Toyota Prius: Service Plug Grip (for Hev Model)

Toyota Prius (XW60) 2023-2025 Service Manual / Engine/Hybrid System / Hybrid / Battery Control / Service Plug Grip (for Hev Model)

Removal
Inspection
Installation

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 service plug grip 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 power 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 Procedures are not Performed	Necessary Procedures	Link
Front Camera System	Drive the Toyota Prius vehicle straight ahead at 35 km/h (22 mph) or more for 5 second or more.

Items for which learning is completed by operating the vehicle normally

Effect/Inoperative Function When Necessary Procedures are not Performed	Necessary Procedures	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 standard position is recognized.	-

CAUTION / NOTICE / HINT

COMPONENTS (REMOVAL)

Procedure		Part Name Code
1	CHECK FOR DTC	-		-	-
2	NEGATIVE AUXILIARY BATTERY TERMINAL	-		-	-
3	BATTERY SERVICE HOLE COVER	58441M	-	-	-
4	SERVICE PLUG GRIP	G3834		-	-

PROCEDURE

1. CHECK FOR DTC

(1) Check for DTCs.

Powertrain > Hybrid Control > Trouble Codes Powertrain > HV Battery > Trouble Codes Powertrain > Motor Generator > Trouble Codes

CAUTION:

Confirm that DTC P0AA649 (Hybrid / EV Battery Voltage System Isolation Internal Electronic Failure), P1C7C49 (Hybrid / EV Battery Voltage System Isolation (A/C Area) Internal Electronic Failure), P1C7D49 (Hybrid / EV Battery Voltage System Isolation (Hybrid/EV Battery Area) Internal Electronic Failure), P1C7E49 (Hybrid / EV Battery Voltage System Isolation (Transaxle Area) Internal Electronic Failure) or P1C7F49 (Hybrid / EV Battery Voltage System Isolation (Direct Current Area) Internal Electronic Failure) are not output before removing or installing the HV battery. If this DTC is output, perform troubleshooting for this DTC first.
To reduce the risk of electric shock, do not perform troubleshooting before checking for DTCs.

2. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

for M20A-FXS:
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for 2ZR-FXE:
Click here

3. REMOVE BATTERY SERVICE HOLE COVER

4. REMOVE SERVICE PLUG GRIP

CAUTION:

Be sure to wear insulated gloves.
Do not inspect or service the high voltage system with the service plug grip installed.
To reduce the risk of electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the Toyota Prius vehicle.
To reduce the risk of electric shock, make sure to wait at least 10 minutes after removing the service plug grip to fully discharge the high voltage capacitor inside the inverter with converter assembly.
Keep the removed service plug grip in your pocket to prevent other technicians from accidentally installing it while you are servicing the Toyota Prius vehicle.

NOTICE:

After removing the service plug grip, turning the power switch on (READY) may cause a malfunction. Do not turn the power switch on (READY) unless instructed by the repair manual.
Do not touch the terminals of the service plug grip.
If the service plug grip has been struck or dropped, replace it.

	Remove in this Direction (1)		Remove in this Direction (2)
	Remove in this Direction (3)	-	-

(1) While wearing insulated gloves, rotate the handle of the service plug grip and remove the service plug grip as indicated by the arrows, in the order shown in the illustration.

Inspection

INSPECTION

PROCEDURE

1. INSPECT SERVICE PLUG GRIP

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

Standard Resistance:

Tester Connection	Condition	Specified Condition	Result
Service Plug Grip	Always	Below 1 Ω	Ω

If the result is not as specified, replace the service plug grip.

Installation

INSTALLATION

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure		Part Name Code
1	SERVICE PLUG GRIP	G3834		-	-
2	BATTERY SERVICE HOLE COVER	58441M	-	-	-
3	NEGATIVE AUXILIARY BATTERY TERMINAL	-	-	-	-
4	PERFORM INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL	-	-	-

PROCEDURE

1. INSTALL SERVICE PLUG GRIP

CAUTION:

Be sure to wear insulated gloves.

NOTICE:

Before installing the service plug grip, check that no parts or tools remain and that the high voltage terminals and connectors are connected securely.
After pulling the service plug grip down by 90°, make sure to slide it until a click sound is heard.