Toyota Prius: Hv Battery (for Phev Model)

Toyota Prius (XW60) 2023-2025 Service Manual / Engine/Hybrid System / Hybrid / Battery Control / Hv Battery (for Phev Model)

Inspection
Removal
Installation
Recovery Inspection
Airtight Inspection
Discharging

Inspection

DESCRIPTION

If the vehicle has been subjected to a strong impact, use the following procedure to perform an on-vehicle check.

PROCEDURE

1.	EXTERNAL INSPECTION

CAUTION:

Wear insulating gloves and protective glasses when working.

HINT:

The purpose of the external inspection is to determine the condition of the HV supply battery assembly.
Perform the external inspection after first cleaning away any dust or mud on the HV supply battery assembly and ensuring an appropriate level of cleanliness.

(a) Remove the service plug grip.

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Inspection Item	Inspection Method	Important Points to Check
Abnormal Odor	Smell for Odors	Get under the Toyota Prius vehicle and check for odors (sweet, acrid, or burnt odors)
HV Supply Battery Assembly External Wire Harness/Connector	Visual Inspection	Check the high voltage wire harness and connector condition. Also check for water entry when disconnected.
HV Supply Battery Assembly External Wire Harness/Connector	Visual Inspection	Check the low voltage wire harness and connector condition. Also check for water entry when disconnected.
HV Supply Battery Assembly - Frame Bolt Fastening Inspection	Visual Inspection	Check the fastening points with the body for looseness, falling out, damage, or twisting.
HV Supply Battery Assembly Lower Side External Inspection	Visual Inspection	Check the condition of the paint on the lower side. Check that there is no deformation or rust. Check that the HV supply battery assembly has no abrasion or other damage. Check that there are no signs of flooding or submersion.
Service Plug Grip Inspection	Visual Inspection	Check that the service plug grip has no deformation or abrasion damage, and that the No. 2 traction battery cover and service plug grip are clean and without foreign matter contamination.
Coolant Line Supply/Outlet Inspection	Visual Inspection	Check that the coolant line (refrigerant line) hoses, No. 2 discharge hose sub-assembly and No. 1 discharge hose sub-assembly connecting portions have no fluid leakage.
HV Supply Battery Assembly Upper Side Inspection HINT: Use a mirror and perform inspection in the areas that are visible.	Visual Inspection	Check that there are no cracks, and that the painted surfaces have no bubbling or swelling. Check that the pressure release valve and pressure equalization membrane have no looseness with the body, and that there is no sludge accumulation, deformation, or cracking. Check that there are no signs of flooding or submersion. Check for damage to the No. 1 traction battery carrier and No. 1 traction battery cover (splitting or deformation of the lower and upper seal surfaces, etc.)

(b) If the visual inspection of the HV supply battery assembly reveals deformation/cracking that results in clearly apparent penetration, replace the HV supply battery assembly.

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2.	CHECK FOR AIRTIGHTNESS (ON-Toyota Prius Vehicle)

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Result	Proceed to
OK (External Inspection OK, Airtightness Check OK)	A
NG (External Inspection or Airtightness Check NG)	B

END

3.	REMOVE HV SUPPLY BATTERY ASSEMBLY

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4.	CHECK FOR AIRTIGHTNESS (COMPONENT)

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Result	Proceed to
OK (Remove No. 1 traction battery cover.)	NEXT
NG (After identifying airtightness check problem location, remove the No. 1 traction battery cover.)	NEXT

5.	REMOVE NO. 1 TRACTION BATTERY COVER

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6.	INSULATION INSPECTION HV SUPPLY BATTERY ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Using a megohmmeter set to 500 V, measure the insulation resistance according to the value(s) in the table below.

NOTICE:

Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

Standard Resistance:

Tester Connection	Condition	Specified Condition
A - Battery Outer Case	Always	1 MΩ or higher
B - Battery Outer Case	Always	1 MΩ or higher

*1	HV Battery Main Cable (A)
*2	HV Battery Main Cable (B)
*a	Battery Outer Case

GO TO STEP 13

7.	CHECK NO. 1 TRACTION BATTERY DEVICE BOX

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Check that the service plug grip is not installed.

NOTICE:

After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

(b) Disconnect the high voltage cable connector of the HV battery from the No. 1 traction battery device box assembly.

NOTICE:

Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

NOTICE:

Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

Standard Resistance:

Click Location & Routing(z25,z27) Click Connector(z25) Click Connector(z27)

Tester Connection	Condition	Specified Condition
z25-1 ( ) - Body ground	Ignition switch off	10 MΩ or higher
z27-1 (-) - Body ground	Ignition switch off	10 MΩ or higher

*a	Component without harness connected (No. 1 Traction Battery Device Box Assembly)

REPLACE NO. 1 TRACTION BATTERY DEVICE BOX

8.	CHECK HV SUPPLY BATTERY ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Check that no electrolyte is leaking from each HV supply battery assembly.

Result	Proceed to
Electrolyte is not leaking from the HV supply battery assembly.	A
Electrolyte is leaking from the HV supply battery assembly.	B

REPLACE HV SUPPLY BATTERY ASSEMBLY (HV supply stack sub-assembly that has a leak of electrolyte)

9.	CHECK TRACTION BATTERY PLUG CABLE (NO. 1 HV SUPPLY STACK SUB-ASSEMBLY)

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Check that the service plug grip is not installed.

NOTICE:

After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

(b) Disconnect the traction battery plug cable (HV supply stack sub-assembly) connector from the No. 1 traction battery device box assembly.

NOTICE:

Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

Standard Resistance:

Tester Connection	Condition	Specified Condition
1 - Body ground	Ignition switch off	10 MΩ or higher

*a	Traction Battery Plug Cable Grip

GO TO STEP 18

10.	CHECK NO. 1 HV SUPPLY STACK SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Check that the service plug grip is not installed.

NOTICE:

After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

(b) Disconnect the traction battery cable (No. 1 HV supply stack sub-assembly).

NOTICE:

Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

NOTICE:

Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

Standard Resistance:

Tester Connection	Condition	Specified Condition
2 - Body ground	Ignition switch off	10 MΩ or higher

*a	Traction Battery Plug Cable Grip

GO TO STEP 17

11.	CHECK NO. 3 HV SUPPLY STACK SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Check that the service plug grip is not installed.

NOTICE:

After removing the service plug grip, do not turn the ignition switch to ON (READY), unless instructed by the repair manual because this may cause a malfunction.

(b) Disconnect the traction battery cable (No. 3 HV supply stack sub-assembly).

(d) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

NOTICE:

Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

Standard Resistance:

Tester Connection	Condition	Specified Condition
1 ( ) - Body ground	Ignition switch off	10 MΩ or higher

*a	No. 3 HV Supply Stack Sub-assembly Connector (No. 2 HV Supply Stack Sub-assembly Side)

GO TO STEP 16

12.	REPLACE NO. 2 HV SUPPLY STACK SUB-ASSEMBLY

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NOTICE:

When replacing components, also replace any other components that need to be replaced with new ones at the same time.

13.	PERFORM INTERNAL INSPECTION OF HV SUPPLY BATTERY ASSEMBLY

CAUTION:

Wear insulating gloves and protective glasses when working.

NOTICE:

If an obvious sign of water intrusion is found, replace the HV supply battery assembly.

(a) Check the following items to determine whether there has been water entry into the HV supply battery assembly. If problems are found, replace the malfunctioning components.

Procedure	Inspection Method	Important Points to Check
Inspect for condensation on the inside of the upper cover.	Visual Inspection	Check that the inside of the upper cover has a good appearance, has no condensation, and has no signs that water droplets were present.
Inspect for water entry inside the HV supply battery assembly.	Visual Inspection	Check the condition of the top and sides of the HV battery stack.
		Check the condition of the heater relay.
		Check the condition of the junction block.
		Check the condition of the lower case.
		Check the ECU and SBM condition.
Inspect the appearance and connector connection status of the low voltage wire harness inside the HV supply battery assembly.	Visual Inspection	Check that the external appearance is good, there is no wear or degradation, and the connector is not loose. Check that the harness insulation does not have wear, and has no abnormal discoloration or blackening.
Inspect the high voltage wire harness (including electrical connector) inside the HV supply battery assembly.	Visual Inspection	Check that the external appearance is good, there is no wear or degradation, and the connector is not loose. Check that the harness insulation does not have wear, and has no abnormal discoloration or blackening.
Inspect the torque of the brass high voltage bolts.	Inspection Using Tools	Check for looseness in the torque of all bus bar fastening locations. Tighten to the specified torque.
Inspect the external appearance of the water cooling plate.	Visual Inspection	Check that the coolant line (refrigerant line) hoses/hard type connections are in good condition.
Inspect the external appearance of the water cooling plate.	Visual Inspection	Check that the water cooling plate (refrigerant) has no deformation.
Inspect the cleanliness of the HV supply battery assembly.	Visual Inspection	Check that the cleanliness of the interior is good, and that there is no foreign matter remaining.
Replace the No. 2 HV battery seal.	Component Replacement	Replace the No. 2 HV battery seal.
Inspect the lower surface of the No. 1 traction battery carrier.	Visual Inspection	Check for rust on the lower surface of the No. 1 traction battery carrier.
Inspect the lower surface of the first stage HV battery stack.	Visual Inspection	Check for rust on the lower surface of the first stage HV battery stack.

(b) If any abnormalities are found, replace the affected part(s).

REPLACE REPAIR OR REPLACE MALFUNCTIONING PARTS

14.	INSTALL NO. 1 TRACTION BATTERY COVER

(a) After replacing the airtightness check problem location, install the No. 1 traction battery cover.

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15.	CHECK FOR AIRTIGHTNESS (COMPONENT)

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INSTALL HV SUPPLY BATTERY ASSEMBLY

REPAIR OR REPLACE MALFUNCTIONING PARTS

(a) Identify the leak locations(s) and replace the affected part(s).

16.	REPLACE NO. 3 HV SUPPLY STACK SUB-ASSEMBLY

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NOTICE:

When replacing components, also replace any other components that need to be replaced with new ones at the same time.

GO TO STEP 13

17.	REPLACE NO. 1 HV SUPPLY STACK SUB-ASSEMBLY

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NOTICE:

When replacing components, also replace any other components that need to be replaced with new ones at the same time.

GO TO STEP 13

18.	REPLACE NO. 1 HV SUPPLY STACK SUB-ASSEMBLY

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NOTICE:

When replacing components, also replace any other components that need to be replaced with new ones at the same time.

GO TO STEP 13

Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during HV supply battery assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Replacement of HV supply battery assembly	Battery status info update Battery diagnosis	HV battery status information cannot be updated

CAUTION:

Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.
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To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal.
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If the HV supply battery assembly has been struck or dropped, replace it.
When connecting a connector to the HV supply battery assembly., confirm that the connector is securely connected through the following:
- Push the connector until a click sound is heard.

- Visually check and confirm that the connector is securely connected by pulling on it.
Make sure to insulate the high-voltage connectors and terminals of the HV supply battery assembly with insulating tape after removing it.
If the HV supply battery assembly stored without insulating the connectors and terminals, electric shock or fire may result.
When performing repairs around the HV supply battery assembly, such as using a tap, do not allow metal shavings to enter the HV supply battery assembly.
Do not touch any high voltage wire harnesses, connectors or parts with bare hands.
Do not allow foreign matter, such as grease or oil, to adhere to the bolts or nuts of the HV supply battery assembly.
Do not climb on top of or stand on the HV supply battery assembly.
Do not allow any foreign matter or water to enter the HV supply battery assembly.
If any bolts, nuts or clips are dropped into the HV supply battery assembly, make sure to remove them.
After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

HINT:

When the cable is disconnected / reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

Items for which learning is completed by driving the Toyota Prius vehicle

Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
Front Camera System	Drive the Toyota Prius vehicle straight ahead at 35 km/h (22 mph) or more for 5 seconds or more.

Items for which learning is completed by operating the vehicle normally

Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
1: w/o Power Back Door System 2: w/ Power Back Door System
Power Door Lock Control System*1 Back door opener	Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch.
Power Back Door System*2	Reset back door close position
Air Conditioning System	After the ignition switch is turned to ON, the servo motor and expansion valve standard position is recognized.	-

CAUTION / NOTICE / HINT

COMPONENTS (REMOVAL)

Procedure		Part Name Code
1	PRECAUTION	-		-	-
2	READ VALUE USING GTS	-		-	-
3	REFRIGERANT FROM REFRIGERATION SYSTEM	-		-	-
4	FRONT EXHAUST PIPE ASSEMBLY	17410	-	-	-

Procedure		Part Name Code
5	SERVICE PLUG GRIP	G3834	-	-	-

Procedure		Part Name Code
6	FRONT WIPER ARM HEAD CAP	85292B		-	-
7	SHIELD CAP	85247		-	-
8	FRONT WIPER ARM AND BLADE ASSEMBLY LH	-	-	-	-
9	FRONT WIPER ARM AND BLADE ASSEMBLY RH	-	-	-	-
10	WINDSHIELD LOWER OUTSIDE MOULDING LH	75536D		-	-
11	WINDSHIELD LOWER OUTSIDE MOULDING RH	75535F	-	-	-
12	COWL WATER EXTRACT SHIELD LH	55754F	-	-	-
13	COWL WATER EXTRACT SHIELD RH	55753D	-	-	-
14	COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY	55708	-	-	-
15	CHECK TERMINAL VOLTAGE	-		-	-
16	COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY	55708		-	-
17	COWL WATER EXTRACT SHIELD RH	55753D	-	-	-
18	COWL WATER EXTRACT SHIELD LH	55754F	-	-	-
19	WINDSHIELD LOWER OUTSIDE MOULDING LH	75536D	-	-	-
20	WINDSHIELD LOWER OUTSIDE MOULDING RH	77535F	-	-	-
21	FRONT WIPER ARM AND BLADE ASSEMBLY LH	-		-	-
22	FRONT WIPER ARM AND BLADE ASSEMBLY RH	-		-	-
23	SHIELD CAP	85247	-	-	-
24	FRONT WIPER ARM HEAD CAP	85292B	-	-	-

*1	Connector Cover Assembly	-	-
	Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping": Nm (kgfcm, ft.*lbf)		Nm (kgfcm, ft.*lbf): Specified torque

Procedure		Part Name Code
25	BATTERY BOX COVER	58219K	-	-	-
26	BATTERY BOX PANEL SUB-ASSEMBLY	57302A	-	-	-
27	NO. 1 CENTER FLOOR HEAT INSULATOR SUB-ASSEMBLY	58043B	-	-	-

NO. 23 TRACTION BATTERY BRACKET

Procedure		Part Name Code
28	LIQUID TUBE SUB-ASSEMBLY C	88706C	-	-
29	NO. 8 DISCHARGE TUBE	88G15J	-	-
30	FLOOR UNDER WIRE	821H1	-	-

*A	w/ Solar Charging System	-	-
*1	O-RING	*2	NO. 20 TRACTION BATTERY BRACKET
*3	NO. 23 TRACTION BATTERY BRACKET	-	-
●	Non-reusable part		Compressor oil ND-OIL 11 or equivalent

Procedure		Part Name Code
31	HV SUPPLY BATTERY ASSEMBLY	G9510	-	-
32	VALVE TO CONNECTOR TUBE	88295A	-	-
33	PERFORM RECOVERY INSPECTION	-	-	-

*1	O-RING	-	-
●	Non-reusable part		Compressor oil ND-OIL 11 or equivalent

PROCEDURE

1. PRECAUTION

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2. READ VALUE USING GTS

(1) Read the Data List.

Enter the following menus: Powertrain / HV supply battery assembly / Data List / Hybrid/EV Battery Temperature 1 to 20.

Powertrain > HV Battery > Data List

Tester Display
Hybrid/EV Battery Temperature 1
Hybrid/EV Battery Temperature 2
Hybrid/EV Battery Temperature 3
Hybrid/EV Battery Temperature 4
Hybrid/EV Battery Temperature 5
Hybrid/EV Battery Temperature 6
Hybrid/EV Battery Temperature 7
Hybrid/EV Battery Temperature 8
Hybrid/EV Battery Temperature 9
Hybrid/EV Battery Temperature 10
Hybrid/EV Battery Temperature 11
Hybrid/EV Battery Temperature 12
Hybrid/EV Battery Temperature 13
Hybrid/EV Battery Temperature 14
Hybrid/EV Battery Temperature 15
Hybrid/EV Battery Temperature 16
Hybrid/EV Battery Temperature 17
Hybrid/EV Battery Temperature 18
Hybrid/EV Battery Temperature 19
Hybrid/EV Battery Temperature 20

NOTICE:

If any of the temperatures listed in "Hybrid/EV Battery Temperature 1 to 20" are 50°C or more, leave the Toyota Prius vehicle until the temperature drops to less than 50°C.

3. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

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4. REMOVE FRONT EXHAUST PIPE ASSEMBLY

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5. REMOVE SERVICE PLUG GRIP

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6. REMOVE FRONT WIPER ARM HEAD CAP

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7. REMOVE SHIELD CAP

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8. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH

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9. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH

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10. REMOVE WINDSHIELD LOWER OUTSIDE MOULDING LH

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11. REMOVE WINDSHIELD LOWER OUTSIDE MOULDING RH

(a) Use the same procedure as for the LH side.

12. REMOVE COWL WATER EXTRACT SHIELD LH

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13. REMOVE COWL WATER EXTRACT SHIELD RH

(a) Use the same procedure as for the LH side.

14. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

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15. CHECK TERMINAL VOLTAGE

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16. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

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17. INSTALL COWL WATER EXTRACT SHIELD RH

18. INSTALL COWL WATER EXTRACT SHIELD LH

19. INSTALL WINDSHIELD LOWER OUTSIDE MOULDING LH

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20. INSTALL WINDSHIELD LOWER OUTSIDE MOULDING RH

(a) Use the same procedure as for the LH side.

21. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH

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22. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH

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23. INSTALL SHIELD CAP

24. INSTALL FRONT WIPER ARM HEAD CAP

25. REMOVE BATTERY BOX COVER

26. REMOVE BATTERY BOX PANEL SUB-ASSEMBLY

*1	Service Plug Grip	*2	No. 23 Traction Battery Bracket
*a	Projection	*b	Turn
*c	Button	-	-

(1) Insert the projection of the service plug grip and turn the button of the No. 23 traction battery bracket counterclockwise to release the lock to remove the No. 23 traction battery bracket.

(2) Remove the 4 bolts, 3 nuts and battery box panel sub-assembly.

27. REMOVE NO. 1 CENTER FLOOR HEAT INSULATOR SUB-ASSEMBLY

28. DISCONNECT LIQUID TUBE SUB-ASSEMBLY C

CAUTION:

Be sure to wear insulated gloves and protective goggles.

NOTICE:

Seal the openings of the disconnected parts with vinyl tape to prevent entry of moisture and foreign matter.

29. DISCONNECT NO. 8 DISCHARGE TUBE

CAUTION:

Be sure to wear insulated gloves and protective goggles.

NOTICE:

Seal the openings of the disconnected parts with vinyl tape to prevent entry of moisture and foreign matter.

30. DISCONNECT FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves and protective goggles.

NOTICE:

Insulate the disconnected terminals and connector with insulating tape.

*a	Green-colored Lock	-	-
	Slide	-	-

(1) Disengage the rubber cap and slide it as shown in the illustration.

(2) Using a screwdriver, slide the green-colored lock of the connector as shown in the illustration to release it and disconnect the floor under wire.

(d) w/ Solar Charging System:

*1	Service Plug Grip	*2	No.23 Traction Battery Bracket
*a	Projection	*b	Turn
*c	Button	-	-

(1) Insert the projection of the service plug grip and turn the button of the No.23 traction battery bracket counterclockwise to release the lock to remove the No.23 traction battery bracket.

(2) Remove the nut and No.20 traction battery bracket.

(e) w/ Solar Charging System:

*a	Green-colored Lock	-	-
	Slide	-	-

(1) Disengage the rubber cap and slide it as shown in the illustration.

(2) Using a screwdriver, slide the green-colored lock of the connector as shown in the illustration to release it and disconnect the floor under wire.

(3) Disengage the clamp.

31. REMOVE HV SUPPLY BATTERY ASSEMBLY

CAUTION:

Because the weight of the HV supply battery assembly is extremely heavy, make sure to follow the work procedures described in the repair manual.
If work is not performed according to the procedures described in the repair manual, there is a danger that the components could fall down.
Do not damage the HV supply battery assembly with the fork etc.
Be sure to wear insulated gloves and protective goggles.

Area That Can Touch The Ground

(1) Using an engine lifter and 4 attachments or equivalent tools, support the HV supply battery assembly as shown in the illustration.

NOTICE:

Do not allow foreign matter, such as grease or oil, to adhere to the bolts of the HV supply battery assembly.
To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.
Since the HV supply battery assembly is very heavy, 2 people are needed to remove it. When removing the HV supply battery assembly, be careful not to damage the parts around it.
When removing/installing/moving the HV supply battery assembly, make sure not to tilt it more than 80°.
If the HV supply battery assembly has been struck or dropped, replace it.
Do not apply any load outside of the area that can touch the ground.

Area That Can Touch The Ground

(1) Slowly lower the engine lifter to remove the HV supply battery assembly.

NOTICE:

Be careful not to drop the HV supply battery assembly.

(2) Follow the procedure below when moving the HV supply battery assembly from the engine lifter.

(3) Install the SST at the position shown in the illustration.

SST: 09893-42010

(4) Using 4 hooks, 4 belt slings and a chain block, hoist the HV supply battery assembly.

NOTICE:

When removing/installing/moving the HV supply battery assembly, make sure not to tilt it more than 80°.

(5) Using the height adjustable attachment, set so that the HV supply battery assembly is in contact with the position shown in the illustration, and place the HV supply battery assembly on the height adjustable attachment.

NOTICE:

To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.
When removing/installing/moving the HV supply battery assembly, make sure not to tilt it more than 80°.
If the HV supply battery assembly has been struck or dropped, replace it.
Do not apply any load outside of the area that can touch the ground.
Do not place the lower surface of the battery on the ground.

32. REMOVE VALVE TO CONNECTOR TUBE

CAUTION:

Be sure to wear insulated gloves and protective goggles.

NOTICE:

Insulate the disconnected terminals and connector with insulating tape.
Seal the openings of the disconnected parts with vinyl tape to prevent entry of moisture and foreign matter.

33. PERFORM RECOVERY INSPECTION

(a) Before returning the HV supply battery assembly, make sure to perform a recovery inspection.

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Installation

INSTALLATION

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure		Part Name Code
1	VALVE TO CONNECTOR TUBE	88295A		-	-
2	HV SUPPLY BATTERY ASSEMBLY	G9510		-	-

*1	O-RING	-	-
	Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping": Nm (kgfcm, ft.*lbf)		Nm (kgfcm, ft.*lbf): Specified torque
●	Non-reusable part		Compressor oil ND-OIL 11 or equivalent

Procedure		Part Name Code
3	FLOOR UNDER WIRE	821H1	-	-
4	NO. 8 DISCHARGE TUBE	88G15J	-	-
5	LIQUID TUBE SUB-ASSEMBLY C	88706C	-	-

*A	w/ Solar Charging System	-	-
*1	O-RING	*2	NO. 20 TRACTION BATTERY BRACKET
*3	NO. 23 TRACTION BATTERY BRACKET	-	-
	Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping": Nm (kgfcm, ft.*lbf)		Nm (kgfcm, ft.*lbf): Specified torque
●	Non-reusable part		Compressor oil ND-OIL 11 or equivalent

Procedure		Part Name Code
6	NO. 1 CENTER FLOOR HEAT INSULATOR SUB-ASSEMBLY	58043B	-	-	-
7	BATTERY BOX PANEL SUB-ASSEMBLY	57302A		-	-
8	BATTERY BOX COVER	58219K	-	-	-

*1	NO. 23 TRACTION BATTERY BRACKET	-	-
	Nm (kgfcm, ft.*lbf): Specified torque	-	-

Procedure		Part Name Code
9	SERVICE PLUG GRIP	G3834	-	-	-

Procedure		Part Name Code
10	FRONT EXHAUST PIPE ASSEMBLY	17410	-	-	-
11	CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT	-	-	-
12	WARM UP COMPRESSOR	-	-	-
13	INSPECT FOR REFRIGERANT LEAK	-	-	-
14	PERFORM INITIALIZATION	-	-	-

PROCEDURE

1. INSTALL VALVE TO CONNECTOR TUBE

CAUTION:

Be sure to wear insulated gloves and protective goggles.

NOTICE:

Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.
Keep the O-ring and O-ring fitting surface free of foreign matter.

(1) Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the HV supply battery assembly.

Compressor Oil:

ND-OIL 11 or equivalent

(2) Install the 2 O-rings to the valve to connector tube.

(3) Install the valve to connector tube to the HV supply battery assembly with the bolt.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

2. INSTALL HV SUPPLY BATTERY ASSEMBLY

CAUTION:

Because the weight of the HV supply battery assembly is extremely heavy, make sure to follow the work procedures described in the repair manual.
If work is not performed according to the procedures described in the repair manual, there is a danger that the components could fall down.
Do not damage the HV supply battery assembly with the fork etc.
Be sure to wear insulated gloves and protective goggles.

Area That Can Touch The Ground

(1) Using an engine lifter and 4 attachments or equivalent tools, support the HV supply battery assembly as shown in the illustration.

NOTICE:

Do not allow foreign matter, such as grease or oil, to adhere to the bolts of the HV supply battery assembly.
To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent.
Since the HV supply battery assembly is very heavy, 2 people are needed to remove it. When removing the HV supply battery assembly, be careful not to damage the parts around it.
When removing/installing/moving the HV supply battery assembly, make sure not to tilt it more than 80°.
If the HV supply battery assembly has been struck or dropped, replace it.
Do not apply any load outside of the area that can touch the ground.

(2) Raise the HV supply battery assembly until there is no clearance between the HV supply battery assembly and Toyota Prius vehicle.

NOTICE:

Be careful not to drop the HV supply battery assembly.

Bolt (A)

(Bolt Length: 28 mm (1.102 in.))

Bolt (B)

(Bolt Length: 24 mm (0.945 in.))

Torque:

bolt(A) :

43 N·m {438 kgf·cm, 32 ft·lbf}

bolt(B) :

20 N·m {204 kgf·cm, 15 ft·lbf}

3. CONNECT FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves and protective goggles.

*a	Green-colored Lock	-	-
	Slide	-	-

(1) Connect the connector and slide the green-colored lock as shown in the illustration to lock it securely.

NOTICE:

Check that the waterproofing lip covers the connector ends.

*a

Waterproofing Lip
Check that there are no foreign substances attached within the connector and to the waterproofing lip.

(2) Slide the rubber cap as shown in the illustration and engage it.

(1) Connect the floor under wire to the HV supply battery assembly.

NOTICE:

Make sure that the connectors are connected securely.

(2) Install the bolt.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

(d) w/ Solar Charging System:

*a	Green-colored Lock	-	-
	Slide	-	-

(1) Engage the clamp.

(2) Connect the connector and slide the green-colored lock as shown in the illustration to lock it securely.

NOTICE:

Check that the waterproofing lip covers the connector ends.

*a

Waterproofing Lip
Check that there are no foreign substances attached within the connector and to the waterproofing lip.

(3) Slide the rubber cap as shown in the illustration and engage it.

(e) w/ Solar Charging System:

*1	No.23 Traction Battery Bracket	-	-
*a	Button	*b	Push

(1) Install the No.20 traction battery bracket to the HV battery with the nut.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(2) Install the No.23 traction battery bracket, then push the button to lock it.

4. CONNECT NO. 8 DISCHARGE TUBE

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(1) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the No. 8 discharge tube.

Compressor Oil:

ND-OIL 11 or equivalent

NOTICE:

Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.

(2) Install the O-ring to the No. 8 discharge tube.

NOTICE:

Keep the O-ring and O-ring fitting surface free of foreign matter.

(3) Install the No. 8 discharge tube to the HV supply battery assembly with the bolt.

Torque:

9.8 N·m {100 kgf·cm, 87 in·lbf}

5. CONNECT LIQUID TUBE SUB-ASSEMBLY C

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(1) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the liquid tube sub-assembly c.

Compressor Oil:

ND-OIL 11 or equivalent

NOTICE:

(2) Install the O-ring to the liquid tube sub-assembly c.

NOTICE:

Keep the O-ring and O-ring fitting surface free of foreign matter.

(3) Install the liquid tube sub-assembly c to the HV supply battery assembly with the bolt.

Torque:

9.8 N·m {100 kgf·cm, 87 in·lbf}

6. INSTALL NO. 1 CENTER FLOOR HEAT INSULATOR SUB-ASSEMBLY

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

7. INSTALL BATTERY BOX PANEL SUB-ASSEMBLY

*1	No.23 Traction Battery Bracket	-	-
*a	Button	*b	Push

(1) Install the battery box panel sub-assembly with the 4 bolts and 3 nuts.

Torque:

17 N·m {173 kgf·cm}

(2) Install the No.23 traction battery bracket, then push the button to lock it.

8. INSTALL BATTERY BOX COVER

Torque:

7.5 N·m {76 kgf·cm, 6 ft·lbf}

9. INSTALL SERVICE PLUG GRIP

Click here

10. INSTALL EXHAUST PIPE ASSEMBLY FRONT

Click here

11. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

Click here

12. WARM UP COMPRESSOR

Click here

13. INSPECT FOR REFRIGERANT LEAK

Click here

14. PERFORM INITIALIZATION

Click here

Recovery Inspection

CAUTION / NOTICE / HINT

CAUTION:

When disposing of an HV supply battery assembly, make sure to return it through an authorized collection agent who is capable of handling it safely. If the HV supply battery assembly is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.
Before returning the HV supply battery assembly, make sure to perform a pre-return inspection.
Accidents such as electric shock may result if an HV supply stack sub-assembly is discharged improperly and disposed or abandoned.
Therefore, make sure to return all HV batteries through an authorized collection agent.
To reduce the risk of fire, HV supply battery assembly must not be stored in an area where they will be exposed to fire or high temperatures.
If the temperature of the HV supply battery assembly is high, leave it to cool down.

HINT:

In order to return the HV supply battery assembly in a safe manner, it may be necessary to discharge it. The following pre-return inspection procedure can be used to determine whether or not it is necessary to discharge the HV supply battery assembly the method that may be required.

PROCEDURE

1.	INSPECT FOR ELECTROLYTE LEAK

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Position the HV supply battery assembly as shown in the illustration and leave it for 5 minutes.

*a	155 mm (6.10 in.) or more

(b) Check that no electrolyte is leaking from the HV supply battery assembly.

OK:

There is no electrolyte leaking from the HV supply battery assembly.

CAUTION:

Perform this procedure in an area where the battery will not be exposed to fire.
Do not touch the HV supply battery assembly, unless absolutely necessary, as electrolyte may be leaking.

NOTICE:

If there is an electrolyte leak, make sure to wear insulated gloves and goggles and clean it using a piece of cloth. Do not leave electrolyte-contaminated cloths unattended. Dispose of them according to law or local regulations.

DISCHARGING

2.	CHECK FOR DTCS

(a) Check the previously recorded DTCs which resulted in replacement of the HV supply battery assembly.

Result	Proceed to
DTC record not available.	A
The HV supply battery assembly was replaced due to a reason other than the DTCs listed in the following table.	B
The HV supply battery assembly was replaced due to one of the DTCs listed in the following table.	C

DTC No.
P1A6017
P1A6317
P1A6617
P31AA17
P0C3000
P31B300
P1C7D49

GO TO STEP 5

DISCHARGING

3.	CHECK HV SUPPLY BATTERY ASSEMBLY VOLTAGE

CAUTION:

Be sure to wear insulated gloves.

(a) Measure the voltage according to the value(s) in the table below.

Standard Voltage:

Tester Connection	Condition	Specified Condition
A - B	Always	Below 226.4 V

CAUTION:

Make sure not to cross the probes of the electrical tester.

*1	HV Battery Main Cable (A)
*2	HV Battery Main Cable (B)

DISCHARGING

4.	INSULATION INSPECTION OF HV SUPPLY BATTERY ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Using a megohmmeter set to 500 V, measure the insulation resistance according to the value(s) in the table below.

NOTICE:

Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

Standard Resistance:

Tester Connection	Condition	Specified Condition
A - Battery Outer Case	Always	1 MΩ or higher
B - Battery Outer Case	Always	1 MΩ or higher

*1	HV Battery Main Cable (A)
*2	HV Battery Main Cable (B)
*a	Battery Outer Case

DISCHARGING

5.	HV SUPPLY BATTERY ASSEMBLY VISUAL CHECK

CAUTION:

Be sure to wear insulated gloves.

(a) Check that the HV supply battery assembly is not deformed or damaged.

OK:

The HV supply battery assembly is not deformed or damaged.

RETURN HV SUPPLY BATTERY ASSEMBLY

DISCHARGING

Airtight Inspection

AIRTIGHT INSPECTION

CAUTION / NOTICE / HINT

NOTICE:

When the No. 1 traction battery cover has been removed, use the following procedure to perform a component airtightness check.
Click here
If the Toyota Prius vehicle has been subjected to a strong impact, use the following procedure to perform an on-vehicle airtightness check.
Click here

PROCEDURE

1. CHECK FOR AIRTIGHTNESS (COMPONENT)

(a) Using SST, cover each of the connector portions.

SST: 09893-42020

HINT:

See Service Bulletin for the S-3103 INFORMATION ABOUT NEW SST FOR PRIUS PHEV AND PRIUS PRIME

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

*A	w/ Solar Charging System

(b) Install SST with the wing bolt as shown in the illustration.

SST: 09893-10010

SST: 09893-47010

09893-04010

09893-04020

Wing Bolt

(d) Install SST to the HV supply battery sub-assembly with the bolt.

Torque:

7.5 N·m {76 kgf·cm, 6 ft·lbf}

(e) Install SST to the HV supply battery sub-assembly with the 4 bolts.

Torque:

12.2 N·m {124 kgf·cm, 9 ft·lbf}

NOTICE:

Visually check the mounting surface of the No. 2 traction battery cover for foreign matter and dust before mounting.
Do not use compressed air or solvents to clean.

(f) Pump the pump as shown in the illustration until SST gauge pressure becomes 2.0 kPa.

HINT:

The pressure should reach 2.0 kPa after approximately 20 pumps.

(g) Close the valve, wait 20 minutes, and then check that the gauge pressure has not decreased by more than the specified value.

OK:

After waiting for 20 minutes, pressure has not decreased by 0.1 kPa or more.

HINT:

If the gauge pressure display has disappeared, press the power button and check the gauge pressure.
If the pressure has decreased, apply soapy water to the areas shown in the illustration to identify the location of the leak

*A

w/ Solar Charging System

-

-

*a

Apply Area

-

-

*a	Valve Open
*b	Valve Close
*c	Power Button

(h) Remove the 4 bolts and SST from the HV supply battery sub-assembly.

(i) Remove the bolt and SST from the HV supply battery sub-assembly.

(j) Remove SST from each of the connector portions.

2. CHECK FOR AIRTIGHTNESS (ON-Toyota Prius Vehicle)

(a) Remove the service plug grip.

Click here

(b) Check the terminal voltage.

Click here

HINT:

When performing Check Terminal Voltage when referring to the procedure to remove the HV battery, make sure to reinstall the components that were removed during the Check Terminal Voltage procedure.

Click here

(d) Remove the battery box cover.

Click here

(e) Remove the battery box panel sub-assembly.

Click here

(f) Remove the No. 1 center floor heat insulator sub-assembly.

Click here

(g) Disconnect the floor under wire.

Click here

(h) Connect SST to the disconnected openings of the HV floor under wire and HV battery charger wire, and cover them with SST.

SST: 09893-42020

HINT:

See Service Bulletin for the S-3103 INFORMATION ABOUT NEW SST FOR PRIUS PHEV AND PRIUS PRIME

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

*A	w/ Solar Charging System

(i) Install SST with the wing bolt as shown in the illustration.

SST: 09893-10010

Wing Bolt

(j) Remove the bolt and cover from the HV supply battery sub-assembly.

(k) Install SST to the HV supply battery sub-assembly with the bolt.

Torque:

7.5 N·m {76 kgf·cm, 6 ft·lbf}

(l) Install SST to the HV supply battery sub-assembly with the 4 bolts.

Torque:

14.4 N·m {147 kgf·cm, 11 ft·lbf}

NOTICE:

Visually check the mounting surface of the SST for foreign matter and dust before mounting.
Do not use compressed air or solvents to clean.

(m) Pump the pump as shown in the illustration until SST gauge pressure becomes 2.0 kPa.

HINT:

The pressure should reach 2.0 kPa after approximately 20 pumps.

(n) When the gauge pressure reaches 2.0 kPa, close the valve.

*a	Valve Open
*b	Valve Close
*c	Power Button

(o) Leave the Toyota Prius vehicle for 20 minutes, then check that the gauge pressure has not decreased by more than the specified value.

OK:

After waiting for 20 minutes, pressure has not decreased by 0.1 kPa or more.

HINT:

If the result is not as specified, replace the HV supply battery assembly.

(p) Remove the 4 bolts and SST from the HV supply battery sub-assembly.

(q) Remove the bolt and SST from the HV supply battery sub-assembly.

(r) Remove SST from each of the connector portions.

(s) Connect the floor under wire.

Click here

(t) Install the No. 1 center floor heat insulator sub-assembly.

Click here

(u) Install the battery box panel sub-assembly.

Click here

(v) Install the battery box cover.

Click here

(w) Install the front exhaust pipe assembly.

Click here

(x) Install the service plug grip.

Click here

(y) Perform high voltage fuse accumulated load history reset.

Click here

Discharging

DISCHARGING

PROCEDURE

1. DISCHARGING

CAUTION:

Be sure to wear insulated gloves and protective goggles.

NOTICE:

When discharging using salt water solution, first add a measured amount of water to the container, and then add the concentrated salt water solution.
Calculate the salt water concentration based on the measured volume of water in the container so that a 1% salt water solution will be made after adding the concentrated salt water solution to the water in the container where HV supply battery assembly is set.

(a) Prepare HV supply battery assembly

(1) Install the 4 Hooks B and 2 belt slings.

Hook B

(2) Set the HV supply battery assembly in the container (A).

(3) Remove the 4 Hooks B and 2 belt slings.

(b) Prepare to discharge (Add water to container)

(1) Measure the water capacity of the container (B).

HINT:

Water capacity of the container (B) is assumed as X (liters).

*a	Example
*b	Container B

(2) Using the container (B), add water to the container (A) until the HV supply battery assembly is completely submerged.

NOTICE:

Make sure to record the times the container (B) was filled with water to add water to the container (A).

*a	Example
*b	Water Surface
*c	Container A
*d	Container B

(3) Using the following formula, calculate the amount of water added to the container (A).

Amount of water added to the container (A):

Y (liters) = Water capacity of the container (B) x Number of times the container (B) was filled with water to submerge the HV supply battery assembly

HINT:

Amount of water added to the container (A) is assumed as Y (liters).

(1) While measuring the amount of water, fill about half of the container (B) with water.

HINT:

Amount of water added to the container (B) is assumed as Z (liters).

*a	Example
*b	Container B

(2) Calculate the amount of salt to be added to the container (A) so that a 1% salt water solution will be made.

Amount of Salt:

Amount of salt (kg) = (Y (liters) Z (liters)) x 0.01

(3) Add the calculated amount of salt to the container (B) and stir it thoroughly.

*a	Example
*b	Container B

(d) Add salt water solution

(1) Add the concentrated salt water solution to the container (A).

(e) Discharge

(1) Leave the HV supply battery assembly as is for 24 hours or more until discharge is complete.

CAUTION:

Do not place a lid on the container.
Make sure to leave the HV supply battery assembly and container as is for 24 hours or more.
Display a warning sign to inform others that discharge is being performed.

(f) Confirm discharge completion

(1) Check that bubbles are not forming in the container.

NOTICE:

If bubbles are forming, discharge may not be completed yet. Do not place a lid on the container.

(g) Display a warning sign such as "DO NOT TOUCH! (DISCHARGE BEING PERFORMED) to inform others. Make a copy of the warning sign and place it near the HV supply battery assembly being discharged.