Toyota Prius: Refrigerant Line (for Phev Model)
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 the traction battery cooler tube removal/installation are shown below.
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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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. |
|
| 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
| 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 | NO. 1 TRACTION BATTERY DEVICE BOX ASSEMBLY | - | - | - | - |
| 2 | NO. 1 TRACTION BATTERY HEATER RELAY | G96J1 | - | - | - |
| 3 | BATTERY VOLTAGE SENSOR | 89892A | - | - | - |
| 4 | BATTERY ECU ASSEMBLY | 89890A | - | - | - |
| 5 | NO. 14 TRACTION BATTERY BRACKET | G963E |
| - | - |
| 6 | NO. 10 TRACTION BATTERY BRACKET | G963A |
| - | - |
| 7 | NO. 2 TRACTION BATTERY COOLER TUBE | G96N2 |
| - | - |
| 8 | NO. 1 TRACTION BATTERY COOLER TUBE | G96N1 |
| - | - |
| *1 | O-RING | - | - |
| ● | Non-reusable part |
| Compressor oil ND-OIL 11 or equivalent |
PROCEDURE
1. REMOVE NO. 1 TRACTION BATTERY DEVICE BOX ASSEMBLY
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2. REMOVE NO. 1 TRACTION BATTERY HEATER RELAY
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3. REMOVE BATTERY VOLTAGE SENSOR
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4. REMOVE BATTERY ECU ASSEMBLY
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5. REMOVE NO. 14 TRACTION BATTERY BRACKET
| CAUTION: Be sure to wear insulated gloves and protective goggles. |
6. REMOVE NO. 10 TRACTION BATTERY BRACKET
| CAUTION: Be sure to wear insulated gloves and protective goggles. |
7. REMOVE NO. 2 TRACTION BATTERY COOLER TUBE
| CAUTION: Be sure to wear insulated gloves and protective goggles. NOTICE: Do not apply excessive force to the pipe. |
(1) Remove the 2 O-rings from the No. 2 traction battery cooler tube.
NOTICE:
Seal the openings of the disconnected parts with vinyl tape to prevent entry of moisture and foreign matter.
8. REMOVE NO. 1 TRACTION BATTERY COOLER TUBE
| CAUTION: Be sure to wear insulated gloves and protective goggles. NOTICE: Do not apply excessive force to the pipe. |
(1) Remove the 2 O-rings from the No. 1 traction battery cooler tube.
NOTICE:
Seal the openings of the disconnected parts with vinyl tape to prevent entry of moisture and foreign matter.
Installation
INSTALLATION
CAUTION / NOTICE / HINT
COMPONENTS (INSTALLATION)
| Procedure | Part Name Code |
|
|
| |
|---|---|---|---|---|---|
| 1 | NO. 1 TRACTION BATTERY COOLER TUBE | G96N1 |
| - | - |
| 2 | NO. 2 TRACTION BATTERY COOLER TUBE | G96N2 |
| - | - |
| 3 | INSPECT FOR REFRIGERANT LEAK | - | - | - |
|
| 4 | NO. 10 TRACTION BATTERY BRACKET | G963A |
| - | - |
| 5 | NO. 14 TRACTION BATTERY BRACKET | G963E |
| - | - |
| 6 | BATTERY ECU ASSEMBLY | 89890A | - | - | - |
| 7 | BATTERY VOLTAGE SENSOR | 89892A | - | - | - |
| 8 | NO. 1 TRACTION BATTERY HEATER RELAY | G96J1 | - | - | - |
| 9 | NO. 1 TRACTION BATTERY DEVICE BOX ASSEMBLY | - | - | - | - |
| *1 | O-RING | - | - |
| N*m (kgf*cm, ft.*lbf): Specified torque |
| Compressor oil ND-OIL 11 or equivalent |
| ● | Non-reusable part | - | - |
PROCEDURE
1. INSTALL NO. 1 TRACTION BATTERY COOLER TUBE
| CAUTION: Be sure to wear insulated gloves and protective goggles. NOTICE: Do not apply excessive force to the pipe. |
(1) Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the No. 1 traction battery cooler 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 2 O-rings to the No. 1 traction battery cooler tube.
NOTICE:
Keep the O-ring and O-ring fitting surface free of foreign matter.
Torque:
7.5 N·m {76 kgf·cm, 66 in·lbf}
2. INSTALL NO. 2 TRACTION BATTERY COOLER TUBE
| CAUTION: Be sure to wear insulated gloves and protective goggles. NOTICE: Do not apply excessive force to the pipe. |
(1) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the No. 2 traction battery cooler 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 2 O-rings to the No. 2 traction battery cooler tube.
NOTICE:
Keep the O-ring and O-ring fitting surface free of foreign matter.
Torque:
7.5 N·m {76 kgf·cm, 66 in·lbf}
3. INSPECT INSPECT FOR REFRIGERANT LEAK
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4. INSTALL NO. 10 TRACTION BATTERY BRACKET
| CAUTION: Be sure to wear insulated gloves and protective goggles. |
Torque:
7.5 N·m {76 kgf·cm, 66 in·lbf}
5. INSTALL NO. 14 TRACTION BATTERY BRACKET
| CAUTION: Be sure to wear insulated gloves and protective goggles. |
Torque:
7.5 N·m {76 kgf·cm, 66 in·lbf}
6. INSTALL BATTERY ECU ASSEMBLY
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7. INSTALL BATTERY VOLTAGE SENSOR
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8. INSTALL NO. 1 TRACTION BATTERY HEATER RELAY
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9. INSTALL NO. 1 TRACTION BATTERY DEVICE BOX ASSEMBLY
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Airtight Inspection
AIRTIGHT INSPECTION
PROCEDURE
1. INSPECT INSPECT FOR REFRIGERANT LEAK
| (a) Sufficiently apply compressor oil to 2 SST O-rings. SST: 09893-10060 SST: 09893-10070 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. |
|
| (b) Install the SST with the 2 bolts. Torque: 9.8 N·m {100 kgf·cm, 7 ft·lbf} |
|
| (c) Connect a refrigerant recovery unit to the SST. NOTICE: Use the refrigerant recovery unit in accordance with the manufacturer's instruction manual. |
|
(d) Perform vacuum drawing.
OK:
Can maintain the vacuum state for more than 5 minutes.
Toyota Prius (XW60) 2023-2025 Service Manual
Refrigerant Line (for Phev Model)
Actual pages
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