this may damage the engine.
   Fig 31: Covering Openings Of Removed Parts & Engine Openings

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. When removing and installing intake system parts, cover the openings of the removed parts and engine openings. Use adhesive tape or other suitable materials.
3. When installing intake system parts, check that no metal particles have entered the engine or installed parts.

Fig 32: Identifying Clamp Track & Spring Type Clamp

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Before removing a hose, check the clamp position so that it can be reinstalled in the same position.
2. Replace any deformed or dented clamps with new ones.
3. When reusing a hose, attach the clamp on the clamp track portion of the hose.
4. For a spring type clamp, it may be necessary to spread the tabs slightly after installation by pushing them in the direction of the arrows as shown in the illustration.

Fig 33: Identifying Vehicles Equipped With Mobile Communication Systems

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the antenna as far away from the ECU and sensors of the vehicle electronic systems as possible.
2. Install the antenna and feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle electronic systems. For details about ECU and sensor locations, refer to the article on the applicable components.
3. Keep the antenna and feeder separate from other wiring as much as possible. This will prevent signals sent from the communication equipment from affecting vehicle equipment and vice versa.
4. Check that the antenna and feeder are correctly adjusted.
5. Do not install a high-powered mobile communication system.

1. When the headlights are illuminated, do not cover the headlights for 3 minutes or more.
   Fig 34: Identifying Covered Headlight

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *1	Illumination for 3 minutes or more prohibited if covered

   NOTE:

   As the headlight outer lens is made of resin, the resulting heat created when covering the headlight for an extended period of time may deform the headlight.

1. NOTICES FOR WHEN TESTING WITH DRUM TESTER
   1. When testing with a 2-wheel drum tester such as a speedometer tester, a combination speedometer and brake tester, or a chassis dynamometer, perform the following procedure to enter inspection mode and disable the TR(A)C and VSC systems. Refer to INSPECTION MODE PROCEDURE .
      NOTE:

      • If the vehicle is tested in normal mode on the tester, TR(A)C and VSC operation may cause the vehicle to jump off of the tester.
      • Secure the vehicle with chains for safety.
      • Make sure to cancel inspection mode after completing a check using a 2-wheel drum tester.
      • After performing a check, never drive the vehicle without canceling inspection mode.

      HINT: 

      • During inspection mode, the TRC and VSC systems are disabled and slip indicator light is illuminated.
      • Inspection mode is canceled when the power switch is turned off. As a result, if it is necessary to perform an inspection after the power switch has been turned off, perform the procedure again to re-enter inspection mode.
2. NOTICES FOR VSC RELATED PROCEDURES
   1. For VSC related parts, adjustments are required after removal and installation. Therefore, perform removal and installation only when necessary.
   2. When performing VSC related procedures, be sure to strictly follow the preparation and completion procedures.
   3. When performing removal and installation or replacement of VSC related parts, first disconnect the cable from the negative (-) auxiliary battery terminal.

1. BASIC OPERATION
   1. This vehicle is equipped with an electronic shift lever system. This system electrically communicates the driver's intended shift state to the ECUs responsible for system control. The system also uses an electrically operated transaxle parking lock mechanism.

      HINT: 

      The parking lock mechanism of the transaxle cannot be operated if the auxiliary battery is discharged or has been disconnected. There is no mechanical connection between the P position switch (transmission shift main switch), shift lever and the transaxle.

   2. This system allows the driver to select the reverse (R), neutral (N), drive (D) and brake (B)* shift states using the shift lever or select park (P) by pushing the P position switch (transmission shift main switch). Shift states are ECU controlled based on the actions of the driver and various conditions. Shift states can be verified using the shift position indicator in the combination meter or by using the Techstream.
      • *: For enhanced engine braking.

1. VEHICLE CONDITIONS
   1. Before activating inspection mode, turn the air conditioning off, start the hybrid system with park (P) selected, and check that the engine stops within several seconds after starting (engine warm up check).
   2. Activate the appropriate inspection mode and inspect the vehicle. Refer to INSPECTION MODE PROCEDURE .

      HINT: 

      Different types of inspection mode are available. One is maintenance mode, and the other is certification mode. The following table indicates the mode appropriate for each test item.

      The shift state for each test is as follows:

      Test Item	Mode	Shift State
      1. Vehicle straight travelling test (side slip inspection)	Maintenance mode or normal mode	D
      2. Braking force test	Normal mode	N
      3. Speedometer test	Maintenance mode	D
      4. Exhaust gas test (idling)	Maintenance mode	P
      5. Headlight test	Maintenance mode or normal mode	P

   3. Cancel inspection mode immediately after completion of inspection.
      NOTE:

      Driving the vehicle without canceling inspection mode may damage the transaxle.

2. WHEN USING A BRAKE TESTER
   WARNING:

   Be sure to perform the test in maintenance mode.

   NOTE:

   • A high-speed type brake tester cannot be used.
   • Vehicle speed should be less than 0.5 km/h (0.3 mph).
   • Follow all usage and safety procedures in the operator's manual for the brake tester.
   1. Place the wheels to be tested (front or rear) onto the rollers.
   2. Start the hybrid system to allow normal brake booster operation.
   3. Move the shift lever to N and confirm that neutral (N) has been selected.
   4. Operate the brakes to perform the test.
3. WHEN USING A SPEEDOMETER TESTER
   WARNING:

   Be sure to perform the test in maintenance mode.

   NOTE:

   Do not perform rapid starting or quick acceleration on a speedometer tester. If rapid starting or quick acceleration is performed on a speedometer tester, damage may occur to the transaxle.

   1. Depress the accelerator pedal slowly and gradually accelerate the vehicle. Make a measurement.
   2. After the measurement, use the brakes to gradually decelerate the vehicle.
4. WHEN USING A CHASSIS DYNAMOMETER
   1. Always set an appropriate load before starting the test.
      NOTE:

      Sudden acceleration or deceleration of the vehicle on a chassis dynamometer under minimal load may damage the transaxle.

5. WHEN USING AN ON-VEHICLE BALANCER
   1. Raise the vehicle until all 4 wheels are off the ground.
   2. Support the vehicle with safety stands at an appropriate height. Make sure that the vehicle does not lean in any direction, and that the tires are completely clear of the floor.
   3. Place the vibration pick-up unit into position for the wheel to be measured*1.
   4. Release the parking brake.
   5. Check that no dragging force exists when turning each wheel by hand.
   6. Put the wheel balancer in position.
   7. Wheel balance measurement should be done by using both the engine and the wheel balancer drive roller to spin the wheels.

      HINT: 

      *1: Different on-vehicle wheel balancers have different requirements for mounting the vibration pick-up unit(s). Refer to the operator's manual for the wheel balancer to confirm requirements for use.

      NOTE:

      • Be sure to perform the test in maintenance mode.
      • Start the engine and then increase the vehicle speed gradually with drive (D) selected.
      • Do not accelerate or decelerate suddenly.
      • Deceleration should be done by braking gradually.
      • Make sure that no one is standing in-line with the spinning wheels.
      • Measurement should be done quickly.
      • Confirm that the vehicle is securely immobilized.
      • Follow all usage and safety procedures in the operator's manual for the wheel balancer.

1. Use one of the following methods to tow the vehicle.
2. If the vehicle has trouble with the chassis or drivetrain, use method 1 (flatbed truck).
   Fig 35: Identifying Acceptable Towing Methods

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   Do not use any towing method other than those shown above.

3. If a tow truck is not available, in an emergency vehicle may be temporarily towed using a cable or chain secured to the emergency towing eyelet(s). This should only be attempted on hard surfaced roads for short distances below 30 km/h (19 mph).

   A driver must be in the vehicle to steer and operate the brakes. The vehicle's wheels, drivetrain, axles, steering and brakes must be in good condition.

   1. Emergency towing procedure
      1. Turn the power switch on (IG).
      2. Depress the brake pedal and move the shift lever to N.
      3. Release the parking brake.
      4. Release the brake pedal slowly.
      NOTE:

      • Use extreme caution when towing the vehicle.

        Avoid sudden starts or erratic driving maneuvers which place excessive stress on the emergency towing eyelet and the cables or chains.

      • If the hybrid system is off, the power assist for the brakes and steering will not function, making steering and braking more difficult.
      • Do not turn off the power switch.

        Turning off the power switch may result in engagement of the parking lock, resulting in a hazardous situation or accident.

      HINT: 

      • Neutral (N) cannot be selected if the auxiliary battery is discharged or if it has been disconnected.
      • There is a possibility that neutral (N) cannot be selected when parts related to the transmission control ECU have a malfunction.
4. The following towing methods shown below are dangerous and can damage the vehicle, so do not use them.
   Fig 36: Identifying Unacceptable Towing Methods

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Do not tow the vehicle with only front wheels on the ground.
   2. Do not use a sling-type towing method either from the front or rear.
      NOTE:

      If these towing methods are used either from the front or rear, the following may occur.

      • The drivetrain may overheat and be damaged.
      • If a sling-type tow truck is used, damage may occur to the vehicle body.

1. Use only unleaded gasoline.
2. Avoid performing unnecessary spark tests.
   1. Perform a spark test only when absolutely necessary. Perform a spark test as rapidly as possible with the injector connectors disconnected.
3. While testing, never race the engine unless instructed.
4. Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter.