Toyota - Alphard - Owners Manual - 2002 - 2020

Gasoline-Electric Hybrid Synergy Drive ATH20 Series Foreword This guide was developed to educate and assist dismantlers in the safe handling of Toyota Alphard gasoline-electric hybrid vehicles. Alphard 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 Alphard 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 Alphard 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 Alphard hybrid identification. • Major hybrid component locations and descriptions. By following the information in this guide, dismantlers will be able to handle Alphard 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 Alphard Hybrid........................................................................................................................1 Alphard Hybrid Identification .................................................................................................................2 Exterior .........................................................................................................................................................3 Alphard 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 ...........................................................................................................................35 iii About the Alphard Hybrid The Alphard joins the Prius as a 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: 1. 2. Gasoline stored in the fuel tank for the gasoline engine. 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 Alphard 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. following illustration demonstrates how the Alphard hybrid operates in various driving modes. The 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 and to drive the motor. 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 Electricity o Normal Driving Electricity and gasoline p Acceleration Electricity and gasoline (additional electricity extracted from batteries) 1 q Deceleration Charging batteries r Stopping Engine automatically stopped Alphard Hybrid Identification In appearance, the 2012 model year Alphard hybrid is a 5-door wagon. compartment illustrations are provided to assist in identification. Exterior, interior, and engine The alphanumeric 17 character Vehicle Identification Number (VIN) is provided in the under the right side front seat and left side door pillar. Example VIN: JTEHB21H08000001 An Alphard hybrid is identified by the first 8 alphanumeric characters JTEHB21H. Right Side Floor and Left Side B Pillar 2 Alphard Hybrid Identification (Continued) Exterior n logos on the back door. o E-Four logo on the back door. p logo on each front fender. p Exterior Left Side View p Exterior Front and Left Side View p n o Exterior Rear and Left Side View 3 Alphard Hybrid Identification (Continued) Interior q 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. q Interior View q Hybrid System Indicator READY Indicator Light Instrument Cluster View 4 Alphard Hybrid Identification (Continued) Engine Compartment r 2.5-liter aluminum alloy gasoline engine. s Logo on the plastic engine cover. t Orange colored high voltage power cables. s r Engine Compartment View t t Power Cables 5 Hybrid Component Locations & Descriptions Component Location 12 Volt n Auxiliary Battery Hybrid o Vehicle (HV) Battery Pack Power p Cables Left Side of Cargo Area Center Console Inverter/ Converter q Engine Compartment Gasoline r Engine Engine Compartment Front Electrics Motor Engine Compartment Electric t Generator Engine Compartment Undercarriage and Engine Compartment Description A lead-acid battery that supplies power to the low voltage devices. 244.8 Volt Nickel Metal Hydride (NiMH) battery pack consisting of 21 low voltage (9.6 or 14.4 Volt) modules connected in series. Orange colored power cables carry high voltage Direct Current (DC) between the HV battery pack, inverter/converter, and A/C compressor. These cables also carry 3-phase Alternating Current (AC) between the inverter/converter, electric motors, and generator. Boosts and inverts the high voltage electricity from the 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. Provides two functions: 1) Powers vehicle. 2) Powers generator to recharge the HV battery pack. The engine is started and stopped under control of the vehicle computer. 3-phase high voltage AC permanent magnet electric motor contained in the front transaxle. It is used to power the front wheels. 3-phase high voltage AC generator that is contained in the transaxle and recharges the HV battery pack. A/C Compressor Engine Compartment (with Inverter) u 3-phase high voltage AC electrically driven motor compressor. Fuel Tank and Fuel Line v Undercarriage and Center The fuel tank provides gasoline via a fuel line to the engine. The fuel line is routed under the center of vehicle. Rear Electric Motor w Rear Sub-Frame 3-phase high voltage AC permanent magnet electric motor contained in the rear transaxle. It is used to power the rear wheels. 6 Hybrid Component Locations & Descriptions (Continued) Specifications Gasoline Engine: Electric Motors Front: Rear: 148 hp (110 kW), 2.4-liter Aluminum Alloy Engine Transmission: HV Battery: Curb Weight: Fuel Tank: Frame Material: Body Material: Seating Capacity: Automatic Only (electrically controlled continuously variable transaxle) 244.8 Volt Sealed NiMH Battery 4,839 lbs/2,195 kg 17.2 gals/65.0 liters Steel Unibody Steel Panel 7 standard 141 hp (105 kW), Permanent Magnet Motor 67 hp (50 kW), Permanent Magnet Motor n w o r q p p u ts u r q o p w t s v 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 Alphard 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. 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 Alphard 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 in the center console. 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. Components Powered by the HV Battery Pack • • • Front Electric Motor Inverter/Converter Motor A/C Compressor • • • Rear Electric Motor Power Cables Electric Generator HV Battery Pack Battery pack voltage 244.8 V Number of NiMH battery modules in the pack 21 (Upper Side: 9, Lower Side: 12) NiMH battery module voltage 9.6 V (Upper Side) 14.4 V (Lower Side) NiMH battery module dimensions 14.5 x 0.6 x 3.8 in (Upper Side) (368.2 x 15.6 x 95.8 mm) NiMH battery module dimensions 21.5 x 0.6 x 3.8 in (Lower Side) (546.6 x 15.6 x 95.8 mm) NiMH module weight (Upper Side) 3.3 lbs (1.5 kg) NiMH module weight (Lower Side) 5.1 lbs (2.3 kg) NiMH battery pack dimensions 25 x 43 x 7 in (630 x 1080 x 180 mm) NiMH battery pack weight 136.5 lbs (61.9 kg) 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 Alphard 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 cargo area. 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 Center Console 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 in the instrument cluster and indicate “CHECK illuminate the master warning light 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 Hybrid Vehicle Computer A/C Compressor o Electric Generator p Inverter/ Converter 00 Volt DC Electric Motor o AC 3-Phas p Electric Motor (Rear) n 12 Volt Auxiliary Battery HV Battery Pack High Voltage Safety System – Vehicle Shut Off (READY-OFF) 244.8 Volt DC Hybrid Vehicle Computer A/C Compressor Electric Generator Electric Motor (Rear) Inverter/ Converter 244.8 Volt DC Electric Motor HV Battery Pack AC 3-Phas 12 Volt Auxiliary Battery 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 Alphard 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. electrolyte is a caustic alkaline (pH 13.5) that is damaging to human tissues. The NiMH battery 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. is approximately in the middle of this scale. A safe (neutral) substance 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 Alphard hybrid. 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. Remove the 3 deck boards. Remove the auxiliary boxes. Disconnect the battery negative terminal. 2. Remove No. 3 console box retainer. 3. Remove the service plug grip. Caution: Wear insulated gloves for the following 3 steps. (1) Slide the handle of the service plug grip to the right. (2) Raise the release handle of the service plug grip (3) Remove the service plug grip. (4) Apply insulating tape to the socket of the service plug grip to insulate it. 15 Read 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 (15A). 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 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. 18 4. REMOVE NO. 3 CONSOLE BOX RETAINER 5. REMOVE SERVICE PLUG GRIP Caution: Wear insulated gloves for the following 3 steps. (1) Slide the handle of the service plug grip to the right. (2) Raise the release handle of the service plug grip (3) Remove the service plug grip. (4) Apply insulating tape to the socket of the service plug grip to insulate it. 6. REMOVE ENGINE ROOM SIDE COVER 7. SEPARATE ENGINE ROOM RELAY BLOCK (1) Disconnect the clamp. (2) Remove the 2 bolts and separate the engine room relay block. 19 8. REMOVE CONNECTOR COVER ASSEMBLY Caution: • Do not touch the high voltage connectors and terminals for 10 minutes after the service plug grip is removed. • Wear insulated gloves. (1) Remove the 2 bolts and connector cover assembly. Hint: Cover the hole where cable was connected with tape or equivalent (non-residue type) to prevevt entry of foreign matter. 9. CHECK TERMINAL VOLTAGE Caution: Wear insulated gloves. (1) Using the voltmeter, measure the voltage between the terminals of the 2 phase connectors (N-P). Standard voltage: 0 V Hint: Use mesurering range of DC750V or more on the voltmeter. 10. REMOVE COWL SIDE TRIM BOARD RH (1) Remove the clip. (2) Disengage the clip, claw and 2 guides, and remove the cowl side trim board RH. 20 11. REMOVE DOOR SCUFF PLATE ASSEMBLY RH (1) Disengage the claw, 6 clips and 3 guides, and remove the door scuff plate assembly RH. 12. REMOVE NO. 3 FLOOR CARPET MOULDING (1) Using a screwdriver, turn the clip 90°counterclockwise to release the 2 locks, and remove the 2 No. 3 floor carpet mouldings. 13. REMOVE FRONT SEAT LEG COVER RH (1) Operate the slide and vertical power seat switch knob and move the seat to the foremost position.. (2) Turn back the floor carpet. (3) Disengage the 6 claws and guide, and remove the front seat leg cover RH. 14. REMOVE FRONT SEAT HEADREST ASSEMBL 21 15. REMOVE FRONT SEAT ASSEMBLY (for Driver Side) (1) The seat travel distance can be customized, this function is OFF. (2) Remove the 2 bolts on the rear side of the seat. (3) Operate the slide and vertical power seat switch knob and move the seat to the rearmost position. (4) Using a screwdriver wrapped with protective tape, disengage the 2 claws and guide, and open the cover. (5) Using a screwdriver wrapped with protective tape, disengage the 2 claws and guide, and open the cover. (6) Remove the 2 bolts on the front side of the seat. (7) Operate the slide and vertical power seat switch knob and move the seat to the center position. Also operate the reclining power seat switch knob and move the seatback to the upright position (8) Disconnect the cable from the negative (-) battery terminal. Caution: Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system. 22 (9) Disconnect the 2 connectors. (10) Remove the front seat assembly. 16. REMOVE FRONT SEAT ASSEMBLY (for Front Passenger Side) Hint: Use the same procedure for the Driver side. 17. REMOVE NO. 1 AMPLIFIER BRACKET (1) Disconnect the 2 connectors. (2) Remove the 2 bolts and No. 1 amplifier bracket. 18. REMOVE CENTER FLOOR CARPET COVER RH (1) Using a clip remover, remove the 2 clips. 23 (2) Disengage the 4 claws and remove the center floor carpet cover RH. 19. REMOVE CENTER FLOOR CARPET COVER LH (1) Using a clip remover, remove the clip. (2) Disengage the 5 claws and remove the center floor carpet cover LH. 24 20. REMOVE CONSOLE BOX HOLDER COVER (1) Disengage the 4 claws and remove the 3 console box hole cover.. 21. REMOVE CONSOLE BOX CARPET 22. REMOVE CONSOLE BOX ASSEMBLY (1) Using a clip remover, remove the 6 clips. (2) Remove the 2 screws. 25 (3) Disengage the 6 claws and 2 guides as shown in the illustration. (4) Disengage the 2 clamps. (5) Disconnect the 2 connectors and remove the console box assembly. 23. REMOVE UPPER HYBRID BATTERY COVER SUB-ASSEMBLY Caution: Wear insulated gloves. Hint: Cover the hole where the service plug grip was connected with tape or equivalent (nonresidue type) to prevent. (1) Remove the 7 bolts and upper hybrid battery cover sub-assemmbly. 26 24. REMOVE FRONT HYBRID BATTERY SHIELD Caution: Wear insulated gloves. (1) Remove the 4 bolts and front hybrid battery shield. . 25. REMOVE REAR HYBRID BATTERY SHIELD Caution: Wear insulated gloves. (1) Remove No.1 hybrid battery rear shield seal. (2) Remove No.1 hybrid battery seal (3) Remove No.2 hybrid vehicle battery seal (4) Remove the 6 bolts and rear hybrid battery shield. 26. REMOVE HYBRID CONVERTER PROTECTOR Caution: Wear insulated gloves. (1) Remove the 2 bolts, 2 nuts and hybrid converter protector. 27 27. REMOVE HYBRID CONVERTER SHIELD Caution: Wear insulated gloves. (1) Using the service plug grip, remove the battery cover lock striker. (2) Remove the 2 bolt, nut and hybrid converter shield. 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. 28. DISCONNECT NO.2 ENGINE ROOM WIRE Caution: Wear insulated gloves. (1) Using an insulated tool, remove the 3 nuts and disconnect the No.2 engine room wire. Hint: Insulate the disconnected terminals with insulating tape. (2) Disengage the 3 claws and remove the No.1 terminal cap. (3) Loosen the bolt and disengage the 2 claws. (4) Disconnect the clamp and disconnect the No.2 engine room wire. (5) Disconnect the clamp and disconnect the No. 2 engine room wire. 28 29. REMOVE BATTERY COOLING BLOWER ASSEMBL (for Upper Side) (1) Remove the clip (2) Disconnect the connector and 2 clamps. (3) Remove the 3 nuts and battery cooling blower assembly. Hint: Be sure not to touch the fan part of the battery cooling blower assembly. 30. REMOVE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Caution: Wear insulated gloves. (1) Disconnect the 7 connectors. Hint: Insulate the disconnected connectors Terminals with insulating tape. (2) Remove the nut and filter noise capacitor. 29 (3) Remove the 2 bolts and hybrid battery junction block assembly. 31. REMOVE BATTERY SMART UNIT Caution: Wear insulated gloves (3) Disconnect the 3 connectors. Hint: Insulate the removed connector with insulating tape. (4) Remove the bolt and battery smart unit. 32. DISCONNECT WIRE HARNESS Caution: Wear insulated gloves. (1) Remove the 2 bolts and disconnect the electric vehicle battery plug. (2) Disconnect the 20 clamps and 6 connectors. Hint: Insulate the disconnected connectors with insulating tape. 30 33. REMOVE HV BATTERY (for Upper Side) Caution: Wear insulated gloves. Hint: • Make sure that the HV battery is not tilted over 80°during transport, removal, and installation. • Secure the wire harness with electrical tape to prevent it from getting caught when removing the battery or other parts. • Since the HV battery is very heavy, 2 people are needed to remove the HV battery.When removing the HV battery. (1) Disconnect the connector. (2) Disconnect the hybrid battery hose. (3) Remove the 6 bolts and HV battery (for upper side) as shown in the illustration. 31 34. REMOVE HYBRID VEHICLE CONVERTER Caution: Wear insulated gloves. (1) Remove the 2 nuts and junction terminal. (2) Disconnect the 2 connectors. (3) Remove the 3 bolts and hybrid vehicle converter. 35. REMOVE WIRE HARNESS Caution: Wear insulated gloves. (1) Disconnect the 2 clamps and connector. (2) Disconnect the 4 clamps and remove the wire harness. 32 36. REMOVE NO.2 HYBRID BATTERY EXHAUST DUCT (1) Remove the clip and No.2 hybrid exhaust duct. 37. REMOVE NO.3 HYBRID VEHICLE BATTERY EXHAUST DUCT LH (1) Remove the clip and No.3 hybrid vehicle battery exhaust duct LH. 38. REMOVE HV BATTERY. (for Lower Side) Caution: Wear insulated gloves. Hint: • Make sure that the HV battery is not tilted over 80°during transport, removal, and installation. • Secure the wire harness with electrical tape to prevent it from getting caught when removing the battery or other parts. • Since the HV battery is very heavy, 2 people are needed to remove the HV battery. (1) Disconnect the hybrid battery hose from the floor panel. (2) Disconnect the connector. 33 (3) Remove the 6 bolts. (4) Put the ropes through the parts as shown in the illustration and remove the HV battery (lower side). 34 HV Battery Caution Label 35