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YARIS Hybrid

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Gasoline-Electric

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Hybrid Synergy Drive

MXPH10/MXPH11 Series
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Foreword

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This guide was developed to educate and assist dismantlers in the safe handling of Toyota YARIS
Hybrid gasoline-electric hybrid vehicles. YARIS Hybrid dismantling procedures are similar to other

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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

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YARIS Hybrid, as they may not be familiar to dismantlers.

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High voltage electricity powers the electric motor, generator, Air Conditioning (A/C) compressor and
inverter/converter. All other automotive electrical devices such as the head lights, radio, and gauges

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are powered from a separate 12 Volt auxiliary battery. Numerous safeguards have been designed into
the YARIS Hybrid to help ensure the high voltage, approximately 177.6 Volt, Lithium-ion (Li-ion)

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Hybrid Vehicle (HV) battery pack is kept safe and secure in an accident.
The Lithium-ion battery pack contains sealed batteries that are similar to rechargeable batteries used in
some battery operated power tools and other consumer products. The electrolyte is absorbed in the cell
plates and will not normally leak out even if the battery is cracked. If the electrolyte is leaking, do not
touch any leaked liquid because it could be the organic electrolyte that contains carbonate ester-based.
If contact is unavoidable, wipe up the liquid using a cloth while wearing rubber gloves, goggles and an
organic solvent mask. Do not leave electrolyte-contaminated cloths unattended. Please contaminated
cloths in an appropriate airtight container and dispose of them according to local regulations.
High voltage cables, identifiable by orange insulation and connectors, are isolated from the metal chassis
of the vehicle.

Additional topics contained in the guide include:

• Toyota YARIS Hybrid identification.
• Major hybrid component locations and descriptions.

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

 2022 Toyota Motor Corporation

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

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Table of Contents

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About the YARIS Hybrid ............................................................................................................................. 1

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YARIS Hybrid Identification..................................................................................................................... 2
Exterior ......................................................................................................................................................... 3

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Interior........................................................................................................................................................... 4
Engine Compartment .................................................................................................................................... 5

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Hybrid Component Locations & Descriptions ........................................................................................... 6
Specifications ................................................................................................................................................ 7

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

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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 a vehicle ................................................................................................................................. 15

Removal of HV battery .............................................................................................................................. 20

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About the YARIS Hybrid

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The YARIS Hybrid 5-door hatchback joins the hybrid model for Toyota.
Hybrid Synergy Drive means that the vehicle contains a gasoline engine and an electric
motor for power. The two hybrid power sources are stored on board the vehicle:

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

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

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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

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the battery pack; unlike a pure all electric vehicle, the YARIS Hybrid never needs to be
recharged from an external electric power source.

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

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

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

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

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

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

 Starting  Normal Driving  Acceleration  Deceleration  Stopping

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

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YARIS Hybrid Identification

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In appearance, the 2022 model year YARIS Hybrid is nearly identical to the conventional,
non-hybrid Toyota YARIS. The YARIS Hybrid is a 5-door hatchback. Exterior, interior,
and engine compartment illustrations are provided to assist in identification.

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The alphanumeric 15 character Vehicle Identification Number (VIN) is provided in the left side
windshield cowl, under the right side front seat, and on the left side B pillar.

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Example VIN:

JTDKBAA3 0000000

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

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A YARIS Hybrid is identified by the 5th alphanumeric character of the VIN.

 Engine Series Battery Type

B M15A-FXE Lithium-ion Battery

Vehicle Identification Number Certification Label or Name Label

Vehicle Identification Number

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

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YARIS Hybrid Identification (Continued)

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Exterior

logo on the back door and each front fender.

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

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Exterior Front and Left Side View

*1: for TMMF, TMMCZ Made

*2: for TMC Made
Exterior Rear and Left Side View

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YARIS Hybrid Identification (Continued)

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Interior
 The instrument cluster (hybrid system indicator, READY indicator, and warning lights)
located in the dash behind the steering wheel, is different than the one on the conventional,

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non-hybrid YARIS.

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Notice:

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

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Interior View

Hybrid System Indicator

READY Indicator

Combination Meter View

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YARIS Hybrid Identification (Continued)

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Engine Compartment

 1.5-liter aluminum alloy gasoline engine.

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 Orange colored high voltage power cables.

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Power Cables

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Hybrid Component Locations & Descriptions

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Component Location Description
12 Volt Auxiliary Cabin Area, Supplies electricity to the electrical components.

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Battery  Mounted Under
Rear Seat
Hybrid Vehicle Cabin Area, • Supplies electrical power to MG1 and MG2 in

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(HV) Battery Mounted Under accordance with the driving conditions of the vehicle.

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Pack Rear Seat • Recharged by MG1 and MG2 in accordance with the
SOC and the driving conditions of the vehicle.
Power Cables  Undercarriage and Connects the HV battery, inverter with converter

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Engine assembly, hybrid vehicle transaxle assembly and
Compartment compressor with motor assembly.

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Inverter/ Engine • Converts the direct current from the boost converter
Converter  Compartment into alternating current for MG1 and MG2, and vice
versa (from AC to DC).
•Boosts the HV battery nominal voltage of DC 177.6 V
up to a maximum voltage of DC 580 V and vice versa
(steps down DC 580 V to DC 177.6 V).
Gasoline Engine Engine Provides two functions:
 Compartment 1) Powers vehicle.
2) Powers generator to recharge the HV battery pack.
The engine is started and stopped under control of the
vehicle computer.
Electric Motor  Engine • MG2, which is driven by electrical power from MG1
Compartment 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 Engine MG1, which is driven by the engine, generates
 Compartment 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 Engine 3-phase high voltage AC electrically driven motor
(with Inverter)  Compartment compressor.

DC-DC Converter Engine Steps down the HV battery nominal voltage of DC 177.6
for 12 Volt Compartment V to approximately DC 14 V in order to supply electricity
Auxiliary Battery to the electrical components, as well as to recharge the
 auxiliary battery.
Fuel Tank and Fuel Undercarriage and The fuel tank provides gasoline via a fuel line to the
Line  Center engine. The fuel line is routed under the center of
vehicle.
*Numbers in the component column apply to the illustrations on the following page.

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Hybrid Component Locations & Descriptions (Continued)

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Specifications

Gasoline Engine: 67 kW, 1.5-liter Aluminum Alloy Engine*1

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68 kW, 1.5-liter Aluminum Alloy Engine*2
Electric Motor: 59 kW, Permanent Magnet Motor

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Transmission: Automatic Only
HV Battery: 177.6 Volt Sealed Li-ion Battery

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Curb Weight: 2,392 – 2,491 lbs / 1,085 - 1,130 kg*1
2,381 – 2,601 lbs / 1,080 - 1,180 kg*2

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Fuel Tank: 36.0 liters / 9.5 Us. gals / 7.9 Imp. gals
33.0 liters / 8.7 Us. gals / 7.3 Imp. gals*3
Frame Material: Steel Unibody

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Body Material: Steel Panels
Seating Capacity: 5 passenger

*1: for Australia

*2: for Europe
*3: Models with light weight package

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Hybrid Synergy Drive Operation

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Once the READY indicator is illuminated in the instrument cluster, the vehicle may be
driven. However, the gasoline engine does not idle like a typical automobile and will
start and stop automatically. It is important to recognize and understand the READY

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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

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the engine compartment is silent.

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

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• 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.

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The vehicle may be powered by:
1. The electric motor only.
2. A combination of both the electric motor and the gasoline engine.

Combination Meter READY Indicator

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Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery

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The YARIS Hybrid features a high voltage Hybrid Vehicle (HV) battery pack that contains
sealed Lithium-ion (Li-ion) battery cells.

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HV Battery Pack
• The HV battery pack is enclosed in a metal case and is rigidly mounted to the cabin area

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under the rear seat. The metal case is isolated from high voltage and concealed by carpet
in the cabin area.

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• The HV battery pack consists of 48 low voltage (3.7 Volt) Li-ion battery cells connected in
series to produce approximately 177.6 Volts. Each Li-ion battery cell is non-spillable and

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sealed in a metal case.

• The electrolyte used in the Li-ion battery cell is a flammable organic electrolyte. The

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electrolyte is absorbed into the battery cell separator and will not normally leak, even in a
collision.

HV Battery Pack
Battery pack voltage 177.6 V
Number of Li-ion battery cells in the pack 48
Li-ion battery cell voltage 3.7 V

Components Powered by the HV Battery Pack

• Electric Motor • Inverter/Converter

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

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Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (Continued)

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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.

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Auxiliary Battery

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• The YARIS Hybrid contains a sealed lead-acid 12 Volt battery. This 12 Volt auxiliary
battery powers the vehicle electrical system similar to a conventional vehicle.

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As with other conventional vehicles, the negative terminal of the auxiliary battery is
grounded to the metal chassis of the vehicle.

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• The auxiliary battery is located in the cabin area.

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177.6 Volt HV Battery Pack

12 Volt Auxiliary

HV Battery

12 Volt Auxiliary Battery and HV Battery Pack Mounted in Cabin Area

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High Voltage Safety

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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

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boosts the HV battery voltage from 177.6 to 580 Volts DC. The inverter/converter creates
3-phase AC to power the motor. Power cables are routed from the inverter/converter to each
high voltage motor (electric motor, electric generator, and A/C compressor). The following

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systems are intended to help keep occupants in the vehicle and emergency responders safe from

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high voltage electricity:

High Voltage Safety System

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• 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

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controlled by 12 Volt normally open relays *. When the vehicle is shut off, the relays
stop electrical flow from leaving the HV battery pack.

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

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

• A ground fault monitor in the hybrid vehicle computer * continuously monitors for high
voltage leakage to the metal chassis while the vehicle is running. If a malfunction is
detected, the hybrid vehicle computer * will indicating a message that the hybrid system
is malfunctioning will be displayed on the multi-information display.

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

*Numbers apply to the illustration on the following page.

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High Voltage Safety (Continued)

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Service Plug Grip
• The high-voltage circuit is cut by removing the service plug grip (see page 15).

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Hybrid Vehicle Computer

00 ➍
Volts DC 12 Volts

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Auxiliary
Battery

A/C ➋
Compressor

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➋
Electric Inverter/ ❸ ❸
Generator Converter

0.0
Electric
Motor Volts DC
➊
HV Battery Pack
0 Volts AC
3-Phase

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

Hybrid Vehicle Computer

177.6
Volts DC 12 Volts
Auxiliary
Battery

A/C
Compresso
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Electric Inverter/
Generator Converter

Electric 177.6
Motor Volts DC

580 Volts HV Battery Pack

AC Max
3-Phase

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

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Precaution to be observed when dismantling the vehicle

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WARNING:

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・ The high voltage system may remain powered for up to 10

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minutes after the vehicle is shut off or disabled. To prevent
serious injury or death from severe burns or electric shock,

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avoid touching, cutting, or breaching any orange high voltage
power cable or high voltage component.

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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.

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Spills

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The YARIS 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

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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

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leak. Any liquid electrolyte that leaks from a Li-ion battery cell quickly evaporates.

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WARNING:
・ The Li-ion battery contains organic electrolyte. Only a small

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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.

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Dismantling a vehicle

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The following 4 pages contain general instructions for use when working on a YARIS Hybrid.

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Read these instructions before proceeding to the HV battery removal instructions on page 20.

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WARNING:
・ The high voltage system may remain powered for up to 10

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minutes after the vehicle is shut off or disabled. To prevent
serious injury or death from severe burns or electric shock, avoid

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touching, cutting, or breaching any orange high voltage power
cable or any high voltage component.

1. Remove rear under side cover RH.

(1) Remove the 2 clips.
(2) Disengage the clips and guides to
remove the rear under side cover RH.

2. Shut off the ignition (READY indicator is off). Then disconnect the cable from the
negative auxiliary battery terminal.
(1) Loosen the nut, and disconnect the cable
from the negative (-) auxiliary battery
terminal.

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3. Remove rear under side cover LH.

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(1) Remove the clip.
(2) Disengage the clips and guides to

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remove the rear under side cover LH.

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4. Remove service plug grip.
Caution:

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・Be sure to 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.

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・To reduce the risk of electric shock, make

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sure to wait at least 10 minutes after
removing the service plug grip to fully

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discharge the high voltage capacitor
inside the inverter with converter

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assembly.

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・Keep the removed service plug grip in
your pocket to prevent other technicians

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from accidentally installing it while you
are servicing the vehicle.

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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.

(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.

(2) (3)

(1)

5. Carry the removed service plug grip in your pocket to prevent other staff from
accidentally reinstalling it while you are dismantling the vehicle.

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6. Make other staff aware that a high-voltage system is being dismantled by using the

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following sign: CAUTION: HIGH-VOLTAGE. DO NOT TOUCH (see page 19).
7. If the service plug grip cannot be removed PM_IGCT Fuse

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due to damage to the vehicle, remove the
PM_IGCT fuse (7.5 A).

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Caution:

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This operation shuts off the HV system.
Be sure to wear insulated gloves

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because high voltage is not shut off
inside the HV battery. When it is

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possible to remove the service plug grip,
remove it and continue the procedure.

8. After disconnecting or exposing a

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

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Removal of HV battery

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WARNING:

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・ Be sure to wear insulated gloves when handling high-voltage

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parts.
・ Even if the vehicle is shut off and the relays are off, be sure to

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remove the service plug grip before performing any further
work.

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・ Power remains in the high voltage electrical system for 10
minutes even after the HV battery pack is shut off because the

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circuit has a condenser that stores power.
・ Make sure that the tester reading is 0 V before touching any
high-voltage terminals which are not insulated.
・ The SRS may remain powered for up to 90 seconds after the
vehicle is shut off or disabled. To prevent serious injury or
death from unintentional SRS deployment, avoid cutting the
SRS components.

1. SHUT OFF IGNITION (READY indicator is off)

2. REMOVE REAR UNDER SIDE COVER

RH.
(1) Remove the 2 clips.
(2) Disengage the clips and guides to
remove the rear under side cover RH.

3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY

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

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4. REMOVE REAR UNDER SIDE COVER

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LH.
(1) Remove the clip.

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(2) Disengage the clips and guides to
remove the rear under side cover LH.

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5. REMOVE SERVICE PLUG GRIP.

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Caution:
・Be sure to 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.
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.
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(1) While wearing insulated gloves, rotate the handle of the service plug grip and remove

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the service plug grip as indicated by the arrows, in the order shown in the illustration.

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(2) (3)

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(1)

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6. DISCONNECT ENGINE WIRE
Caution:
Be sure to wear insulated gloves.
Notice:
Do not allow any foreign matter or water to
enter the inverter with converter assembly.
(1) Move the lock lever while pushing the
lock on the connector, and disconnect the
inverter with converter assembly
connector.
Notice:
・Do not damage the terminals, connector
housing or inverter with converter assembly during disconnection.
・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.
・Do not touch the waterproof seal or terminals of the connector.

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(2) for LHD:

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Disengage the 3 clamps and disconnect for LHD
the engine wire.

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for RHD:
Disengage the 2 clamps and disconnect

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the engine wire.

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for RHD

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7. REMOVE CONNECTOR COVER
ASSEMBLY
(B)
Caution:
Be sure to wear insulated gloves.
(1) Remove the bolt (B).
(A)
(2) Using a T25 "TORX" socket wrench,
remove the bolt (A) and connector cover
assembly from the inverter with converter
assembly.
Notice:
・Do not touch the connector cover assembly waterproof seal.
・Do not allow any foreign matter or water to enter the inverter with converter assembly.

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8. CHECK TERMINAL VOLTAGE

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Caution:
Be sure to wear insulated gloves.

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Notice:
Do not allow any foreign matter or water to enter

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the inverter with converter assembly.

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(1) Using a voltmeter, measure the voltage
between the terminals of the 2 phase

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connectors.
Standard voltage: 0 V

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Hint:
Use measuring range of DC 750 V or more on the voltmeter.

9. DISCONNECT REAR CENTER SEAT

OUTER BELT ASSEMBLY
(1) Using a screwdriver with its tip wrapped
in protective tape, disconnect the rear
center seat outer belt assembly as shown
in the illustration.

Protective Tape

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10. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY

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(1) Remove the bench type rear seat cushion assembly
(2) Remove the rear seat cushion lock hook

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(3) Remove the rear under cover
(4) Remove the rear seat cushion leg sub-assembly

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(1)

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(2)

(3)

×6

(4)

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11. REMOVE BATTERY COOLING

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BLOWER ASSEMBLY
(1) Disconnect the battery cooling blower

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assembly connector.
(2) Disengage the 2 clamps.

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(3) Remove the 3 bolts to remove the battery

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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.

12. REMOVE HV BATTERY UPPER

COVER PANEL
Caution:
Be sure to wear insulated gloves.
(1) Using the service plug grip, remove the
battery cover lock striker.
Hint:
Insert the projection of the service plug grip
and turn the button of the battery cover lock Service Plug Grip
striker counterclockwise to release the lock.
(2) Remove the 5 nuts and HV battery upper
Turn
cover panel from the HV battery. Button
Projection

Battery Cover Lock Striker

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13. ISCONNECT HV FLOOR UNDER WIRE

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Shield Ground
Caution:
Be sure to wear insulated gloves.

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Notice:
Insulate each disconnected high-voltage

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connector with insulating tape. Wrap the

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connector from the wire harness side to the
end of the connector.

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(1) Disconnect the 2 HV battery junction block assembly connectors.
(2) Disconnect the shield ground from the HV battery.

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14. DISCONNECT FLOOR WIRE
Caution:
Be sure to wear insulated gloves.
(1) Disengage the clamp.
(2) Disconnect the electric vehicle battery plug
assembly connector.
(3) Disconnect the HV battery junction block
assembly connector.

15. REMOVE NO.1 HV BATTERY HOSE

(1) Disconnect the No. 1 HV battery hose
from the vehicle.
(2) Disengage the 2 claws to remove the No.
1 HV battery hose from the HV battery.

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 EC
U
16. DISCONNECT FLOOR WIRE

PR
Caution:
Be sure to wear insulated gloves.

O
(1) Disengage the clamp.
(2) Disconnect the HV battery connector.

C
EN
TE
17. REMOVE HV BATTERY

R
Caution:
Be sure to wear insulated gloves.
(1) Remove the 4 bolts and HV battery from
the vehicle.
Notice:
• Do not allow foreign matter, such as
grease or oil, to adhere to the bolts of the
HV battery.
• To prevent the wire harness from being caught, make sure to bundle the wire
harness using insulating tape or equivalent.
• Use cardboard or another similar material to protect the HV battery and vehicle
body from damage.
• Since the HV battery is very heavy, 2 people are needed to remove it. When
removing the HV battery, be careful not to damage the parts around it.
• When removing the HV battery from the vehicle, do not allow it to contact the
vehicle.
• When removing/installing/moving the HV battery, make sure not to tilt it more than
80°.
• Insulate the disconnected terminals or connectors with insulating tape.

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