Precaution [01/2023 - 11/2023]

1. During inspection work, to prevent the auxiliary power supply control system from activating and causing operation of electrical devices such as the radiator fan and water pump to start at unintended timing, press and hold the ignition switch (push start switch) for 5 seconds to prohibit auxiliary power supply control system.

   HINT: 

   • When the ignition switch (push start switch) is pressed and held for 5 seconds, messages about auxiliary power supply control system is displayed in the meter.
   • After the inspections in the motor compartment are completed, turning the ignition switch ON (READY) will restore the prohibited controls.
2. Before the following operations are conducted, take precautions to prevent electric shock by turning the ignition switch off, wearing insulated gloves, and removing the service plug grip from traction battery assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   • Inspecting the high-voltage system
   • Disconnecting the low voltage connector of the inverter assembly
   • Disconnecting the low voltage connector of the EV battery
   • Disconnecting the low voltage connector of the ESU

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

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

     Refer to INSPECTION MODE PROCEDURE [01/2023 - ]

   • After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

     Refer to BEFORE DISCONNECTING BATTERY [01/2023 - ]

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   HINT: 

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Without waiting for 10 minutes

6. Check the voltage at the terminals in the inspection point in the ESU.
   WARNING:

   Be sure to wear insulated gloves.

   1. Disconnect the cable from the negative (-) auxiliary battery terminal.
   2. Remove the service plug grip.

      Refer to REMOVAL [01/2023 - ]

   3. Remove the No. 2 terminal cover from the ESU.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   4. Using a voltmeter, measure the voltage between the terminals of the 2 phase connectors.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Voltage

      0 V

      HINT: 

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

7. When turning the ignition switch to ON during an inspection, do not press the ignition switch with the brake pedal depressed.
   WARNING:

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

     Refer to INSPECTION MODE PROCEDURE [01/2023 - ]

   • After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

     Refer to BEFORE DISCONNECTING BATTERY [01/2023 - ]

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

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

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

     Refer to INSPECTION MODE PROCEDURE [01/2023 - ]

   • After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

     Refer to BEFORE DISCONNECTING BATTERY [01/2023 - ]

HINT: 

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

1. Be sure to disconnect the cable from the negative (-) auxiliary battery terminal before disconnecting the AMD terminal from the fusible link block assembly.
   NOTE:

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

     Refer to INSPECTION MODE PROCEDURE [01/2023 - ]

   • After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

     Refer to BEFORE DISCONNECTING BATTERY [01/2023 - ]

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	AMD Terminal (ESU Side)
   *b	AMD Terminal (Fusible Link Block Assembly Side)

2. After disconnecting the AMD terminal, wrap it with vinyl insulating tape.
3. Be sure to reconnect the AMD terminal to the fusible link block assembly before reconnecting the cable to the negative (-) terminal of the auxiliary battery.
   NOTE:

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

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

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

     Refer to RECOVERY INSPECTION [01/2023 - ]

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

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

     Therefore, make sure to return traction battery assembly and all EV supply stacks through an authorized collection agent.

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

     *a	Dealer
     *b	Battery Collection Agent

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

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

EV battery learning values are stored in the battery ECU assembly and EV control ECU to display "Have Traction Battery Inspected" on the multi-information display. When either of these ECUs is replaced, the new ECU receives the EV battery learning value data from the other ECU and updates the information.

1. Procedure when replacing both battery ECU assembly and EV control ECU:
   1. Disconnect the cable from the negative (-) auxiliary battery terminal.
   2. Replace either of the ECUs.
   3. Connect the cable to the negative (-) auxiliary battery terminal.
   4. Turn the ignition switch to ON (READY) and wait for 25 minutes or more.
   5. Turn the ignition switch off and disconnect the cable from the negative (-) auxiliary battery terminal.
   6. Replace the other ECU.
   7. Connect the cable to the negative (-) auxiliary battery terminal.
   8. Check that the ignition switch can be turned on (READY).

      HINT: 

      If the battery ECU assembly and EV control ECU are replaced at the same time without following the above procedure, replace either of the ECUs with its original one and then replace it again by following the above procedure. If the correct procedure is not followed, perform the procedure again from the beginning.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

     Refer to INSPECTION MODE PROCEDURE [01/2023 - ]

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

     Refer to BEFORE DISCONNECTING BATTERY [01/2023 - ]

   • When disconnecting and reconnecting the auxiliary battery.

     HINT: 

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

     Refer to AUTOMATIC LEARNING CHART [01/2023 - ]