ARTICLE BEGINNING SERVICE PRECAUTIONS

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1 Page 1 of 96 ARTICLE BEGINNING SERVICE PRECAUTIONS WARNING: WARNING: CAUTION: When performing any inspection or service procedure on this vehicle, ensure following service precautions are followed to prevent personal injury or death due to extremely high voltage. Read ALL service precautions before proceeding with service procedure. Vehicle is equipped with air bag supplemental restraint system. Before attempting ANY repairs involving steering column, instrument panel or related components, see SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM in AIR BAG RESTRAINT SYSTEMS article. When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See appropriate COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. The Following Service Precautions Must Be Followed: Ensure ignition is off and ignition key is removed from ignition before performing any inspection or service procedure in engine compartment, as engine may automatically start and shut off when ignition is on and READY light is illuminated. READY light is displayed just above shift lever position indicator on instrument cluster at center of instrument panel. Read all service and warning labels in engine compartment before performing any procedures. All high-voltage wiring harnesses contain Orange connectors. DO NOT touch any wiring harness that contains Orange connectors. High-voltage battery and other high-voltage components may be identified by HIGH VOLTAGE caution labels on them. DO NOT touch these components. If necessary to inspect or service high-voltage system, ensure ignition is off. Remove service plug and wait at least 5 minutes to ensure high voltage is fully discharged before touching any high-voltage wiring harness, connectors or components. Service plug is located on service plug assembly at driver's side front corner of luggage compartment, near highvoltage battery. See Fig. 1. Ensure service plug is stored in a location in which no one may install service plug while technician is working on vehicle. If necessary to touch any high-voltage wiring harness, connectors or components, ensure service plug is removed and battery voltage or less exists at electrical connector. Use Toyota insulated gloves when touching any high-voltage wiring harness, connectors or components. Ensure insulated gloves are dry and in good condition and that no holes exist in insulated gloves by applying air to insulated glove before touching any high-voltage wiring harness, connectors or components.

2 Page 2 of 96 DO NOT wear any metal objects while working on vehicle which may accidently drop and cause a short circuit. If any high-voltage wiring harness connector is disconnected, ensure terminal on wiring harness connector is wrapped with tape to prevent wiring harness connector from contacting any surface. If servicing high-voltage system, place sign on roof of vehicle to indicate to other technicians that high-voltage system is being serviced.

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4 Page 4 of 96 Fig. 1: Locating Service Plug & Service Plug Assembly HYBRID VEHICLE CONTROL SYSTEM PRECAUTION CAUTION: A repair operation incorrectly performed on the hybrid vehicle (HV) could cause an electrical shock, leakage or explosion. Be sure to perform repair operations correctly. 1. Remove key from ignition switch. 2. Ensure that charge connector is disconnected. 3. Wear insulating gloves always. 4. Disconnect negative (-) terminal cable from auxiliary battery. 5. Remove service plug and do not start any repair operation before 5 minutes have passed.

5 Page 5 of 96 Fig. 2: Removing Service Plug WARNING: Due to the discharge resistance, it takes at least 5 minutes before the V electricity is sufficiently discharged from the condenser in the inverter circuit. Even after the 5 minutes have passed, the following precaution should be observed. Before touching a V cable or any other cable which you cannot identify, use the tester to confirm that the voltage through the cable is 12 V or less After removing the service plug, cover the plug connector using rubber or vinyl tape. After removing V cable, be sure to cover terminal using vinyl 7. tape. Use insulated tools. Do not leave tools or parts (bolts, nuts, etc.) inside cabin. WARNING: A metallic object may drop and cause a short-circuit. 10. Do not wear metallic objects such as mechanical pencils or scales. HV BATTERY HV BATTERY COMPONENTS

6 Page 6 of 96 Fig. 3: Locating Hybrid Vehicle Battery & Related Components (1 Of 2)

7 Page 7 of 96 Fig. 4: Locating Hybrid Vehicle Battery & Related Components (2 Of 2)

8 Page 8 of 96 HV BATTERY REMOVAL Remove service plug. See PRECAUTION. Remove LUGGAGE TRIM. Remove REAR SEAT. Remove power cable : a. Using the service plug, turn the interlock counterclockwise to unlock. NOTE: When the interlock is damaged, be sure to replace it with new one. Fig. 5: Identifying Battery Carrier Catch Bracket Mounting Nuts b. c. Remove the 3 nuts and battery carrier catch bracket. Remove the 2 bolts and power cables.

9 Page 9 of 96 Fig. 6: Identifying Power Cable Mounting Bolts 5. d. Remove the earth terminal. Remove battery bracket. Remove the 13 bolts and nut, RH and LH battery brackets.

10 Page 10 of 96 Fig. 7: Identifying Right & Left Side Battery Brackets Disconnect connector : a. Disconnect the 2 connectors from the battery ECU. b. Disconnect the connector from the SMR. c. Disconnect the connector from the service plug assembly. Remove duct. See 3-6. Remove HV battery : WARNING: Since alkaline electrolyte may be on the hose end, carry out the operation with considerable care. a. b. Disconnect the battery hose from the body. Remove the 5 bolts and HV battery.

11 Page 11 of 96 Fig. 8: Identifying HV Battery Mounting Bolts HV BATTERY DISASSEMBLY 1. Remove battery module set bolt. Turn the battery assembly upside down, remove the 76 battery module bolts. NOTE: When turning it over, prevent the flange from being deformed. When not removing a battery module, skip the operation of step (1. 2. Remove battery cover. Remove the 12 bolts, screw and battery cover. 3. Remove service plug :

12 Page 12 of 96 a. b. Remove the rear RH and LH busbar module protectors. Remove the 2 nuts for busbar module. Fig. 9: Identifying Busbar Terminal Mounting Nuts c. Remove the nut and wire harness protector.

13 Page 13 of 96 Fig. 10: Identifying Wire Harness Protector Nut d. Remove the 3 bolts and service plug assembly.

14 Page 14 of 96 Fig. 11: Identifying Service Plug Mounting Bolts 4. Remove power cable for SMR : a. Remove the front RH and LH busbar module protectors. b. Remove the 2 nuts, and disconnect the power cable from the front busbar module.

15 Page 15 of 96 Fig. 12: Identifying Power Cable To Front Busbar Module Mounting Nuts 5. c. Remove the SMR cover from the SMR. d. Remove 2 bolts, and disconnect the power cable for SMR. Remove SMR : NOTE: When the interlock is damaged, be sure to replace it with new one. a. b. Using the service plug, turn the interlock counterclockwise to unlock. Remove the 3 bolts and SMR.

16 Page 16 of 96 Fig. 13: Identifying SMR Mounting Bolts 6. Remove HV battery thermistor.

17 Page 17 of 96 Fig. 14: Identifying Battery Thermistor 7. Remove battery ECU : a. Disconnect the connector. b. Remove the 2 bolts and battery ECU.

18 Page 18 of 96 Fig. 15: Identifying Battery ECU Mounting Bolts Remove battery hose. Remove busbar module : a. Remove the 36 nuts, RH and LH rear busbar modules. b. Remove the 36 nuts, RH and LH front busbar modules. Remove battery clamp bolt.

19 Page 19 of 96 Fig. 16: Identifying Battery Clamp Remove the 4 bolts and battery clamp bolt. WARNING: Never remove the battery clamp bolt until 4 hours has passed after the ignition switch is turned OFF. An explosion due to expansion could occur. 11. Remove RH battery bracket. Remove the 2 bolts and RH battery bracket.

20 Page 20 of 96 Fig. 17: Identifying Battery Bracket To Battery Carrier Mounting Bolts WARNING: Never remove the RH battery bracket until 4 hours has passed after the ignition switch is turned OFF. An explosion due to expansion could occur. 12. Remove 38 HV battery modules. HV BATTERY INSPECTION Inspect HV Battery Thermistor Using an ohmmeter, measure the resistance between terminals.

21 Page 21 of 96 Fig. 18: Identifying HV Battery Thermistor Terminals Standard resistance: 1 To 2: 9-11 kohm at 25 C (77 F). 3 To 4: 9-11 kohm at 25 C (77 F). 5 To 6: 9-11 kohm at 25 C (77 F). 7 To 8: 9-11 kohm at 25 C (77 F). 7 To 10: 9-11 kohm at 25 C (77 F). IF resistance is not specified, replace the HV battery thermistor. HV BATTERY REASSEMBLY 1. Install battery module.

22 Page 22 of 96 Install the 38 battery modules to the battery carrier. NOTE: Packs containing 2 battery module each are arranged in the order of 1 to 19 from the ECU side. Starting from the positive terminal of the battery module on the battery ECU side, install 38 battery modules by alternately connecting the positive and negative terminals to the vehicle front side. 2. Install battery clamp bolt. Install the battery clamp bolt with the 2 bolts. Torque: 23 N.m (230 kgf.cm, 16 ft.lbf).

23 Page 23 of 96 Fig. 19: Identifying Battery Clamp To Battery Carrier Mounting Bolts 3. Install RH battery bracket. Install the RH battery bracket with the 4 bolts. Torque: 23 N.m (230 kgf.cm, 16 ft.lbf). Fig. 20: Identifying Battery Bracket To Battery Carrier & Clamp Mounting Bolts 4. Install battery hose

24 Page 24 of 96 Fig. 21: Identifying Battery Hoses 5. Install HV battery thermistor.

25 Page 25 of 96 Fig. 22: Identifying Battery Thermistor 6. Install battery ECU : a. Install the battery ECU with the 2 bolts. Torque: 3.3 N.m (33 kgf.cm, 29 in.lbf). 7. b. Connect the connector for HV battery thermistor. Install busbar module : a. Install the front busbar module with the 74 nuts. Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf). b. Install the rear RH and LH busbar modules with the 74 nuts. Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf).

26 Page 26 of 96 Fig. 23: Identifying Battery ECU Mounting Bolts 8. Install SMR : a. Install the SMR with the 3 bolts. Torque: 5.0 N.m (50 kgf.cm, 44 in.lbf). b. Connect the power cable for SMR with the 2 bolts. Torque: 5.0 N.m (50 kgf.cm, 44 in.lbf). c. d. Install the SMR cover to the SMR. Connect the connector to the cover for external uniform charger and lock the cover.

27 Page 27 of 96 Fig. 24: Identifying SMR Mounting Bolts e. Connect the power cable for SMR with 2 new nuts. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf). f. Install the front RH and LH busbar module protectors.

28 Page 28 of 96 Fig. 25: Identifying Power Cable To Front Busbar Module Mounting Nuts 9. Install service plug : a. Install the service plug with the 3 bolts.

29 Page 29 of 96 Fig. 26: Identifying Service Plug Mounting Bolts Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf). b. Install the wire harness protector with the nut.

30 Page 30 of 96 Fig. 27: Identifying Wire Harness Protector Nut c. Install the busbar module with 2 new nuts

31 Page 31 of 96 Fig. 28: Identifying Busbar Terminal Mounting Nuts Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) Install rear RH and LH busbar module protector. Install battery cover. Install the battery cover with the 12 bolts and screw.

32 Page 32 of 96 Fig. 29: Identifying Battery Cover Mounting Bolts "A"-"C" & Screw Torque: Bolt A: 18 N.m (185 kgf.cm, 13 ft.lbf). Bolt B: 8.0 N.m (80 kgf.cm, 71 in.lbf). Bolt C: 7.0 N.m (70 kgf.cm, 62 in.lbf). Screw: 6.0 N.m (61 kgf.cm, 53 in.lbf). 12. Install battery module set bolt. Turn the battery assembly upside down, install the 76 battery module set bolts. Torque: 4.0 N.m (40 kgf.cm, 35 in.lbf). HV BATTERY INSTALLATION 1. Install HV battery.

33 Page 33 of 96 a. Set the HV battery to the body. WARNING: Since alkaline electrolyte may be on the hose end, carry out the operation with considerable care. 2. b. Connect the battery hose to the body. Install battery bracket. a. Install the RH and LH battery bracket with the 13 bolts and nut. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf). Fig. 30: Identifying Right & Left Side Battery Brackets b. Install and tighten the 5 bolts for HV battery. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf).

34 Page 34 of 96 Fig. 31: Identifying HV Battery Mounting Bolts 3. Install high tension cable : a. Install the earth terminal. b. Install the high tension cable with the 2 bolts. Torque: 5.0 N.m (50 kgf.cm, 44 in.lbf).

35 Page 35 of 96 Fig. 32: Identifying High Tension Cable Mounting Bolts NOTE: When installing a cover, never fail to pass the interlock button.

36 Page 36 of 96 Fig. 33: Identifying Battery Carrier Catch Bracket Mounting Nuts c. Install the battery carrier catch bracket with the 3 nuts. Torque: 8.0 N.m (80 kgf.cm, 71 in.lbf) Install duct. See 2-5. Connect connector : a. Connect the 2 connectors to the battery ECU. b. Connect the connector to the SMR, c. Connect the connector to the service plug assembly. Install REAR SEAT. Install LUGGAGE TRIM. Install service plug. See PRECAUTION.

37 Page 37 of 96 CONVERTER AND INVERTER ASSEMBLY ON-VEHICLE INSPECTION OF CONVERTER & INVERTER ASSEMBLY 1. Inspect inverter : a. Turn the IG switch OFF and disconnect the 4 connectors. b. Apply battery positive voltage to connector B terminal 5 (IGCT) on the inverter side through a fuse, and battery negative voltage to connector B terminal 6 (GND). c. Measure the voltage and resistance between each terminal shown in Fig. 34 and Fig. 35 and ground. Fig. 34: Identifying Inverter Terminals Of Connectors A-D

38 Page 38 of 96 Fig. 35: Identifying Inverter Connector Terminal Specifications 2. Inspect converter : a. Function check Measure the voltage of an auxiliary battery terminal when the "READY" lamp is OFF and ON.

39 Page 39 of 96 Fig. 36: Locating The Driving Ready Light READY lamp is OFF: Approximately 12 V. READY lamp is ON: Approximately 14 V. b. Output current check 1. Disconnect the MG2 power cable from the inverter. See (a. 2. Install AC/DC 400 A probe to the wire harness of the IP connector of the converter. 3. Connect the MG2 power cable to the inverter. See ( i. 4. With the READY lamp ON, operate electric devices one by one and measure the output current. Standard: 100 A or less. NOTE: If more than 100 A is shown momentarily, check for the following:

40 Page 40 of 96 Ground short of electric device. Overload caused by installation of excessive device. PTC heater operation. CONVERTER & INVERTER ASSEMBLY COMPONENTS

41 Page 41 of 96 Fig. 37: Locating Converter & Inverter Related Components (1 Of 2)

42 Page 42 of 96 Fig. 38: Locating Converter & Inverter Related Components (2 Of 2) CONVERTER & INVERTER ASSEMBLY REMOVAL

43 Page 43 of Remove service plug. See PRECAUTION. 2. Drain HV coolant. See Step 2) in Replace Coolant in HYBRID TRANSAXLE ON- VEHICLE REPAIR. 3. Remove COWL TOP PANEL. 4. Verify "ZERO" V. CAUTION: Before starting step (a ), 5 minutes or more should be passed after removing the service plug. Be careful to prevent foreign matter from entering the inside of connector cover. a. Disconnect the connector of the battery power cable and insulate it with packaging tape. Using a torx socket wrench (T30), remove the 4 screws and inverter terminal b. cover. NOTE: Slide the connector cover to disconnect the circuit breaker sensor connector. c. d. Using a torx socket wrench (T40), remove the 2 screws, circuit breaker sensor and connector cover. Using a voltmeter, measure the voltage between terminals of 3 phases (U-V, V-W, U- W) and each terminal and body ground to verify them to be approximately 0 V.

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46 Page 46 of 96 Fig. 39: Identifying Converter & Inverter Assembly 5. Remove converter & inverter assembly : CAUTION: Be careful to prevent foreign matter from entering the inside of connector cover. Fig. 40: Identifying MG2 Power Cable Securing & Terminal Bolts a. Remove the 6 bolts and 3 power cables for MG2. CAUTION: Remove the power cables for MG1 together with converter & inverter assembly.

47 Page 47 of 96 Be careful to prevent foreign matter from entering the inside of connector cover. Fig. 41: Identifying MG1 Power Cable Terminal Bolts b. c. d. e. Remove the 3 bolts and power cables for MG1. Remove the bolt and ground cable. Disconnect the 3 water hoses from the converter & inverter assembly. Remove the 4 bolts and converter & inverter assembly.

48 Page 48 of 96 Fig. 42: Locating Converter & Inverter Assembly Mounting Bolts & Water Hose Connections DISASSEMBLY OF CONVERTER & INVERTER 1. Remove inverter reservoir tank : a. Remove the 2 bolts, nuts and inverter reservoir tank. b. Remove the O-ring from the inverter reservoir tank.

49 Page 49 of 96 Fig. 43: Identifying Inverter Reservoir Tank CAUTION: Do not remove the inverter cover unless necessary. Doing so may result in vehicle breakdown or electric shock. When replacing the inverter cover, quickly replace it to prevent water, dirt or dust from entering into the inverter. 2. Remove inverter cover : a. Remove the 12 bolts and inverter cover.

50 Page 50 of 96 Fig. 44: Identifying Inverter Cover Bolts 3. b. Remove the gasket from the inverter cover. Remove bracket : Remove the 6 bolts and 4 brackets. 4. Remove water hose. REASSEMBLY OF CONVERTER & INVERTER 1. Install water hose.

51 Page 51 of Install bracket. Install the 4 brackets with the 6 bolts. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf). 3. Install inverter cover : a. Install a new gasket to the inverter cover. b. Install the inverter cover with the 12 bolts. Torque: 2.5 N.m (25 kgf.cm, 22 in.lbf). Fig. 45: Identifying Inverter Cover Bolts & Gasket Orientation 4. Install inverter reservoir tank : a. Install a new O-ring to the inverter reservoir tank.

52 Page 52 of 96 b. Install the inverter reservoir tank with the 2 bolts and nuts. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf). Fig. 46: Identifying Inverter Reservoir Tank INSTALLATION OF CONVERTER & INVERTER 1. Install converter & inverter assembly : a. Install the converter & inverter assembly with the 4 bolts.

53 Page 53 of 96 Fig. 47: Identifying Inverter Cover & Mounting Bolts Torque: 21 N.m (214 kgf.cm, 15 ft.lbf). b. c. d. e. Connect the 3 water hoses to the converter & inverter assembly. Connect the 4 connectors. Connect the 2 power cable connectors. Install the ground cable to the radiator upper support. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf). f. Install the power cables for MG1 with the 3 bolts. Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf).

54 Page 54 of 96 CAUTION: Be careful to prevent foreign matter from entering the inside of connector cover. Fig. 48: Identifying MG1 Power Cable Terminal Bolts g. Install the connector cover and circuit breaker sensor with the 2 screws.

55 Page 55 of 96 Fig. 49: Identifying Circuit Breaker Sensor Mounting Screws Torque: 20 N.m (204 kgf.cm, 15 ft.lbf). h. i. Connect the connector for circuit breaker sensor. Install the 3 power cables for MG2 with the 6 bolts. Torque: Bolt A: 19.5 N.m (199 kgf.cm, 14 ft.lbf). Bolt B: 8.0 N.m (82 kgf.cm, 71 in.lbf). CAUTION: Be careful to prevent foreign matter from entering the inside of connector cover.

56 Page 56 of 96 Fig. 50: Identifying MG2 Power Cable Securing Bolts "B" & Terminal Bolts "A" j. Install the gasket and inverter terminal cover with the 4 screws.

57 Page 57 of 96 Fig. 51: Identifying Inverter Terminal Cover Screws Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) Install COWL TOP PANEL. Install service plug. See PRECAUTION. Fill with HV coolant. See Step 2) in Replace Coolant in HYBRID TRANSAXLE ON- VEHICLE REPAIR. Operation after replacing converter & inverter assembly : Even if the master warning light is not lit, clear DTC using a TOYOTA hand-held tester. When replacing a converter & inverter assembly of the vehicle in which no error occurs, also clear DTC using a TOYOTA hand held tester. NOTE: When a TOYOTA hand-held tester cannot be used, disconnect the auxiliary battery for 1 minute or more and connect it again.

58 Page 58 of Checking after replacing converter & inverter assembly. Depressing the accelerator pedal to a degree of 50 %, increase the speed up to approximately 15 km/h 3 or 4 times to check that there is no problem in the inverter operation. HV WATER PUMP HV WATER PUMP COMPONENTS

59 Page 59 of 96 Fig. 52: Locating Hybrid Vehicle Water Pump Mounting Related Components HV WATER PUMP REMOVAL

60 Page 60 of Drain HV coolant. See Step 2) Replace Coolant in HYBRID TRANSAXLE ON- VEHICLE REPAIR. Remove FRONT BUMPER COVER. Remove LH heat light. Remove HV water pump : a. Disconnect the connector for HV water pump. b. Disconnect the 2 water hoses from the HV water pump. c. Remove the 2 bolts and HV water pump. Fig. 53: Identifying Hybrid Vehicle (Heater) Water Pump Mounting Bolts INSPECTION OF HV WATER PUMP Check HV Water Pump Operation Apply battery voltage to the HV water pump setting terminal 1 as negative pole and terminal 2 as positive and check that the pump operates.

61 Page 61 of 96 CAUTION: Pay special attention to the poles and never make a mistake. This check should be done for a short time (10 second or less). Fig. 54: Identifying Hybrid Vehicle (Heater) Water Pump Terminals INSTALLATION OF HV WATER PUMP 1. Install HV water pump : a. Install the HV water pump with the 2 bolts. Torque: 7.0 N.m (70 kgf.cm, 62 in.lbf) b. Connect the 2 water hoses.

62 Page 62 of 96 c. Connect the connector for HV water pump. 2. Install LH head light. 3. Install FRONT BUMPER COVER. 4. Fill with HV coolant. Fig. 55: Identifying Hybrid Vehicle (Heater) Water Pump Mounting Bolts INVERTER RADIATOR INVERTER RADIATOR COMPONENTS

63 Page 63 of 96 Fig. 56: Identifying Inverter Radiator Related Components INVERTER RADIATOR REMOVAL

64 Page 64 of Drain HV coolant. See Step 2) Replace Coolant in HYBRID TRANSAXLE ON- VEHICLE REPAIR. Remove FRONT BUMPER COVER. Disconnect ambient temperature sensor. Disconnect water temperature switch connector. Remove water temperature switch. Disconnect 2 water hoses. Remove inverter radiator : Remove the 3 nuts and inverter radiator. Fig. 57: Identifying Inverter Radiator Mounting Nuts INSPECTION OF INVERTER RADIATOR Inspect Water Temperature Switch Using a ohmmeter and thermometer, check continuity between terminals. Standard:

65 Page 65 of 96 No continuity at 48 C (118.4 F) or less. Continuity at more than 55 C (131 F). Fig. 58: Testing Water Temperature Switch INSTALLATION OF INVERTER RADIATOR 1. Install inverter radiator : Install the inverter radiator with the 3 nuts.

66 Page 66 of 96 Fig. 59: Identifying Inverter Radiator Mounting Nuts Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf). 2. Connect 2 water hoses. 3. Install water temperature switch. Torque: 7.4 N.m (75 kgf.cm, 65 in.lbf) Connect water temperature switch connector. Connect ambient temperature sensor. Install FRONT BUMPER COVER. Fill with HV coolant. See Step 2) Replace Coolant in HYBRID TRANSAXLE ONVEHICLE REPAIR. HV BATTERY COOLING COMPONENTS

67 Page 67 of 96 Fig. 60: Locating Hybrid Vehicle Battery Cooling System Related Components REMOVAL 1. Remove REAR SEAT. 2. Remove LUGGAGE TRIM.

68 Page 68 of Remove inner ventilator duct. Remove the 4 bolts and inner ventilator duct. 4. Remove lower quarter ventilator duct. Remove the 2 bolts and lower quarter ventilator duct. Fig. 61: Identifying Lower Quarter & Inner Ventilator Duct Mounting Bolts 5. Remove quarter ventilator duct : a. Disconnect the connector for blower motor control. b. Remove the 6 screws and quarter ventilator duct.

69 Page 69 of 96 Fig. 62: Identifying Quarter Ventilator Duct Mounting Bolts 6. Remove quarter inner No. 2 duct. Remove the 2 screws and quarter inner No. 2 duct.

70 Page 70 of 96 Fig. 63: Identifying Quarter Inner No. 2 Duct Mounting Bolts 7. Remove blower assembly : a. Remove the quarter ventilation inner duct. b. Disconnect the connector for blower motor. c. Remove the bolt, 2 nuts and blower assembly.

71 Page 71 of 96 Fig. 64: Identifying Blower Assembly Mounting Bolts DISASSEMBLY Remove Blower Motor Control a. Using a drill, drill out the 2 rivet heads and remove the blower motor control. b. Gently and vertically put the drill to the rivet, and cut the rivet flanges. NOTE: Prizing the hole with a drill can lead to damage to the rivet hole or breaking the drill. Take care as the cut rivet is hot. c. Using a vacuum cleaner, remove the drilled rivet and their dust.

72 Page 72 of 96 Fig. 65: Identifying Blower Motor Control Mounting Rivets INSPECTION 1. Inspect blower motor operation. See DTC P3077: BATTERY COOLING FAN MOTOR CIRCUIT MALFUNCTION. 2. Inspect battery fan relay : a. Remove the battery fan relay.

73 Page 73 of 96 Fig. 66: Locating Battery Fan Relay b. Inspect the battery fan relay continuity. 1. Using an ohmmeter, check that there is continuity between terminals 1 and 2.

74 Page 74 of 96 Fig. 67: Testing Battery Fan Relay Continuity If there is no continuity, replace the relay. 2. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. c. Inspect the battery fan relay operation. 1. Apply battery voltage across terminals 1 and 2.

75 Page 75 of 96 Fig. 68: Testing Battery Fan Relay Operation 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. d. Install the battery fan relay. REASSEMBLY Install Blower Motor Control Using an air riveter or hand riveter, install the blower motor control.

76 Page 76 of 96 Fig. 69: Identifying Blower Motor Control Mounting Rivets NOTE: Do not prize a riveter, as riveter is damaged, it is not tightened and the mandrel is bent.

77 Page 77 of 96 Fig. 70: Causes Of Improper Rivet Installation (1 Of 3) Do not tilt the riveter and disconnect the rivet from the material while handling a riveter, as the materials are not tightened firmly.

78 Page 78 of 96 Fig. 71: Causes Of Improper Rivet Installation (1 Of 3) Install the rivet while attaching materials, as they are not tightened firmly.

79 Page 79 of 96 Fig. 72: Causes Of Improper Rivet Installation (1 Of 3) INSTALLATION 1. Install blower assembly : a. Connect the connector for blower motor. b. Install the blower assembly with the bolt and 2 nuts. Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf). c. install the quarter ventilation inner duct.

80 Page 80 of 96 Fig. 73: Identifying Blower Assembly Mounting Bolts 2. Install quarter inner No. 2 duct. Install the quarter inner No. 2 duct with the 2 screws.

81 Page 81 of 96 Fig. 74: Identifying Quarter Inner No. 2 Duct Mounting Bolts 3. Install quarter ventilator duct. a. Install the quarter ventilator duct with the 6 screws. b. Connect the connector for blower motor control.

82 Page 82 of 96 Fig. 75: Identifying Quarter Ventilator Duct Mounting Bolts 4. Install lower quarter ventilator. Install the lower quarter ventilator duct with the 2 bolts. Torque: 4.0 N.m (41 kgf.cm, 35 in.lbf). 5. Install inner ventilator duct. Install the inner ventilator duct with the 4 bolts. Torque: 4.0 N.m (41 kgf.cm, 35 in.lbf). 6. Install LUGGAGE TRIM. 7. Install. REAR SEAT.

83 Page 83 of 96 Fig. 76: Identifying Lower Quarter & Inner Ventilator Duct Mounting Bolts SERVICE PLUG INSPECTION Check Continuity Using an ohmmeter, check continuity between the terminals.

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86 Page 86 of 96 Fig. 77: Testing Service Plug Fig. 78: Service Plug Specifications AUXILIARY BATTERY INSPECTION CAUTION: Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not perform tests with a high voltage insulation resistance tester. Never disconnect the battery while the engine is running. 1. Check battery electrolyte level. Check the electrolyte quantity of each cell. If under the lower level, replace the battery (or add distilled water if possible). Check the charging system. 2. Check battery voltage : a. After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the engine, turn the ignition switch ON and turn on the electrical

87 Page 87 of 96 system (headlight, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge. b. Turn the ignition switch OFF and turn off the electrical systems. c. Measure the battery voltage between the negative (-) and positive (+) terminals of the battery. Standard voltage: V at 20 C (68 F). If the voltage is less than specification, charge the battery. 3. Check battery terminals, fusible link and fuses : a. Check that the battery terminals are not loose or corroded. If the terminals are corroded, clean the terminals. b. Check the fusible link, H-fuses, M-fuse and fuses for continuity. SPEED SENSOR (RESOLVER) AND TEMPERATURE SENSOR INSPECTION Inspect Speed Sensor (Resolver) And Temperature Sensor NOTE: The range of standard values for the temperature sensor is shown in Fig. 80. Using an ohmmeter, measure resistance at each terminals.

88 Page 88 of 96 Fig. 79: Speed Sensor (Resolver) & Temperature Sensor Specifications

89 Page 89 of 96 Fig. 80: Determining Temperature Sensor Resistance Values

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92 Page 92 of 96 Fig. 81: Identifying Speed Sensor (Resolver) & Temperature Sensor Terminals POWER CABLE COMPONENTS

93 Page 93 of 96 Fig. 82: Identifying Power Cable Related Components

94 Page 94 of 96 INSPECTION Inspect Power Cable If any damage mentioned below is identified at visual inspection, replace the power cable. 1. Area covered by protector: When the protector is so damaged that the corrugated tube for the power cable inside the protector is exposed. Fig. 83: Identifying Types Of Power Cable Damage (1 Of 2) 2. Other area: When the corrugated tube is so damaged that the coating inside the power cable is exposed.

95 Page 95 of 96 Fig. 84: Identifying Types Of Power Cable Damage (2 Of 2) HV ECU COMPONENTS

96 Page 96 of 96 Fig. 85: Identifying Hybrid Vehicle ECU Related Components 2008 Mitchell Repair Information Co., LLC.

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