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 THE 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 manual, the actual torque will be excessive and parts will be damaged.

2. PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE

CAUTION:
This vehicle has a hybrid control system that operates at voltages of up to 650 V. An organic electrolyte containing carbonic acid esters as its main component is used as the electrolyte for the HV battery. Be sure to follow the instructions in this manual 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 manual 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 performing work involving high-voltage wires, use either a tool wrapped with vinyl insulation tape or an insulated tool.

(n) When installing hybrid control 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 combination meter assembly 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 manual 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
This vehicle uses a 12 V auxiliary and a 207 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.

HINT
The booster terminal cannot be used to rescue a vehicle with a discharged battery.

(1) Engage the parking brake.

(2) Turn the power switch off and remove the key from the interior detection area.

(3) 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.

Text in Illustration

(4) Start the engine of the rescue vehicle and run the engine at a speed slightly higher than usual.

(5) 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.

(b) When the HV battery is discharged:

(1) Using the electric vehicle charger cable assembly, charge the HV battery.

HINT
Perform this operation when the HV battery is discharged or low, or if "TRACTION BATTERY PROTECTION MODE RESTART AFTER SHIFTING TO P POSITION" is displayed and DTC P3000-388 or 389 is stored in the power management control ECU.

6. ACTIONS TO BE TAKEN FOR VEHICLES DAMAGED BY IMPACT

CAUTION:
This vehicle has a hybrid control system that operates at voltages of up to 650 V. An organic electrolyte containing carbonic acid esters as its main component is used as the electrolyte for the HV battery. Be sure to follow the instructions in this manual 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, organic solvent mask, safety shoes and solvent resistant apron (for organic solvent))

* Soap

* 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

(b) Actions to be taken at the accident site

CAUTION:
* Do not touch any bare cables that may have high-voltage. If a cable must be touched or if accidental contact is possible, wear insulated gloves and insulate the cable using insulating tape.
* If the vehicle catches on fire, use an ABC fire extinguisher to extinguish the fire. Trying to extinguish a fire using only a small amount of water can be more dangerous than effective. Use a substantial amount of water or wait for firefighters.
* Visually check the HV battery and the immediate area for any electrolyte leakage. Do not touch any leaked liquid because it could be organic electrolyte that contains carbonic acid esters.
* The electrolyte is flammable. Keep all ignition sources such as open flame and hot objects away from the electrolyte.
* Electrolyte leaks may cause acute poisoning if a high concentration of the vapor from the organic solvent is inhaled. In case of inhalation, move the affected person to a place with ample fresh air and let them lie quietly. Seek medical care.
* If the vehicle is immersed in water, do not touch any high-voltage components or cables including service plug grips. This is to prevent a shock hazard. Work on the vehicle only after the vehicle has been pulled out of the water.
* In case of skin contact with the electrolyte, wash the area thoroughly with soap and plenty of water, and seek medical care. Immediately remove any contaminated clothing. Prolonged contact with the electrolyte may cause skin irritation.
* If the electrolyte comes in contact with your eyes, call out loudly for help. Do not rub your eyes. Immediately flush them with a large amount of water for at least 15 minutes and seek medical care.
* If electrolyte is swallowed, seek medical care immediately. Do not induce vomiting, unless instructed by the doctor.
(1) Check the vicinity of the HV battery for any leakage of the electrolyte.

CAUTION:
Do not touch any leaked liquid because it could be the organic electrolyte that contains carbonic acid esters. If contact is unavoidable, wipe the fluid off using a cloth while wearing rubber gloves, goggles and an organic solvent mask. Do not leave electrolyte-contaminated cloths unattended. Place contaminated cloths in an appropriate airtight container and dispose of them according to local regulations.

(2) If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the following procedure.

CAUTION:
Be sure to wear insulated gloves, goggles and safety shoes.

Text in Illustration

(3) Turn the power switch off.

HINT
If the power switch cannot be turned off, remove the IGCT fuse and IG2 fuse from the engine room relay block and junction block assembly. Confirm that the READY light is off.

Text in Illustration

(4) Disconnect the cable from the negative (-) auxiliary battery terminal.

(5) Wear insulated gloves and then remove the service plug grip.

NOTICE:
After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

(c) Moving the damaged vehicle

If any of the following conditions is met, tow the vehicle away using a tow truck.

NOTICE:
When towing the vehicle, refer to the "PRECAUTIONS FOR TOWING VEHICLES".

* One or more of the high-voltage components and cables are damaged.

* Components related to driving, the transaxle, or the fuel system are damaged.

* The master warning light is on.

* The READY light does not come on when attempting to turn the power switch on (READY).

CAUTION:
Before towing the vehicle away using a tow truck, disconnect the cable from the negative (-) auxiliary battery terminal and remove the service plug grip.

NOTICE:
Perform the procedure below if the master warning light turns on, or there are abnormal noises, unusual smells, or strong vibrations while driving:

(1) Park the vehicle in a safe place.

(2) Apply the parking brake, and then push the P position switch.

(3) Turn the power switch off, and disconnect the cable from the negative (-) auxiliary battery terminal.

(4) Remove the service plug grip while wearing insulated gloves.

(d) Actions required after moving the damaged vehicle

(1) Procedure

If there is liquid on the floor, it could be organic electrolyte containing carbonic acid esters. Wipe the liquid away while wearing rubber gloves, goggles and an organic solvent mask. Do not leave electrolyte-contaminated cloths unattended. Place contaminated cloths in an appropriate airtight container and dispose of them according to local regulations.

(e) Items to be prepared (when repairing a damaged vehicle)

* Protective clothing (insulated gloves, rubber gloves, goggles, organic solvent mask, safety shoes and solvent resistant apron (for organic solvent))

* Soap

* 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

(f) Precautions to be observed when servicing a damaged vehicle

CAUTION:
Always follow instructions to ensure safety.

CAUTION:
* Do not touch any bare cables that may have high-voltage. If a cable must be touched or if accidental contact is possible, wear insulated gloves and insulate the cable using insulating tape.
* Visually check the HV battery and the immediate area for any electrolyte leakage. Do not touch any leaked liquid because it could be organic electrolyte that contains carbonic acid esters.
* The electrolyte is flammable. Keep all ignition sources such as open flame and hot objects away from the electrolyte.
* Electrolyte leaks may cause acute poisoning if a high concentration of the vapor from the organic solvent is inhaled. In case of inhalation, move the affected person to a place with ample fresh air and let them lie quietly. Seek medical care.
* In case of skin contact with the electrolyte, wash the area thoroughly with soap and plenty of water, and seek medical care. Immediately remove any contaminated clothing. Prolonged contact with the electrolyte may cause skin irritation.
* If the electrolyte comes in contact with your eyes, call out loudly for help. Do not rub your eyes. Immediately flush them with a large amount of water for at least 15 minutes and seek medical care.
* If electrolyte is swallowed, seek medical care immediately. Do not induce vomiting, unless instructed by the doctor.
(1) Wear insulated or rubber gloves, goggles, and safety shoes.

(2) Check the HV battery and immediate area for any electrolyte leakage.

CAUTION:
Do not touch any leaked liquid because it could be the organic electrolyte that contains carbonic acid esters. If contact is unavoidable, wipe the fluid off using a cloth while wearing rubber gloves, goggles and an organic solvent mask. Do not leave electrolyte-contaminated cloths unattended. Place contaminated cloths in an appropriate airtight container and dispose of them according to local regulations.

(3) Do not touch any bare cables that could be high voltage cables. If a cable must be touched or if accidental contact is possible, follow the following instructions: 1) wear insulated gloves and goggles, 2) measure the voltage between the cable and body ground using an electrical tester, and 3) insulate the cable using insulating tape.

(4) If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the procedure below.

CAUTION:
Do not touch any bare cables that may have high-voltage. If a cable must be touched or if accidental contact is possible, wear insulated gloves and insulate the cable using insulating tape.

(5) Turn the power switch off.

(6) Disconnect the cable from the negative (-) auxiliary battery terminal.

(7) Wear insulated gloves, and then remove the service plug.

NOTICE:
After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

(g) Precautions to be taken when disposing of an HV battery

(1) When disposing of an HV battery, make sure to return it through an authorized collection agent who is capable of handling it safely. If the HV battery is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.

CAUTION:
* Before returning the HV battery, make sure to perform recovery inspection Testing and Inspection.
* Accidents such as electric shock may result if the HV battery is disposed of improperly or abandoned. Therefore, make sure to return all HV batteries through an authorized collection agent.
* To reduce the risk of fire, the HV battery must not be stored in an area where it will be exposed to fire or high temperatures.
(h) Precautions to be observed when towing

(1) Tow the damaged vehicle with its front and rear wheels lifted off the ground.

CAUTION:
Towing the damaged vehicle with its front wheels on the ground will cause the motor to generate electricity. This electricity could, depending on the nature of the damage, leak and cause a fire.

(i) Towing with the 4 wheels on the ground

CAUTION:
* If the vehicle needs to be towed using a rope with all 4 wheels on the ground, do not exceed 30 km/h (19 mph) and tow only for a short distance and then have the vehicle towed by a truck.
* Turn the power switch on (IG), move the shift lever to N and confirm that neutral (N) has been selected.
* Make sure not to turn the power switch off while the vehicle is being towed. Park (P) may be selected, while being towed can result in damage or an accident.
* If any abnormality is present in the damaged vehicle while towing, stop towing immediately.
HINT
* Neutral (N) cannot be selected if the auxiliary battery is disconnected.
* There is a possibility that neutral (N) cannot be selected when parts related to the transmission control ECU have a malfunction.