Precaution [11/2021 - ]

1. Before the following operations are conducted, take precautions to prevent electric shock by turning the ignition switch off, wearing insulated gloves, and removing the service plug grip from HV battery.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   • Inspecting the high-voltage system
   • Disconnecting the low voltage connector of the hybrid motor control inverter assembly
   • Disconnecting the low voltage connector of the HV battery
   • Disconnecting the low voltage connector of the electric vehicle charger assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   • To prevent the key from being locked in the vehicle, make sure to enter e-latch inspection mode and enable the manual release handle before disconnecting the cable from the negative (-) auxiliary battery terminal.

     Refer to INSPECTION MODE PROCEDURE [11/2021 - ]

   • After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

     Refer to BEFORE DISCONNECTING BATTERY [11/2021 - ]

   • When disconnecting and reconnecting the auxiliary battery.

     Refer to WORK PROCEDURE [11/2021 - ]

     HINT: 

     When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

     Refer to AUTOMATIC LEARNING CHART [11/2021 - ]

   • After removing the service plug grip, turning the ignition switch to ON (READY) may cause a malfunction. Do not turn the ignition switch to ON (READY) unless instructed by the repair information.
2. To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

3. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

4. After removing the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals.

   HINT: 

   Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the hybrid motor control inverter assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Without waiting for 10 minutes

5. Check the voltage at the terminals in the inspection point in the hybrid motor control inverter assembly.
   WARNING:

   Be sure to wear insulated gloves.

   1. Remove the connector cover assembly from the hybrid motor control inverter assembly.

      Refer to PROCEDURE - Step 9

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      NOTE:

      • Do not touch the connector cover assembly waterproof seal.
      • Do not allow any foreign matter or water to enter the hybrid motor control inverter assembly.
   2. Measure the voltage according to the value(s) in the table below.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Voltage

      Tester Connection	Condition	Specified Condition
      Inspection point	At least 10 minutes after removing the service plug grip	0 V

      HINT: 

      Set the tester to DC750 V or more to measure the voltage.

   3. Reinstall the connector cover assembly.
6. When turning the ignition switch to ON during an inspection, do not press the ignition switch with the brake pedal depressed.
   WARNING:

   Pressing the ignition switch with the brake pedal depressed causes the system to enter the READY-on state. This is very dangerous because high voltage may be applied to the inspection area.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

7. Turn the ignition switch off, wear insulated gloves, and disconnect the cable from the negative (-) terminal of the auxiliary battery before touching any of the orange-colored wires of the high-voltage system.
   NOTE:

   • After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

     Refer to BEFORE DISCONNECTING BATTERY [11/2021 - ]

   • When disconnecting and reconnecting the auxiliary battery.

     Refer to WORK PROCEDURE [11/2021 - ]

     HINT: 

     When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

     Refer to AUTOMATIC LEARNING CHART [11/2021 - ]

8. Turn the ignition switch off before performing any resistance checks.
9. Turn the ignition switch off before disconnecting or reconnecting any connectors.
10. When performing work involving high-voltage wires, use either a tool wrapped with vinyl insulation tape or an insulated tool.
11. When high-voltage connectors are removed, wrap the connectors with vinyl insulating tape to prevent foreign matter or water from entering them.

1. When the warning light is illuminated, or the auxiliary battery has been disconnected and reconnected, attempting to turn the ignition switch to ON (READY) may not start the system (the system may not enter the READY-on state) on the first attempt. If so, turn the ignition switch off and reattempt to start the hybrid system.
   NOTE:

   • To prevent the key from being locked in the vehicle, make sure to enter e-latch inspection mode and enable the manual release handle before disconnecting the cable from the negative (-) auxiliary battery terminal.

     Refer to INSPECTION MODE PROCEDURE [11/2021 - ]

   • After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

     Refer to BEFORE DISCONNECTING BATTERY [11/2021 - ]

   • When disconnecting and reconnecting the auxiliary battery.

     Refer to WORK PROCEDURE [11/2021 - ]

     HINT: 

     When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

     Refer to AUTOMATIC LEARNING CHART [11/2021 - ]

HINT: 

The AMD terminal is connected to the positive (+) terminal of the auxiliary battery. To prevent damage when disconnecting the AMD terminal, perform the following procedures.

1. Be sure to disconnect the cable from the negative (-) auxiliary battery terminal before disconnecting the AMD terminal from the No. 1 luggage room relay block and junction block.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	AMD Terminal (DC/DC Converter Assembly Side)
   *2	AMD Terminal (No. 1 Luggage Room Relay Block and Junction Block Side)

   NOTE:

   • To prevent the key from being locked in the vehicle, make sure to enter e-latch inspection mode and enable the manual release handle before disconnecting the cable from the negative (-) auxiliary battery terminal.

     Refer to INSPECTION MODE PROCEDURE [11/2021 - ]

   • After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

     Refer to BEFORE DISCONNECTING BATTERY [11/2021 - ]

   • When disconnecting and reconnecting the auxiliary battery.

     Refer to WORK PROCEDURE [11/2021 - ]

     HINT: 

     When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

     Refer to AUTOMATIC LEARNING CHART [11/2021 - ]

2. After disconnecting the AMD terminal, wrap it with vinyl insulating tape.
3. Be sure to reconnect the AMD terminal to the No. 1 luggage room relay block and junction block before reconnecting the cable to the negative (-) terminal of the auxiliary battery.
   NOTE:

   A short to ground may occur if the AMD terminal is disconnected before the cable is disconnected from the negative (-) auxiliary battery terminal. If a short to ground occurs, a fusible link or fuse may break.

1. When disposing of HV batteries and HV supply stack sub-assemblies, make sure to return them through an authorized collection agent who is capable of handling them safely. If they are returned via the manufacturer specified route, they will be returned properly and in a safe manner by an authorized collection agent.
   WARNING:

   • Before returning the HV battery, make sure to perform a recovery inspection.

     Refer to RECOVERY INSPECTION [11/2021 - ]

   • Before returning the HV supply stack sub-assembly, make sure to perform a recovery inspection.

     Refer to RECOVERY INSPECTION [11/2021 - ]

   • After removing the HV battery or the HV supply stack sub-assembly, keep it away from water. Exposure to water may cause the HV battery or the HV supply stack sub-assembly to produce heat, resulting in a fire.

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   • Accidents such as electric shock may result if the HV battery or the HV supply stack sub-assembly is disposed of improperly or abandoned.

     Therefore, make sure to return HV battery and all HV supply stack sub-assemblies through an authorized collection agent.

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

     *a	Dealer
     *b	Battery Collection Agent

   • To reduce the risk of fire, HV battery or HV supply stack sub-assemblies must not be stored in an area where they will be exposed to fire or high temperatures.
   • If the temperature of the HV battery and HV supply stack sub-assembly is high, leave the vehicle until the temperature drops.
   • Make sure to insulate the high-voltage connectors and terminals of the HV battery or HV supply stack sub-assemblies with insulating tape after removing them.

     If the HV battery stored without insulating the connectors and terminals, electric shock or fire may result.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Before performing work on electronic components, disconnect the cable from the negative (-) auxiliary battery terminal to prevent damage to the electrical system or electrical components.
2. Before disconnecting and reconnecting the auxiliary battery cable, turn the ignition switch off and the headlight switch off. Then loosen the terminal nut completely. Do not damage the cable or terminal.
3. When the auxiliary battery cable is disconnected, the clock and radio settings and stored DTCs are cleared. Therefore, before disconnecting the auxiliary battery cable, make a note of them.
   NOTE:

   • To prevent the key from being locked in the vehicle, make sure to enter e-latch inspection mode and enable the manual release handle before disconnecting the cable from the negative (-) auxiliary battery terminal.

     Refer to INSPECTION MODE PROCEDURE [11/2021 - ]

   • After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

     Refer to BEFORE DISCONNECTING BATTERY [11/2021 - ]

   • When disconnecting and reconnecting the auxiliary battery.

     Refer to WORK PROCEDURE [11/2021 - ]

     HINT: 

     When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

     Refer to AUTOMATIC LEARNING CHART [11/2021 - ]