Lexus - UX260h - Service Manual - 2018 - 2018

UX2 250 0h h/260 0h Gasolin G ne-Elecctric Lexus L H Hybrid d Drive MZAH100/MZAH15 Series S Foreword This guide was developed to educate and assist dismantlers in the safe handling of Lexus UX250h/260h gasoline-electric hybrid vehicles. UX250h/260h dismantling procedures are similar to other non-hybrid Lexus vehicles with the exception of the high voltage electrical system. It is important to recognize and understand the high voltage electrical system features and specifications of the Lexus UX250h/260h, as they may not be familiar to dismantlers. High voltage electricity powers the front electric motor, rear electric motor (for AWD), generator, Air Conditioning (A/C) compressor and inverter/converter. All other automotive electrical devices such as the head lights, radio, and gauges are powered from a separate 12 Volt auxiliary battery. Numerous safeguards have been designed into the UX250h/260h to help ensure the high voltage, approximately 216 Volt, Nickel Metal Hydride (NiMH) Hybrid Vehicle (HV) battery pack is kept safe and secure in an accident. The NiMH HV battery pack contains sealed batteries that are similar to rechargeable batteries used in some battery operated power tools and other consumer products. The electrolyte is absorbed in the cell plates and will not normally leak out even if the battery is cracked. In the unlikely event the electrolyte does leak, it can be easily neutralized with a dilute boric acid solution or vinegar. High voltage cables, identifiable by orange insulation and connectors, are isolated from the metal chassis of the vehicle. Additional topics contained in the guide include:  Lexus UX250h/260h identification.  Major hybrid component locations and descriptions. By following the information in this guide, dismantlers will be able to handle UX250h/260h hybrid-electric vehicles as safely as the dismantling of a conventional gasoline engine automobile.  2018 Toyota Motor Corporation All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of Toyota Motor Corporation. ii Table of Contents About the UX250h/260h ............................................................................................................................... 1 UX250h/260h Identification ......................................................................................................................... 2 Exterior ......................................................................................................................................................... 3 Interior ........................................................................................................................................................... 4 Engine Compartment .................................................................................................................................... 5 Hybrid Component Locations & Descriptions ........................................................................................... 7 Specifications ................................................................................................................................................ 8 Lexus Hybrid Drive Operation.................................................................................................................... 9 Vehicle Operation.......................................................................................................................................... 9 Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery...................................................................... 10 HV Battery Pack.......................................................................................................................................... 10 Components Powered by the HV Battery Pack........................................................................................... 10 HV Battery Pack Recycling ......................................................................................................................... 11 Auxiliary Battery .......................................................................................................................................... 11 High Voltage Safety .................................................................................................................................... 12 High Voltage Safety System ....................................................................................................................... 12 Service Plug Grip ........................................................................................................................................ 13 Precaution to be observed when dismantling the vehicle ........................................................................ 15 Necessary Items ......................................................................................................................................... 15 Spills............................................................................................................................................................. 16 Dismantling a vehicle ................................................................................................................................. 17 Removal of HV battery .............................................................................................................................. 22 iii About the UX250h/260h The UX250h/260h 5-door hatchback joins the hybrid model for Lexus. Lexus Hybrid Drive means that the vehicle contains a gasoline engine, a front electric motor and a rear electric motor* for power. The two hybrid power sources are stored on board the vehicle: 1. 2. Gasoline stored in the fuel tank for the gasoline engine. Electricity stored in a high voltage Hybrid Vehicle (HV) battery pack for the front electric motor and rear electric motor*. The result of combining these two power sources is improved fuel economy and reduced emissions. The gasoline engine also powers an electric generator to recharge the battery pack; unlike a pure all electric vehicle, the UX250h/260h never needs to be recharged from an external electric power source. Depending on the driving conditions one or both sources are used to power the vehicle. The following illustration demonstrates how the UX250h/260h operates in various driving modes.  During light acceleration at low speeds, the vehicle is powered by the front electric motor and rear electric motor*. The gasoline engine is shut off.  During normal driving, the vehicle is powered mainly by the gasoline engine. The gasoline engine also powers the generator to recharge the battery pack and to drive the motor.  During full acceleration, such as climbing a hill, both the gasoline engine, the front electric motor and rear electric motor* power the vehicle.  During deceleration, such as when braking, the vehicle regenerates kinetic energy from the front wheels to produce electricity that recharges the battery pack.  While the vehicle is stopped, the gasoline engine, front electric motor and rear electric motor* are off, however the vehicle remains on and operational.  Starting Electricity  Normal Driving Electricity and gasoline  Acceleration Electricity and gasoline (additional electricity extracted from batteries) *: for AWD 1  Deceleration Charging batteries  Stopping Engine automatically stopped UX250h/260h Identification In appearance, the 2019 model year UX250h/260h is nearly identical to the conventional, non-hybrid Lexus UX200. The UX250h/260h is a 5-door hatchback. Exterior, interior, and engine compartment illustrations are provided to assist in identification. The alphanumeric 15 character Vehicle Identification Number (VIN) is provided in the left side windshield cowl, under the right side front seat and on the left side B pillar. Example VIN: JTHY6JBH2000101, JTHU9JBH2000101, JTHY65BH2000101 or JTHU95BH2000101 A UX250h/260h is identified by the first 8 alphanumeric characters JTHY6JBH, JTHU9JBH, JTHY65BH or JTHU95BH. Left Side Windshield Cowl, Under the Right Side Front Seat and Left Side B Pillar 2 UX250h/260h Identification (Continued) Exterior  UX250h/260h logo on the back door.  logos on the each rear door.  Gasoline fuel filler door located on the left side rear quarter panel.  Exterior Front and Left Side View    Exterior Rear and Left Side View 3 UX250h/260h Identification (Continued) Interior  The instrument cluster (hybrid system indicator, READY indicator, and warning lights) located in the dash behind the steering wheel, is different than the one on the conventional, non-hybrid UX200.  A switchable gauge in the combination meter showing either a hybrid system indicator or a tachometer depending on driving mode. Notice: If the vehicle is shut off, the instrument cluster gauges will be “blacked out”, not illuminated.  This illustration is for an LHD model Interior View  READY Indicator READY Indicator  except F Sport  for F Sport Combination Meter View 4 UX250h/260h Identification (Continued) Engine Compartment  2.0-liter aluminum alloy gasoline engine.  Logo on the engine cover.  Orange colored high voltage power cables.   This illustration is for an LHD model Engine Compartment View 5 for 2WD  for AWD   Power Cablees 6 Hybrid Component Locations & Descriptions Component Location Description 12 Volt Auxiliary Battery  Hybrid Vehicle (HV) Battery Pack  Luggage Compartment Cabin Area, Mounted Under Rear Seat Supplies electricity to the electrical components. Gasoline Engine  Engine Compartment Front Electric Motor  Engine Compartment Provides two functions: 1) Powers vehicle. 2) Powers generator to recharge the HV battery pack. The engine is started and stopped under control of the vehicle computer. • MG2, which is driven by electrical power from MG1 and the HV battery, generates motive force for the drive wheels. • During braking, or when the accelerator pedal is not depressed, it generates high-voltage electricity to recharge the HV battery. MG3, which is driven by electrical power from MG1 and the HV battery, generates motive force for the drive wheels. MG1, which is driven by the engine, generates high-voltage electricity in order to operate MG2 and charge the HV battery. Also, it functions as a starter to start the engine. 3-phase high voltage AC electrically driven motor compressor. • Supplies electrical power to MG1, MG2 and MGR*1 in accordance with the driving conditions of the vehicle. • Recharged by MG1 and MG2 in accordance with the SOC and the driving conditions of the vehicle. Power Cables  Undercarriage, Connects the HV battery, inverter with converter Engine assembly, hybrid vehicle transaxle assembly, compressor Compartment and with motor assembly, rear traction motor with transaxle Under the assembly*1 and rear hybrid motor control inverter Luggage assembly*1. Compartment*1 Inverter/ Engine • Converts the direct current from the boost converter Converter  Compartment into alternating current for MG1 and MG2, and vice versa (from AC to DC). •Boosts the HV battery nominal voltage of DC 216 V up to a maximum voltage of DC 650 V and vice versa (steps down DC 650 V to DC 216 V). Rear Inverter *1 Under the •Takes current from the HV battery and branches it to the Luggage inverter with converter assembly. Compartment*1 •Converts the HV battery current to 3-phase AC and supplies it to MGR. Rear Electric Motor  Under the Luggage Compartment*1 Electric Generator Engine  Compartment A/C Compressor Engine (with Inverter)  Compartment DC-DC Converter Engine for 12 Volt Compartment Auxiliary Battery Steps down the HV battery nominal voltage of DC 216V to approximately DC 14 V in order to supply electricity to the electrical components, as well as to recharge the auxiliary battery. Fuel Tank and Fuel Undercarriage and The fuel tank provides gasoline via a fuel line to the Line Center engine. The fuel line is routed under the center of vehicle. *Numbers in the component column apply to the illustrations on the following page. *1: for AWD 7 Hybrid Component Locations & Descriptions (Continued) Specifications Gasoline Engine: Electric Motors Front: Rear: Transmission: HV Battery: Curb Weight: Fuel Tank: Frame Material: 131 kW, 2.0-liter Aluminum Alloy Engine 80 kW, Permanent Magnet Motor 5.3 kW, Permanent Magnet Motor (for AWD) Automatic Only 216 Volt Sealed NiMH Battery 3,395 – 3,704 lbs / 1,540 - 1,680 kg 40.0 – 43.0 liters / 10.6 – 11.4 Us. gals / 8.8 – 9.5 Imp. gals Steel Unibody Body Material: Steel Panels Seating Capacity: 5 passenger                  8  Lexus Hybrid Drive Operation Once the READY indicator is illuminated in the instrument cluster, the vehicle may be driven. However, the gasoline engine does not idle like a typical automobile and will start and stop automatically. It is important to recognize and understand the READY indicator provided in the instrument cluster. When illuminated, it informs the driver that the vehicle is on and operational even though the gasoline engine may be off and the engine compartment is silent. Vehicle Operation  With the UX250h/260h, the gasoline engine may stop and start at any time while the READY indicator is on.  Never assume that the vehicle is shut off just because the engine is off. Always look for the READY indicator status. The vehicle is shut off when the READY indicator is off. The vehicle may be powered by: 1. The front electric motor and the rear electric motor (for AWD) only. 2. A combination of both the front electric motor, the rear electric motor (for AWD) and the gasoline engine. for F Sport except F Sport Combination Meter READY Indicator 9 Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery The UX250h/260h features a high voltage Hybrid Vehicle (HV) battery pack that contains sealed Nickel Metal Hydride (NiMH) battery modules. HV Battery Pack  The HV battery pack is enclosed in a metal case and is rigidly mounted to the cabin area under the rear seat. The metal case is isolated from high voltage and concealed by carpet in the cabin area.  The HV battery pack consists of 30 low voltage (7.2 Volt) NiMH battery modules connected in series to produce approximately 216 Volts. Each NiMH battery module is non-spillable and sealed in a metal case.  The electrolyte used in the NiMH battery module is an alkaline mixture of potassium and sodium hydroxide. The electrolyte is absorbed into the battery cell plates and will not normally leak, even in a collision. HV Battery Pack Battery pack voltage Number of NiMH battery modules in the pack NiMH battery module voltage 216 V 30 7.2 V Components Powered by the HV Battery Pack     Front Electric Motor  Rear Electric Motor (for AWD) Inverter/Converter  Power Cables A/C Compressor  Electric Generator DC-DC Converter for 12 Volt Auxiliary Battery 10 Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (Continued) HV Battery Pack Recycling  The HV battery pack is recyclable. Contact either your Lexus distributor as mentioned on HV Battery Caution Label or the nearest Lexus dealer. Auxiliary Battery  The UX250h/260h contains a sealed lead-acid 12 Volt battery. This 12 Volt auxiliary battery powers the vehicle electrical system similar to a conventional vehicle. As with other conventional vehicles, the negative terminal of the auxiliary battery is grounded to the metal chassis of the vehicle.  The auxiliary battery is located in the luggage compartment area. plastic cover on the left side in the battery compartment. It is concealed by a 12 Volt Auxiliary Battery Mounted in Luggage Compartment Area (Right Side) 216 Volt HV Battery Pack HV Battery Pack Mounted in Cabin Area 11 High Voltage Safety The HV battery pack powers the high voltage electrical system with DC electricity. Positive and negative orange colored high voltage power cables are routed from the battery pack, under the vehicle floor pan, to the inverter/converter. The inverter/converter contains a circuit that boosts the HV battery voltage from 216 to 650 Volts DC. The inverter/converter creates 3-phase AC to power the motor. Power cables are routed from the inverter/converter to each high voltage component (front electric motor, rear electric motor (for AWD), electric generator, and A/C compressor). The following systems are intended to help keep occupants in the vehicle and emergency responders safe from high voltage electricity: High Voltage Safety System  A high voltage fuse * provides short circuit protection in the HV battery pack.  Positive and negative high voltage power cables * connected to the HV battery pack are controlled by 12 Volt normally open relays *. When the vehicle is shut off, the relays stop electrical flow from leaving the HV battery pack. WARNING: ・ The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled. To prevent serious injury or death from severe burns or electric shock, avoid touching, cutting, or breaching any orange high voltage power cable or high voltage component.  Both positive and negative power cables * are insulated from the metal body. High voltage electricity flows through these cables and not through the metal vehicle body. The metal vehicle body is safe to touch because it is insulated from the high voltage components.  A ground fault monitor in the hybrid vehicle computer * continuously monitors for high voltage leakage to the metal chassis while the vehicle is running. If a malfunction is detected, the hybrid vehicle computer * will illuminate the master warning light in the instrument cluster and a message indicating that the hybrid system is malfunctioning will be displayed on the multi-information display.  The HV battery pack relays will automatically open to stop electrical flow in a collision sufficient to activate the SRS. *Numbers apply to the illustration on the following page. 12 High Voltage Safety (Continued) Service Plug Grip  The high-voltage circuit is cut by removing the service plug grip (see page 17). for 2WD Hybrid Vehicle Computer ➍ 0.0 ➋ Volts DC A/C Compressor ➋ Electric Generator 12 Volts Auxiliary Battery 0.0 Volts DC ❸ ❸ Inverter/ Converter Front Electric Motor ➊ HV Battery Pack 0 Volts AC 3-Phase High Voltage Safety System – Vehicle Shut Off (READY-OFF) Hybrid Vehicle Computer 216.0 Volts DC 12 Volts Auxiliary Battery A/C Compressor 216.0 Volts DC Electric Generator Inverter/ Converter Front Electric Motor HV Battery Pack 650 Volts AC Max 3-Phase High Voltage Safety System – Vehicle On and Operational (READY-ON) 13 for AWD Hybrid Vehicle Computer ➍ 0.0 Volts DC 12 Volts Auxiliary Battery ➋ ➋ A/C Compressor 0.0 Volts DC ➋ Electric Generator ❸ ❸ 0.0 Volts DC Inverter/ Converter Front Electric Motor ➊ Rear Electric Motor Rear Inverter HV Battery Pack 0 Volts AC 3-Phase 0 Volts AC 3-Phase High Voltage Safety System – Vehicle Shut Off (READY-OFF) Hybrid Vehicle Computer 216.0 Volts DC 12 Volts Auxiliary Battery A/C Compressor Electric Generator 216.0 Volts DC 216.0 Volts DC Inverter/ Converter Rear Electric Motor Front Electric Motor Rear Inverter HV Battery Pack 216 Volts AC Max 3-Phase 650 Volts AC Max 3-Phase High Voltage Safety System – Vehicle On and Operational (READY-ON) 14 Precaution to be observed when dismantling the vehicle WARNING: ・ The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled. To prevent serious injury or death from severe burns or electric shock, avoid touching, cutting, or breaching any orange high voltage power cable or high voltage component. Necessary Items     Protective clothing such as insulated gloves (electrically insulated), rubber gloves, safety goggles, and safety shoes. Insulating tape such as electrical tape that has a suitable electrical insulation rating. Before wearing insulated gloves, make sure that they are not cracked, ruptured, torn, or damaged in any way. Do not wear wet insulated gloves. An electrical tester that is capable of measuring DC 750 Volts or more. 15 Spills The UX250h/260h contains the same common automotive fluids used in other non-hybrid Lexus vehicles, with the exception of the NiMH electrolyte used in the HV battery pack. electrolyte is a caustic alkaline (pH 13.5) that is damaging to human tissues. The NiMH battery The electrolyte, however, is absorbed in the cell plates and will not normally spill or leak out even if a battery module is cracked. A catastrophic crash that would breach both the metal battery pack case and a metal battery module would be a rare occurrence. A caustic alkaline is at the opposite end of the pH scale from a strong acid. is approximately in the middle of this scale. A safe (neutral) substance Adding a weak acidic mixture, such as a dilute boric acid solution or vinegar, to the caustic alkaline electrolyte will cause the electrolyte to be neutralized. This is similar but opposite to the use of baking soda to neutralize a lead-acid battery electrolyte spill. A Lexus Product Safety Data Sheets (PSDS) is attached to this document.  Handle NiMH electrolyte spills using the following Personal Protective Equipment (PPE): • Splash shield or safety goggles. Fold down helmet shields are not acceptable for acid or electrolyte spills. • • •  Rubber, latex or nitrile gloves. Apron suitable for alkaline. Rubber boots. Neutralize NiMH electrolyte. • • Use a boric acid solution or vinegar. Boric acid solution - 800 grams boric acid to 20 liters water or 5.5 ounces boric acid to 1 gallon of water. 16 Dism mantling a vehicle The ffollowing 4 pages p contain n general insstructions forr use when working w on a UX250h/260h. Readd these instructions beforee proceedingg to the HV battery b remov val instructioons on page 22. 2 WARNIN NG: ・ The high h voltag ge system m may remain powerred for up to 10 minuttes after th he vehicle e is shut off o or disab bled. To prevent seriou us injury or o death frrom severre burns or o electric shock, av void touch hing, cuttin ng, or brea aching an ny orange high voltaage powerr cable or any hig gh voltage e compon nent. 1. S Shut off the ignition (R READY indiicator is offf). Then discconnect thee cable from m the nnegative auxiliary batteery terminall. ((1) Disengaage the clamp p to separatee the auxiliarry battery hosse. ((2) Loosen the nut and disconnect d thhe cable from thee negative (-) auxiliary bbattery terminal. 2. R Remove batttery servicee hole coverr. ((1) Remov ve the clip. ((2) Disengage the 5 cllaws and rem move the battery service holle cover. 17 3. R Remove servvice plug grrip. C Caution: ・Be sure to o wear insu ulated glov ves. ・Do not ins spect or service the hiigh voltage e system wiith the serv vice plug grrip installed. ・To reduce the risk off electric sh hock, make e move the service s plu g grip to sure to rem cut off the e high volta age circuit before servicing the vehicle e. ・To reduce the risk off electric sh hock, make e sure to wa ait at least 10 minutes s after removing the service e plug grip p to fully discharge e the high voltage v cap pacitor inside the inverter with w converrter assembly.. ・Keep the removed r service plug g grip in your pock ket to preve ent other te echnicians from accid dentally ins stalling it w while you are servic cing the veh hicle. No otice: ・ ・After remo oving the serrvice plug grrip, turning the power sw witch on (RE EADY) may cause a malfunction. Do D not turn tthe power sw witch on (RE EADY) unlesss instructed d by m the repair manual. ・ ・Do not touch the termiinals of the sservice plug g grip. Hiint: W Waiting for at least 10 min nutes is requ uired to disc charge the high h voltage capacitor in nside the e inverter with converter assembly. 18 ((1) While wearing w insullated gloves,, rotate the haandle of the service plug grip and rem move the servvice plug grip p as indicatedd by the arro ows, in the orrder shown inn the illustraation. (3) (2) (1) 4. C Carry the rem moved service plug griip in your pocket to preevent other staff from accidentally reinstalling g it while yoou are dismaantling the vehicle. v 5. M Make other staff s aware that a high--voltage sysstem is bein ng dismantleed by using the foollowing siggn: CAUTION: HIGH--VOLTAGE E. DO NOT T TOUCH ((see page 21 1). 6. Iff the servicee plug grip cannot c be reemoved ddue to damagge to the veehicle, remoove the IG G2-MAIN fuse (20 A)). C Caution: T This operattion shuts off the HV system. s B Be sure to wear w insula ated gloves b because hig gh voltage is not shu ut off in nside the HV H battery. When it is p possible to remove th he service p plug grip, IG2-MAIN FFuse rremove it and continu ue the proc cedure. 7. A After disconnnecting or exposing e a hhigh-voltagee connector or terminall, insulate itt immediateely using inssulating tap e. B Before touchhing a bare high-voltag h ge teerminal, weear insulated d gloves. 8. C Check the HV H battery and a nearby aarea for leeakage. Iff you find an ny liquid, itt may be sttrong alkaliine electroly yte. Wear rubber ggloves and goggles g and neutralize tthe liquid using a saturrated boric aacid solution or vvinegar. Thhen wipe up p the liquid using wastee rags etc. 9. Iff the electroolyte comes into contacct with yourr skin, wash h the skin im mmediately uusing a saturrated boric acid a solutioon or a largee amount of water. If the electrollyte adheres to anny article off clothing, ttake the clotthing off im mmediately. 19 10. Iff the electroolyte comes into contacct with yourr eye(s), calll out loudlyy for help. Do not rub your eye(s). In nstead, washh the eye(s)) with a dilu ute boric aciid solution or o a laarge amountt of water and a seek meedical care. 11. W With the excception of th he HV batteery, remove parts by following proocedures wh hich arre similar too conventional Toyota vehicles. For the rem moval of thee HV battery y, reefer to the following f paages. 20 21 Remooval of HV H battery y WAR RNING: ・ Be e sure to wear w insula ated glove es when handling h h high-voltag ge parts. ・ Ev ven if the vehicle v is s shut off and the rellays are offf, be sure e to rem move the service s pllug grip be efore perfforming an ny furtherr wo ork. ・ Po ower remains in the high volta age electrrical systeem for 10 miinutes eve en after the e HV batte ery pack is s shut offf because the cirrcuit has a condens ser that sto ores powe er. ・ Ma ake sure th hat the tes ster readin ng is 0 V before b tou uching any y hig gh-voltage e terminals ls which are not insulated. ・ Th he SRS ma ay remain powered for up to 90 9 second ds after the veh hicle is sh hut off or d disabled. To preve ent seriou us injury or o death from unintentio u onal SRS deploymen d nt, avoid ccutting the e SR RS compon nents. 1. S SHUT OFF IGNITION N (READY iindicator is off) 2. D DISCONNE ECT CABLE E FROM N NEGATIVE E AUXILIA ARY BATT TERY T TERMINAL L ((1) Disengaage the clamp p to separatee the auxiliaryy battery hosse. ((2) Loosen the nut and disconnect d thhe cable from thee negative (-)) auxiliary baattery terminall. 22 3. R REMOVE BATTERY B SERVICE H HOLE C COVER ((1) Removee the clip. ((2) Disengaage the 5 claw ws and remoove the battery service hole cover. 4. R REMOVE SERVICE S PLUG P GRIP P C Caution: ・Be sure to o wear insu ulated glov ves. ・Do not ins spect or service the high voltage e system wiith the serv vice plug grrip installed. ・To reduce e the risk off electric sh hock, make e sure to remove the service s plu ug grip to cut off the e high volta age circuit before servicing the vehicle e. ・To reduce e the risk off electric sh hock, make e sure to wa ait at least 10 minutes s after removing the service plug grip p to fully discharge e the high voltage v cap pacitor inside the e inverter with w converrter assembly.. ・Keep the removed service plug g grip in your pock ket to preve ent other te echnicians s from accid dentally ins stalling it w while you are servic cing the veh hicle. 23 A29644 42 No otice: ・ ・After remo oving the serrvice plug grrip, turning the power sw witch on (RE EADY) may cause a malfunction. Do D not turn tthe power sw witch on (RE EADY) unlesss instructed d by m the repair manual. ・ ・Do not touch the termiinals of the sservice plug g grip. Hiint: W Waiting for at least 10 min nutes is requ uired to disc charge the high h voltage capacitor in nside the e inverter with converter assembly. ((1) While wearing w insullated gloves, rotate the haandle of the service s plug grip and rem move the servvice plug grip p as indicatedd by the arrows, in the orrder shown inn the illustrattion. (3) (2) (1 1) 5. D DISCONNE ECT ENGIN NE WIRE C Caution: B Be sure to wear w insula ated gloves s. No otice: D Do not allow any foreign matter or w water to e enter the inve erter with co onverter asssembly. ((1) Move eaach lock leveer as shown iin the illustratiion and disco onnect the 2 inverter with connverter assem mbly connecttors. N Notice: ・ ・Do not touch the waterproof seal o or o the conne ector. terminals of ・ ・Do not dam mage the terrminals, con nnector hous sing or inverrter with connverter assem mbly during discconnection. ・ ・Cover the hole where the cable w was connecte ed with tape (non-residuue type) or e of fore eign matter. equivalent to prevent entry ・ ・Insulate the disconnec cted termina als with insulating tape. 24 6. R REMOVE CONNECTO C OR COVER R A ASSEMBLY (B) C Caution: B Be sure to wear w insula ated gloves s. (1) Remove the bolt (B).. (22) Using a T25 T "TORX X" socket wreench, (A) remove the t bolt (A) and a connectoor cover assemblyy from the in nverter with cconverter assemblyy. N Notice: ・Do not tou uch the conn nector coverr assembly waterproof w seal. ・ ・Do not allow w any foreig gn matter or water to entter the inverter with convverter assem mbly. 7. C CHECK TERMINAL VOLTAGE V C Caution: B Be sure to wear w insula ated gloves s. ((1) Using a voltmeter, measure m the vvoltage betweenn the terminaals of the 2 phhase connecttors. S Standard vo oltage: 0 V N Notice: D Do not allow any foreign n matter or w water to ente er the inverte er with convverter assem mbly. H Hint: U Use a measu uring range of DC 750 V or more on n the voltme eter. 8. R REMOVE BENCH B TY YPE REAR SEAT C CUSHION ASSEMBL LY ((1) w/ Occup upant Classificcation System:: a) Fold the rear seatb back assemblyy LH and rear seatbback assembly y RH forward. b) Remoove the clips. 25 c) Disconnect the connector. d) Disengage the clamp. e) Remove the clips. f) Disconnect the connector. g) Disengage the clamp. h) Pull back the rear seatback assembly LH and rear seatback assembly RH. 26 ((2) Lift the front edge of o the bench ttype rear seaat Rear Seaat Cushion Fraame Hook Rear Side cushionn assembly ass shown in thhe illustrattion and disen ngage the reaar seat Place Haands Here cushionn frame hooks on the fronnt side of the (1) bench tyype rear seat cushion asseembly from Place Hands H Here the rear seat cushion n lock hooks . ((2) N Notice: B Be sure to ho old the parts s of the seatt cushion a assembly dirrectly next to o the rear se eat cushion frrame hooks when lifting g it. Lifting a different A A Rear Seaat Cushion Fraame Hook Fro ont Side p part of the cu ushion may deform the rear seat ccushion fram me. S Standard Measureme M ent: Area Measu urement A 124 mm (4.882 in.) ((3) Disengaage the rear seat s cushion frame hook on the rear side of the beench type reaar seat cusshion assemb bly as shownn in the illustrration. ((4) Removee the nut to disconnect d thhe rear centerr seat outter belt assem mbly. ((5) Pull outt the rear cen nter seat outeer belt assemblly from the bench b type reear seat cushionn assembly. ((6) Removee the bench type t rear seatt cushion assemblly. 9. R REMOVE REAR R SEAT T CUSHIO ON LOCK H HOOK ((2) Disengaage the clawss to remove tthe rear seat cushionn lock hook as a shown in th the illustrattion. H Hint: U Use the sam me procedurre for the RH H side and L LH side. 27 10. R REMOVE REAR R DOO OR SCUFF P PLATE LH H (11) Disengagge the claws and guides tto remove (1) the rear door d scuff pllate LH as shhown in the (2) illustratioon. Place Haands Here 11. R REMOVE REAR R UND DER SIDE C COVER LH H ((1) Removee the 2 crips. ((2) Disengaage the clips, clows and guuide to remove the rear under side coverr LH as shown in the illustraation. 12. R REMOVE REAR R DOO OR SCUFF P PLATE RH H H Hint: U Use the sam me procedure e for the LH side. 13. R REMOVE REAR R UND DER SIDE C COVER RH H H Hint: U Use the sam me procedure e for the LH side. 14. R REMOVE REAR R UND DER COVER R ((1) Disengaage the 2 clip ps. ((2) Disengaage the 2 guides to removve the rear under coover from thee rear seat cuushion leg sub-asseembly. 28 15. R REMOVE REAR R SEAT T CUSHIO ON LEG S SUB-ASSE EMBLY ((1) Removee the 6 bolts and rear seatt cushion leg sub--assembly. 16. R REMOVE BATTERY B COOLING G B BLOWER ASSEMBL A Y ((1) Disconnnect the batteery cooling bblower assemblly connector. ((2) Disengaage the 2 clam mps. ((3) Removee the 3 bolts. ((4) Disengaage the 2 claw ws to removee the battery cooling blow wer assemblyy. N Notice: ・Be sure no ot to touch th he fan part o of the battery coo oling blowerr assembly. ・Do not lift the battery cooling c blow wer assembly using the wire harness.. 29 17. R REMOVE NO. N 1 HV BATTERY B C COVER P PANEL RH H Service Plug g Grip C Caution: Turn B Be sure to wear w insula ated gloves s. Button ((1) Using thhe service plu ug grip, remo move the Prrojection Battttery Cover Lo ock Striker battery cover c lock sttriker. H Hint: In nsert the pro ojection of th he service p plug grip a and turn the button of the e battery co over lock sstriker counte erclockwise to release tthe lock. ((2) Removee the 3 bolts, 2 nuts and N No. 1 HV battery cover c panel RH R from thee HV battery. 18. D DISCONNE ECT HV FL LOOR UND DER W WIRE C Caution: B Be sure to wear w insula ated gloves s. N Notice: In nsulate each h disconnec cted high-volltage Shield Ground cconnector with insulating g tape. Wrap p the cconnector fro om the wire harness sid e to the e end of the co onnector. ((1) Disconnnect the 2 HV V battery junnction block assembly a con nnectors. ((2) Disconnnect the shielld ground froom the HV battery. 19. D DISCONNE ECT FLOOR R WIRE C Caution: B Be sure to wear w insula ated gloves s. (11) Disengagge the clamp. (22) Disconneect the electric vehicle batttery plug assemblyy connector. (33) Disconneect the HV baattery junctionn block assemblyy connector. 30 20. R REMOVE NO. N 1 HV BATTERY B P PROTECTO OR ((1) Removee the clip and d No. 1 HV bbattery protectoor. 21. D DISCONNE ECT FLOOR R WIRE C Caution: s. B Be sure to wear w insula ated gloves ((1) Disengaage the clamp p. ((2) Disconnnect the batteery voltage s ensor connecttor. 22. R REMOVE HV H BATTE ERY C Caution: s. B Be sure to wear w insula ated gloves ((1) Removee the 5 bolts and HV batttery from the vehiicle. N Notice:  Do not allow a foreign n matter, succh as grease or o oil, to adh here to the b bolts of the HV batte ery.  To preve ent the wire harness fro m being cau ught, make sure s to bunddle the wire harnesss using insula ating tape o or equivalentt.  Use card dboard or another simila ar material to t protect the HV batteryy and vehiclle body fro om damage.  Since th he HV batterry is very hea avy, 2 people are neede ed to removve it. When removing the HV ba attery, be ca reful not to damage d the parts arounnd it.  When re emoving the HV battery from the ve ehicle, do no ot allow it to ccontact the vehicle.  When re emoving/insttalling/movin ng the HV battery, make e sure not too tilt it more than t 80°.  Insulate the disconn nected termiinals or conn nectors with insulating ttape. 31