Gasoline-Electric

Hybrid Synergy Drive

AVV50 Series
Foreword

This guide was developed to educate and assist dismantlers in the safe handling of Toyota Camry
gasoline-electric hybrid vehicles. Camry hybrid dismantling procedures are similar to other non-hybrid
Toyota vehicles with the exception of the high voltage electrical system. It is important to recognize
and understand the high voltage electrical system features and specifications of the Toyota Camry hybrid,
as they may not be familiar to dismantlers.
High voltage electricity powers the A/C compressor, electric motor, generator, and inverter/converter.
All other conventional automotive electrical devices such as the headlights, radio, and gauges are
powered from a separate 12 Volt auxiliary battery. Numerous safeguards have been designed into the
Camry hybrid to help ensure the high voltage, approximately 244.8 Volt, Nickel Metal Hydride (NiMH)
Hybrid Vehicle (HV) battery pack is kept safe and secure in an accident.
The NiMH HV battery pack contains sealed batteries that are similar to rechargeable batteries used in
some battery operated power tools and other consumer products. The electrolyte is absorbed in the cell
plates and will not normally leak out even if the battery is cracked. In the unlikely event the electrolyte
does leak, it can be easily neutralized with a dilute boric acid solution or vinegar.
High voltage cables, identifiable by orange insulation and connectors, are isolated from the metal chassis
of the vehicle.

Additional topics contained in the guide include:

• Toyota Camry hybrid identification.
• Major hybrid component locations and descriptions.

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

© 2011 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.

ii
Table of Contents

About the Camry Hybrid..........................................................................................................................1

Camry Hybrid Identification....................................................................................................................2

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

Camry Hybrid Identification (Continued) ..............................................................................................4

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

Hybrid Component Locations & Descriptions........................................................................................6

Specifications ................................................................................................................................................7

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

Vehicle Operation..........................................................................................................................................8

Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery.....................................................................9

HV Battery Pack............................................................................................................................................9
Components Powered by the HV Battery Pack.............................................................................................9
HV Battery Pack Recycling .........................................................................................................................10
Auxiliary Battery ..........................................................................................................................................10

High Voltage Safety ................................................................................................................................. 11

High Voltage Safety System........................................................................................................................ 11
Service Plug Grip ........................................................................................................................................12

Precaution to be observed when dismantling the vehicle.....................................................................13

Necessary Items .........................................................................................................................................13

Spills..........................................................................................................................................................14

Dismantling the vehicle ...........................................................................................................................15

Removal of HV battery ...........................................................................................................................18

HV Battery Caution Label ...........................................................................................................................30

iii
About the Camry Hybrid
The Camry hybrid continues into its 2nd generation as a gasoline-electric hybrid vehicle.
Hybrid Synergy Drive means that the vehicle contains a gasoline engine and electric motors
for power. The two hybrid power sources are stored on board the vehicle:

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

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

The result of combining these two power sources is improved fuel economy and reduced
emissions. The gasoline engine also powers an electric generator to recharge the battery
pack; unlike a pure all electric vehicle, the Camry hybrid never needs to be recharged from an
external electric power source.

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

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

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

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

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

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

n Starting o Normal Driving p Acceleration q Deceleration r Stopping

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

1
Camry Hybrid Identification
In appearance, the 2012 model year Camry hybrid is a 4-door sedan. Exterior, interior, and engine
compartment illustrations are provided to assist in identification.

The alphanumeric 17 character Vehicle Identification Number (VIN) is provided in the front
windshield cowl, right side floor and on the left side B pillar.

Example VIN:
4T1BD1FK0CU001001 (U.S.A., Canada and South Korea)
JTNBD4FK0CU001001 (General)
A Camry hybrid is identified by the first 8 alphanumeric characters 4T1BD1FK or JTNBD4FK.

Left Side Windshield Cowl, Right Side Floor and Left Side B Pillar

2
Camry Hybrid Identification (Continued)
Exterior

n and logos on the luggage compartment door.

o logo on each front fender.

U.S.A., Canada and South Korea General

o o

Exterior Left Side View

U.S.A., Canada and South Korea General

Exterior Front View

U.S.A., Canada and South Korea General

n
n
n n

Exterior Rear View

General
U.S.A., Canada and South Korea

o n
o n n n

Exterior Rear and Left Side View

3
Camry Hybrid Identification (Continued)
Interior
p Instrument cluster (speedometer, READY light, shift state indicators, warning lights) located in the
center of the dash and near the base of the windshield.

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

U.S.A., Canada and South Korea General

p p

Interior View of Front Door Sill

p READY Indicator

READY Indicator

Instrument Cluster View

4
Camry Hybrid Identification (Continued)
Engine Compartment
q 2.5-liter aluminum alloy gasoline engine.
r Logo on the plastic engine cover.
s Orange colored high voltage power cables.

Engine Compartment View

Power Cables

5
Hybrid Component Locations & Descriptions

Component Location Description

12 Volt n Right Side of A lead-acid battery that supplies power to the low voltage
Auxiliary Battery Trunk devices.
Hybrid o Vehicle Trunk, Mounted to 244.8 Volt Nickel Metal Hydride (NiMH) battery pack
(HV) Battery Pack Cross Member consisting of 34 low voltage (7.2 Volt) modules connected
behind Rear Seat in series.
Power p Cables Undercarriage and Orange colored power cables carry high voltage Direct
Engine Current (DC) between the HV battery pack,
Compartment inverter/converter, and A/C compressor. These cables
also carry 3-phase Alternating Current (AC) between the
inverter/converter, electric motor, and generator.
Inverter/ Engine Boosts and inverts the high voltage electricity from the
Converter q Compartment HV battery pack to 3-phase AC electricity that drives the
electric motors. The inverter/converter also converts AC
electricity from the electric generator and electric motors
(regenerative braking) to DC that recharges the HV
battery pack.
Gasoline r Engine Provides two functions:
Engine 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.
Electrics Engine 3-phase high voltage AC permanent magnet electric motor
Motor Compartment contained in the front transaxle. It is used to power the
front wheels.
Electric t Engine 3-phase high voltage AC generator that is contained in the
Generator Compartment transaxle and recharges the HV battery pack.
A/C Compressor Engine 3-phase high voltage AC electrically driven motor
(with Inverter) u Compartment compressor.
Fuel Tank and Fuel Undercarriage and The fuel tank provides gasoline via a fuel line to the
Line v 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.

6
Hybrid Component Locations & Descriptions (Continued)

Specifications
Gasoline Engine: 155 hp (116 kW), 2.5-liter Aluminum Alloy Engine (U.S.A., Canada, South Korea)
158 hp (118 kW), 2.5-liter Aluminum Alloy Engine (General)
Electric Motors 141 hp (105 kW), Permanent Magnet Motor
Transmission: Automatic Only (electrically controlled continuously variable transaxle)
HV Battery: 244.8 Volt Sealed NiMH Battery
Curb Weight: 3,483 lbs/1,580 kg
Fuel Tank: 17.2 gals/65.0 liters
Frame Material: Steel Unibody
Body Material: Steel Panel
Seating Capacity: 5 standard

o
r

q p
u
ts

n
u r
p o
t v
q s

7
Hybrid Synergy Drive Operation
Once the READY indicator is illuminated in the instrument cluster, the vehicle may be driven.
However, the gasoline engine does not idle like a typical automobile and will start and stop
automatically. It is important to recognize and understand the READY indicator provided in
the instrument cluster. When illuminated, it informs the driver that the vehicle is on and
operational even though the gasoline engine may be off and the engine compartment is silent.

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

• Never assume that the vehicle is shut off just because the engine is off. Always look for the
READY indicator status. The vehicle is shut off when the READY indicator is off.

The vehicle may be powered by:

1. The electric motor only.
2. The gasoline engine only.
3. A combination of both the electric motor and the gasoline engine.

Instrument Cluster READY Indicator

8
Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery
The Camry hybrid features a high voltage Hybrid Vehicle (HV) battery pack that contains sealed
Nickel Metal Hydride (NiMH) battery modules.

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

• The HV battery pack consists of 34 low voltage (7.2 Volt) NiMH battery modules connected in
series to produce approximately 244.8 Volts. Each NiMH battery module is non-spillable and in
a sealed case.

• The electrolyte used in the NiMH battery module is an alkaline mixture of potassium and sodium
hydroxide. The electrolyte is absorbed into the battery cell plates and will not normally leak,
even in a collision.

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

U.S.A., Canada and South

General
Korea
Battery pack voltage 244.8 V 244.8 V
Number of NiMH battery modules in the pack 34 34
NiMH battery module voltage 7.2 V 7.2 V
NiMH battery module dimensions 11 x 4.6 x 4.6 in 11 x 4.6 x 4.6 in
(285 x 0.8 x 117.8 mm) (285 x 0.8 x 117.8 mm)
NiMH module weight 2.3 lbs (1.04 kg) 2.3 lbs (1.04 kg)
NiMH battery pack dimensions 32 x 17.5 x 12.8 in 35.8 x 19.1 x 12.5 in
(817 x 445 x 325 mm) (909 x 486 x 317 mm)
NiMH battery pack weight 103 lbs (47 kg) 107 lbs (49 kg)

Components Powered by the HV Battery Pack

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

9
Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (Continued)

HV Battery Pack Recycling

• The HV battery pack is recyclable. Contact either your Toyota Distributor as mentioned on HV
battery Caution Label (see page 26) or the nearest Toyota dealer.

Auxiliary Battery
• The Camry hybrid also contains a lead-acid 12 Volt battery. This 12 Volt auxiliary battery powers
the vehicle electrical system similar to a conventional vehicle. As with other conventional
vehicles, the auxiliary battery is grounded to the metal chassis of the vehicle.
• The auxiliary battery is located in the trunk. It is concealed by the deck board and auxiliary box
on the right side in the rear quarter panel well.

244.8 Volt HV Battery Pack 12 Volt Auxiliary Battery Mounted in Trunk

HV Battery Pack Mounted in Trunk

10
High Voltage Safety
The HV battery pack powers the high voltage electrical system with DC electricity. Positive and
negative orange colored high voltage power cables are routed from the battery pack, under the vehicle
floor pan, to the inverter/converter. The inverter/converter contains a circuit that boosts the HV
battery voltage from 244.8 to 650 Volts DC. The inverter/converter creates 3-phase AC to power the
motors. Power cables are routed from the inverter/converter to each high voltage motor (electric
motor, electric generator, and A/C compressor). The following systems are intended to help keep
occupants in the vehicle and emergency responders safe from high voltage electricity:

High Voltage Safety System

• A high voltage fuse n* provides short circuit protection in the HV battery pack.

• Positive and negative high voltage power cables o* connected to the HV battery pack are
controlled by 12 Volt normally open relays p*. When the vehicle is shut off, the relays stop
electricity flow from leaving the HV battery pack.

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

• Both positive and negative power cables o* are insulated from the metal chassis, so there is no
possibility of electric shock when touching the metal chassis.

• A ground-fault monitor continuously monitors for high voltage leakage to the metal chassis while
the vehicle is running. If a malfunction is detected, the hybrid vehicle computer q* will
illuminate the master warning light in the instrument cluster and indicate “CHECK
HYBRID SYSTEM” on the multi-information display.

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

*Numbers apply to the illustration on the following page.

11
High Voltage Safety (Continued)

Service Plug Grip

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

q
00
Volt DC 12 Volt
Hybrid Vehicle Computer Auxiliary
Battery

A/C
Compressor
o
o p p
Electric
Generator Inverter/
Converter
00
Electric Volt DC
Motor n
AC
3-Phas
HV Battery Assembly

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

244.8
Volt DC 12 Volt
Hybrid Vehicle Computer Auxiliary
Battery

A/C
Compressor

Electric
Generator Inverter/
Converter
244.8
Electric
Volt DC
Motor

AC
3-Phas
HV Battery Assembly

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

12
Precaution to be observed when dismantling the vehicle

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

Necessary Items
• Protective clothing such as insulated gloves (electrically insulated), rubber gloves, safety goggles,
and safety shoes.
• Insulating tape such as electrical tape that has a suitable electrical insulation rating.
• Before wearing insulated gloves, make sure that they are not cracked, ruptured, torn, or damaged in
any way. Do not wear wet insulated gloves.
• An electrical tester that is capable of measuring DC 750 Volts or more.

13
Spills
The Camry hybrid contains the same common automotive fluids used in other non-hybrid Toyota
vehicles, with the exception of the NiMH electrolyte used in the HV battery pack. The NiMH battery
electrolyte is a caustic alkaline (pH 13.5) that is damaging to human tissues. The electrolyte, however,
is absorbed in the cell plates and will not normally spill or leak out even if a battery module is cracked.
A catastrophic crash that would breach both the metal battery pack case and a metal battery module
would be a rare occurrence.

A caustic alkaline is at the opposite end of the pH scale from a strong acid. A safe (neutral) substance
is approximately in the middle of this scale. Adding a weak acidic mixture, such as a dilute boric acid
solution or vinegar, to the caustic alkaline electrolyte will cause the electrolyte to be neutralized. This
is similar but opposite to the use of baking soda to neutralize a lead-acid battery electrolyte spill.

A Toyota Material Safety Data Sheets (MSDS) is attached to this document.

• Handle NiMH electrolyte spills using the following Personal Protective Equipment (PPE):
• Splash shield or safety goggles. A fold down face shield is not acceptable for acid or
electrolyte spills.
• Rubber, latex or nitrile gloves.
• Apron suitable for alkaline.
• Rubber boots.

• Neutralize NiMH electrolyte.

• Use a boric acid solution or vinegar.
• Boric acid solution - 800 grams boric acid to 20 liters water or 5.5 ounces boric acid to 1
gallon of water.

14
Dismantling the vehicle

The following 2 pages contain general instructions for use when working on a Camry hybrid. Read
these instructions before proceeding to the HV battery removal instructions on page 18.

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

1. Shut off the ignition (READY indicator is off).

Then disconnect the cable from the auxiliary
battery negative (-) terminal.
(1) Remove the 3 deck boards.
(2) Remove the auxiliary boxes.
(3) Disconnect the battery negative terminal.

2. REMOVE NO. 8 HYBRID VEHICLE

BATTERY SHIELD PANEL
(1) Remove the 2 nuts and No. 8 hybrid vehicle
battery shield panel.
3. Remove the service plug grip.
Caution:
Wear insulated gloves for the following 3
steps.
(2) Slide the handle of the service plug grip to the right.
(3) Raise the release handle of the service plug grip
(4) Remove the service plug grip.
(5) Apply insulating tape to the socket of the service plug grip to insulate it.

15
4. Carry the removed service plug grip in your pocket to prevent other staff from accidentally
reinstalling it while you are dismantling the vehicle.
5. Make other staff aware that a high-voltage system is being dismantled by using the
following sign: CAUTION: HIGH-VOLTAGE. DO NOT TOUCH (see page 17).
6. If the service plug grip cannot be removed due to damage to the vehicle, remove the IG2
MAIN fuse (25A).
Caution:
This operation shuts off the HV system. Be sure to wear insulated gloves because
high voltage is not shut off inside the HV battery. When it is possible to remove
the service plug grip, remove it and continue the procedure.

IG2 MAIN
Fuse

7. After disconnecting or exposing a

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

16
17
Removal of HV battery

WARNING:
・ Be sure to wear insulated gloves when handling high-voltage
parts.
・ Even if the vehicle is shut off and the relays are off, be sure to
remove the service plug grip before performing any further
work.
・ Power remains in the high voltage electrical system for 10
minutes even after the HV battery pack is shut off because the
circuit has a condenser that stores power.
・ Make sure that the tester reading is 0 V before touching any
high-voltage terminals which are not insulated.
・ The SRS may remain powered for up to 90 seconds after the
vehicle is shut off or disabled. To prevent serious injury or
death from unintentional SRS deployment, avoid cutting the
SRS components.

1. SHUT OFF IGINITION (READY indicator is off)

2. REMOVE LUGGAGE TRIM SERVICE
HOLE COVER

3. REMOVE 12 V AUXILIARY BATTERY

(1) Disconnect the cable from the auxiliary battery
negative (-) terminal.
(2) Disconnect the cable from the auxiliary battery
positive (+) terminal.
(3) Remove the 12 volt auxiliary battery.

4. REMOVE LUGGAGE COMPARTMENT FLOOR MAT

5. REMOVE SPARE WHEEL COVER ASSEMBLY

18
6. REMOVE LUGGAGE COMPARTMENT
FRONT TRIM COVER
(1) Disengage the 8 fasteners.
(2) Disengage the 3 claws and remove the
luggage compartment front trim cover.

7. REMOVE NO. 8 HYBRID VEHICLE

BATTERY SHIELD PANEL
(1) Remove the 2 nuts and No. 8 hybrid vehicle
battery shield panel.

8. REMOVE SERVICE PLUG GRIP

Caution:
Wear insulated gloves for the following 3 steps.
(1) Slide the handle of the service plug grip.
(2) Raise the release handle of the service plug grip as shown in the illustration below.
(3) Remove the service plug grip.
(4) Apply insulating tape to the socket of the service plug grip to insulate it.

19
9. REMOVE CONNECTOR COVER
ASSEMBLY
Caution:
Wear insulated gloves.
(1) Remove the 2 bolts and connector cover
assembly.

10. CHECK TERMINAL VOLTAGE

(1) Check voltage at the terminals in inspection
point in the power control unit.
Caution:
Wear insulated gloves.
To prevent serious injury or death, do not
proceed with dismantling of the HV system
until the voltage at the terminals in the
inspection point is 0 V.
Standard voltage: 0 V

Hint:
Set the tester to the DC 750 Volts range to measure the voltage.
This inspection is performed to verify that it is safe to remove the HV battery.

11. REMOVE REAR FLOOR FINISH PLATE

(1) Remove the 5 clips.

(2) Disengage the 4 clips and remove the rear floor

finish plate.

20
12. REMOVE NO. 1 LUGGAGE
COMPARTMENT TRIM HOOK
(1) Push the 2 pins and remove the 2 No. 1
luggage compartment trim hooks.

13. REMOVE LUGGAGE COMPARTMENT

INNER TRIM COVER LH
(1) Remove the 3 clips.
(2) Disengage the fastener and remove the luggage
compartment inner trim cover LH.

14. REMOVE LUGGAGE COMPARTMENT

INNER TRIM COVER RH
(1) Remove the 3 clips.
(2) Disengage the fastener and remove the luggage
compartment inner trim cover RH.

15. REMOVE REAR SEAT CUSHION

ASSEMBLY
(1) Disengage the hook of the seat cushion from
the vehicle body as shown in the illustration.
(2) Remove the rear seat cushion assembly.

21
16. REMOVE REAR SEAT CUSHION LOCK
HOOK
(1) Disengage the hook of the seat cushion from
the vehicle body as shown in the illustration.
Hint:
Use the same procedure for the RH side and the
LH side.

17. REMOVE REAR SEATBACK ASSEMBLY

RH
(1) Disengage the 3 fasteners as shown in the
illustration.

(2) Remove the 2 bolts and rear seatback assembly

RH.

18. REMOVE NO. 2 ROOM PARTITION COVER

(1) Using a moulding remover, disengage the claw
and guide, and remove the No. 2 room
partition cover.

19. REMOVE REAR SEATBACK ASSEMBLY

LH
(1) Pull the cable to relock the seatback lock and
fold the rear seatback assembly LH forward.

22
 (2) Disengage the 2 fasteners as shown in the
illustration.

(3) Remove the 2 bolts and rear seatback assembly

LH.

20. REMOVE REAR SIDE SEATBACK

ASSEMBLY LH
(1) Disconnect each connector.
(2) Remove the 2 bolts.
(3) Disengage the hook and remove the rear side
seatback assembly LH.

21. REMOVE REAR SIDE SEATBACK

ASSEMBLY RH
(1) Disconnect each connector.
(2) Remove the 2 bolts.
(3) Disengage the hook and remove the rear side
seatback assembly RH.

22. CUT REAR SEAT BELT LH, REAR SEAT

BELT RH AND REAR SEAT BELT CENTER

23
23. REMOVE CHILD RESTRAINT SEAT
ANCHOR BRACKET SUB-ASSEMBLY LH
(1) Remove the 2 nuts and child restraint seat
anchor bracket sub-assembly LH.
24. DISCONNECT REAR DOOR OPENING
TRIM WEATHERSTRIP LH AND RH
25. REMOVE ROOF SIDE INNER GARNISH LH
AND RH

26. REMOVE CENTER STOP LIGHT SET

(1) Slide the center stop light set in the order and
directions shown by the arrows in the
illustration while pushing it towards the rear of
the vehicle to disengage the 4 claws.

(2) Turn the center stop light set 180 degrees as

shown by the arrow in the illustration.
(3) Disconnect the connector and remove the
center stop light set.

27. REMOVE PACKAGE TRAY TRIM PANEL

ASSEMBLY
(1) Using pliers, disengage the 3 clips from inside
the luggage compartment as shown in the
illustration.
(2) Disengage the 5 guides.
(3) Pass the 3 rear seat belt floor anchors through
the package tray trim panel assembly then
remove the package tray trim panel assembly.

24
28. REMOVE ROOM PARTITION BOARD
(U.S.A., Canada and South Korea)
(1) Using a clip remover, remove the 4 clips.
(2) Disengage the 5 clips and remove the No. 1
room partition board.

(General)
(1) Using a clip remover, remove the clip.
(2) Disengage the 5 claws and clip, and remove
the room partition board LH.

(3) Using a clip remover, remove the 4 clips.

(4) Disengage the 4 clips, and remove the room
partition board RH.

29. REMOVE NO. 1 HYBRID BATTERY

INTAKE DUCT
(1) Remove the 3 clips and No. 1 hybrid battery
intake duct.

25
30. REMOVE NO. 4 HYBRID BATTERY
SHIELD PANEL
Caution:
Wear insulated gloves for the following 2
steps.
(1) Remove the 3 clips and No. 1 hybrid battery
intake duct.
Hint:
Insert the projecting part of the service plug grip
and turn the button of the battery cover lock striker
counterclockwise to release the lock.
(2) Remove the bolt, 2 nuts and No. 4 hybrid
battery shield panel.

31. REMOVE NO. 4 FLOOR WIRE

Caution:
Wear insulated gloves.
Notice:
Insulate the terminals of the removed frame wire with insulating tape.
(1) Disconnect the 2 connectors shown in the
illustration.
(2) Disconnect the shielded wire ground and
disconnect the No. 4 floor wire.

32. DISCONNECT LOW VOLTAGE

CONNECTOR
(1) Disconnect the connector and clamp shown in
the illustration.

26
 (2) Disconnect the 2 connectors.

.
33. REMOVE HV BATTERY
Caution:
Wear insulated gloves.
Notice:
Since the HV battery is very heavy, 2 people are needed to remove the HV battery.
When removing the HV battery, do not damage the parts around it.

(1) Remove the 6 bolts from the HV battery. U.S.A., Canada and South Korea

General

27
(2) Pull the HV battery toward the center of the
luggage compartment.

(3) Remove the 2 nuts and No. 2 hybrid vehicle

battery upper cover bracket.

(4) Remove the clip.

(5) Disengage the 2 claws and remove the No. 2
hybrid battery intake duct.

(6) Disconnect the connector from the battery

cooling blower assembly.
(7) Remove the 3 nuts and battery cooling blower
assembly.

(8) Turn the HV battery 180°.

(9) Pull the HV battery together with the cardboard
toward the rear of the vehicle.

28
 (10) Using a suitable adaptor such as a rope, remove
the HV battery while tilting the HV battery.

34. The HV battery pack is recyclable. Contact your Toyota distributor (if included on the HV
battery caution label) or contact the nearest Toyota dealer (see the next 2 pages for
samples of the HV battery caution label).
Caution:
After removing the HV battery, do not reinstall the service plug grip to the HV
battery.

29
HV Battery Caution Label
1. For U.S.A.

2. For CANADA

30
3. For Korea and General

31