Part 1
INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION
1. BASIC REPAIR HINT
(a) HINTS ON OPERATIONS
CAUTION:
*: Be sure to perform these checks properly, Not performing these checks properly after finishing work can lead to serious accident or injury.
(b) JACKING UP AND SUPPORTING VEHICLE
(1) Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations.
(c) PRECOATED PARTS
Text in Illustration
(1) Precoated parts are bolts and nuts that are coated with seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened or moved in any way, it must be recoated with the specified adhesive.
(3) When reusing a precoated part, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriately to that part.
(4) Some seal lock agents harden slowly. You may have to wait for the seal lock adhesive to harden.
(d) GASKETS
(1) When necessary, use a sealer on gaskets to prevent leaks.
(e) BOLTS, NUTS AND SCREWS
(1) Carefully follow all the specifications for tightening torque. Always use a torque wrench.
(f) FUSES
Text in Illustration
(1) When inspecting a fuse, check that the wire of the fuse is not broken.
(2) If the wire of a fuse is broken, confirm that there are no shorts in its circuit.
(3) When a fuse is replaced, a fuse with the same amperage rating must be used.
(g) CLIPS
(1) The removal and installation methods of typical clips used for vehicle body parts are shown in the table below.
HINT
If clips are damaged during a procedure, always replace the damaged clips with new ones.
(h) CLAWS
(1) The removal and installation methods of typical claws used for vehicle body parts are shown in the table below.
HINT
If claws are damaged during a procedure, always replace the cap or cover that has damaged claws with a new one.
(i) HINGES, GUIDES, CLAMPS, PINS, ETC.
(1) The removal and installation methods of typical hinges, guides, clamps and pins used for vehicle body parts are shown in the table below.
HINT
If clamps are damaged during a procedure, always replace the cap or cover that has damaged clamps with a new one.
(j) REMOVAL AND INSTALLATION OF VACUUM HOSES
(1) To disconnect a vacuum hose, pull and twist it from the end of the hose. Do not pull it from the middle of the hose as this may damage the hose.
Text in Illustration
(2) When disconnecting vacuum hoses, use tags to identify where they should be reconnected.
(3) After completing any hose related repairs, double-check that the vacuum hoses are properly connected. The label under the hood shows the proper layout.
(4) When using a vacuum gauge, never force the hose onto a connector that is too large. If a hose has been stretched, air may leak. Use a step-down adapter if necessary.
(k) TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL
(1) Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with a torque wrench.
* Formula
T' = (L2/(L1 + L2))*T
NOTICE:
If an extension tool or SST is combined with a torque wrench and used to tighten to a torque specification in this information, the actual torque will be excessive and parts will be damaged.
2. PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE
CAUTION:
The vehicle has a hybrid system that operates at voltages up to 650 V. The hybrid system uses an HV battery that contains an electrolyte which is a strong alkali solution that includes potassium hydroxide. Be sure to follow the instructions in this information to handle the system correctly. Failure to do so may result in serious injury or electrocution.
(a) Technicians must undergo special training to be able to service and inspect the high-voltage system.
(b) All high-voltage wire harnesses and connectors are colored orange. The HV battery and other high-voltage components have "High Voltage" caution labels. Do not carelessly touch these wires or components.
(c) When there is a problem with the wire harness or connector of a high-voltage circuit, repairs to the harness or connector should not be attempted. Replace damaged or malfunctioning high voltage cables or connectors.
(d) Before inspecting or servicing the high-voltage system, be sure to follow all safety measures, such as wearing insulated gloves and removing the service plug to prevent electrocution. Carry the removed service plug in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.
NOTICE:
After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.
(e) After removing the service plug grip, wait 10 minutes before touching any of the high-voltage connectors and terminals.
HINT
Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.
(f) Before using insulated gloves, be sure to check them for cracks, tears and other types of damage by performing the following procedure.
(1) Place the glove on its side.
(2) Roll the opening up 2 or 3 times.
(3) Fold the opening in half to close it.
(4) Confirm that there are no air leaks.
(g) When servicing the vehicle, do not carry metal objects like mechanical pencils or rulers that can be dropped accidentally and cause a short circuit.
(h) Before touching a bare high-voltage terminal, wear insulated gloves and use a tester to make sure that the terminal voltage is 0 V.
(i) After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulating tape.
(j) Bolts and nuts for high-voltage terminals should be tightened firmly to the specified torque. Both insufficient and excessive torque can cause failure.
(k) Use the "CAUTION: HIGH VOLTAGE DO NOT TOUCH" sign to notify other technicians that the high-voltage system is being inspected and/or repaired.
(l) After servicing the high-voltage system and before reinstalling the service plug, check again that you have not left a part or tool inside, that the high-voltage terminals are firmly tightened, and that the connectors are correctly connected.
(m) When installing hybrid system components such as the HV battery, make sure that the polarity of all connections is correct.
3. PRECAUTIONS TO BE OBSERVED WHEN INSPECTING OR SERVICING ENGINE COMPARTMENT
(a) The vehicle automatically turns the engine on and off when the READY light on the instrument panel is illuminated. To avoid injury, make sure that both the indicator on the power switch and the READY light on the meter are off.
4. ACTIONS TO BE TAKEN WHEN A WARNING LIGHT IS ILLUMINATED
Text in Illustration
(a) If one of the warning lights (2) to (4) illuminates, connect the Techstream to the DLC3 to check the DTCs (Diagnostic Trouble Codes). Then, refer to the applicable troubleshooting steps in this information to inspect and repair the affected area. The foregoing actions are also required if the READY light does not illuminate when attempting to turn the power switch on (READY).
5. ACTIONS TO BE TAKEN WHEN BATTERIES ARE DISCHARGED
HINT
The vehicle uses a 12 V auxiliary and a 201.6 V HV battery. Therefore, there are 2 recharging methods when the batteries are discharged.
(a) Perform this procedure when the auxiliary battery is fully discharged.
HINT
The following problems indicate that the auxiliary battery is discharged:
* No display appears on the instrument panel when the power switch is turned on (IG).
* The hybrid system does not start.
* The headlights are dim.
* The sound from the horn is weak.
* Park (P) cannot be disengaged.
NOTICE:
Never use a quick charger.
(1) Engage the parking brake.
(2) Turn the power switch off and remove the key from the interior detection area.
(3) Remove the No. 1 relay block cover.
(4) Using booster cables, connect the 12 V auxiliary battery of the rescue vehicle and the auxiliary battery of the stalled vehicle as shown in the illustration.
HINT
Use the booster terminal in the engine compartment.
(5) Start the engine of the rescue vehicle and run the engine at a speed slightly higher than usual.
(6) Turn the power switch on (READY).
NOTICE:
Immediately disconnect the booster cables in the reverse order of connection after the hybrid system has started. Do not leave the booster cables connected because they are not designed for recharging purposes.
If the hybrid system fails to start and the HV battery warning is displayed, the HV battery may be discharged.
Text in Illustration
(b) When the HV battery is discharged:
(1) Using the THS charger, charge the HV battery HV Battery.
HINT
Perform this operation when the HV battery is discharged or low, or if Low Traction Battery is displayed and DTC P3000-388 or 389 is stored in the power management control ECU (HV CPU).
6. ACTIONS TO BE TAKEN FOR VEHICLES DAMAGED BY IMPACT
CAUTION:
The vehicle has a hybrid system that operates at voltages of up to 650 V. The hybrid system uses an HV battery that contains an electrolyte which is a strong alkali solution that includes potassium hydroxide. Be sure to follow the instructions in this information to handle the system correctly. Failure to do so may result in serious injury or electrocution.
(a) Items to be prepared for the accident site
* Protective clothing (insulated gloves, rubber gloves, goggles and safety shoes)
* Saturated boric acid solution 20 liter (21.1 US qts, 17.6 Imp.qts) (obtain 800 g (1.76 lb) of boric acid powder, put it into a container, and dissolve it in water)
* Red litmus paper
* ABC fire extinguisher (effective against both oil flames and electrical flames)
* A shop rag or piece of cloth (for wiping off the electrolyte)
* Insulating tape (for insulating cables)
* Electrical tester