Toyota Prius: Hv Battery Stack (for Phev Model)

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

Removal
Inspection
Installation
Recovery Inspection
Discharging

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 stack sub-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 stack sub-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.
The hybrid system has high-voltage circuits. Accidents, such as electric shock, or electric leaks may result if the hybrid system is not operated in a correct manner. Make sure to follow the correct procedure.
When disposing of an HV supply battery assembly or HV supply stack sub-assembly, make sure to return them through an authorized collection agent who is capable of handling them safely.
Before returning an HV supply stack sub-assembly, make sure to perform a recovery inspection.
Make a note of the output DTCs as some of them may be necessary for "Recovery Inspection" of the HV supply battery assembly and HV supply stack sub-assemblies.

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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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	READ VALUE USING GTS	-		-	-
2	NO. 1 TRACTION BATTERY COOLER TUBE	G96N1	-	-	-
3	HV SUPPLY STACK SUB-ASSEMBLY	-		-	-
4	NO. 17 TRACTION BATTERY BRACKET	G963H		-	-
5	NO. 18 TRACTION BATTERY BRACKET	G963J		-	-
6	NO. 2 TRACTION BATTERY COOLER SHEET	-	-	-	-

*1	NO. 1 HV SUPPLY STACK SUB-ASSEMBLY	*2	NO. 2 HV SUPPLY STACK SUB-ASSEMBLY
*3	NO. 3 HV SUPPLY STACK SUB-ASSEMBLY	*4	NO. 16 TRACTION BATTERY BRACKET
*a	Parts requiring replacement with new ones when replacing the HV supply stack sub-assembly	-	-
●	Non-reusable part	-	-

Procedure		Part Name Code
7	NO. 1 TRACTION BATTERY COOLER CONDUCTOR	-	-	-	-
8	PERFORM RECOVERY INSPECTION	-		-	-

*a	Parts requiring replacement with new ones when replacing the HV supply stack sub-assembly	-	-
●	Non-reusable part	-	-

PROCEDURE

1. READ VALUE USING GTS

(1) Read the Data List.

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 Battery Temperature 1 to 20" are 50°C or more, leave the Toyota Prius vehicle until the temperature drops to less than 50°C.

2. REMOVE NO. 1 TRACTION BATTERY COOLER TUBE

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3. REMOVE HV SUPPLY STACK SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

4. REMOVE NO. 17 TRACTION BATTERY BRACKET

CAUTION:

Be sure to wear insulated gloves and protective goggles.

5. REMOVE NO. 18 TRACTION BATTERY BRACKET

CAUTION:

Be sure to wear insulated gloves and protective goggles.

6. REMOVE NO. 2 TRACTION BATTERY COOLER SHEET

7. REMOVE NO. 1 TRACTION BATTERY COOLER CONDUCTOR

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8. PERFORM RECOVERY INSPECTION

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

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Inspection

INSPECTION

PROCEDURE

1. INSPECT HV SUPPLY STACK SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Remove the HV supply stack sub-assembly.

HINT:

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(b) Inspect the HV supply stack sub-assembly.

(1) Check that no electrolyte is leaking from the HV supply stack sub-assembly.

*1	No. 1 HV Supply Stack Sub-assembly	*2	No. 2 HV Supply Stack Sub-assembly
*3	No. 3 HV Supply Stack Sub-assembly	-	-
*a	Check Part	-	-

OK:

There is no electrolyte leaking from the HV supply stack sub-assembly.

HINT:

If the result is not as specified, replace the HV supply stack sub-assembly.

HINT:

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Installation

INSTALLATION

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure		Part Name Code
1	NO. 1 TRACTION BATTERY COOLER CONDUCTOR	-	-	-	-

*a	Parts requiring replacement with new ones when replacing the HV supply stack sub-assembly	-	-
●	Non-reusable part	-	-

Procedure		Part Name Code
2	NO. 2 TRACTION BATTERY COOLER SHEET	-		-	-
3	NO. 18 TRACTION BATTERY BRACKET	G963J		-	-
4	NO. 17 TRACTION BATTERY BRACKET	G963H		-	-
5	HV SUPPLY STACK SUB-ASSEMBLY	-		-	-
6	NO. 1 TRACTION BATTERY COOLER TUBE	G96N1	-	-	-
7	INSPECT FOR REFRIGERANT LEAK	-	-	-
8	PERFORM UTILITY	-	-	-

*1	NO. 1 HV SUPPLY STACK SUB-ASSEMBLY	*2	NO. 2 HV SUPPLY STACK SUB-ASSEMBLY
*3	NO. 3 HV SUPPLY STACK SUB-ASSEMBLY	*4	NO. 16 TRACTION BATTERY BRACKET
	Nm (kgfcm, ft.*lbf): Specified torque		Compressor oil ND-OIL 11 or equivalent
●	Non-reusable part	-	-

PROCEDURE

1. INSTALL NO. 1 TRACTION BATTERY COOLER CONDUCTOR

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2. INSTALL NO. 2 TRACTION BATTERY COOLER SHEET

NOTICE:

The No. 2 traction battery cooler sheet cannot be reused after removing and installing No. 2 HV supply stack sub-assembly.

*1	No. 1 Traction Battery Heater	*2	No. 2 Traction Battery Cooler Sheet
*a	23mm	*b	295.4mm

(1) Attach the new No. 2 traction battery cooler sheet in the position shown in the illustration.

3. INSTALL NO. 18 TRACTION BATTERY BRACKET

CAUTION:

Be sure to wear insulated gloves and protective goggles.

4. INSTALL NO. 17 TRACTION BATTERY BRACKET

CAUTION:

Be sure to wear insulated gloves and protective goggles.

5. INSTALL HV SUPPLY STACK SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

Hole

(1) Install the HV supply stack sub-assembly with the 3 bolts.

Torque:

11 N·m {112 kgf·cm, 8 ft·lbf}

NOTICE:

Make sure to align the hole of the HV supply stack sub-assembly with the pin.

Torque:

16 N·m {163 kgf·cm, 12 ft·lbf}

6. INSTALL NO. 1 TRACTION BATTERY COOLER TUBE

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7. INSPECT INSPECT FOR REFRIGERANT LEAK

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8. PERFORM UTILITY

NOTICE:

Perform "Battery Diagnosis" after replacing a malfunctioning HV supply stack sub-assembly.
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Perform "Battery Status Info Update" after replacing a malfunctioning HV supply stack sub-assembly.
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Recovery Inspection

CAUTION / NOTICE / HINT

CAUTION:

When disposing of an HV supply stack sub-assembly, make sure to return it through an authorized collection agent who is capable of handling it safely. If it is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.
Before returning an HV supply stack sub-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 supply stack sub-assemblies through an authorized collection agent.
To reduce the risk of fire, HV supply stack sub-assemblies must not be stored in an area where they will be exposed to fire or high temperatures.
If the temperature of an HV supply stack sub-assembly is high, leave it to cool down.

HINT:

In order to return an HV supply stack sub-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 an HV supply stack sub-assembly the method that may be required.

PROCEDURE

1.	INSPECT FOR ELECTROLYTE LEAK

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Inspect for electrolyte leaks after removing the HV supply stack sub-assembly.

OK:

No leak was found on the lower part of the battery outer case.

CAUTION:

Perform this procedure in an area where the battery will not be exposed to fire.
Do not touch the HV supply stack sub-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 stack sub-assembly.

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

DTC No.
P1A6017
P31AA17
P0C3000
P31B300
P1C7D49

GO TO STEP 5

DISCHARGING

3.	CHECK HV SUPPLY STACK SUB-ASSEMBLY VOLTAGE

CAUTION:

Be sure to wear insulated gloves and protective goggles.

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

Standard Voltage:

Tester Connection	Condition	Specified Condition
A - D	Always	Below 88.8 V
B - E
C - F

CAUTION:

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

*1	No. 1 HV Supply Stack Sub-assembly	*2	No. 2 HV Supply Stack Sub-assembly
*3	No. 3 HV Supply Stack Sub-assembly	-	-

DISCHARGING

4.	INSULATION INSPECTION OF HV SUPPLY STACK SUB-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.

Insulation Inspection Area

Standard Resistance:

Tester Connection	Condition	Specified Condition
A - Insulation Inspection Area of the Bolt A	Always	1 MΩ or higher
B - Insulation Inspection Area of the Bolt B
C - Insulation Inspection Area of the Bolt C

DISCHARGING

5.	HV SUPPLY STACK SUB-ASSEMBLY VISUAL CHECK

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Check that the HV supply stack sub-assembly is not deformed or damaged.

OK:

The HV supply stack sub-assembly is not deformed or damaged.

RETURN HV SUPPLY STACK SUB-ASSEMBLY

DISCHARGING

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 the HV supply stack sub-assembly is set.

(a) Prepare HV supply stack sub-assembly

(1) Set the HV supply stack sub-assembly in the container (A).

*a	Example
*b	Container A

(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 stack sub-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 stack sub-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 stack sub-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 stack sub-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 stack sub-assembly being discharged.