2001 Toyota PriusFACTORY OEM SERVICE PROCEDURE

For All Of Vehicles: Precaution

  1. Precautions For High-Voltage Circuit Inspection And Service 
    1. Engineers to be engaged in inspection and servicing related to high-voltage systems should undergo special training.
    2. All the high-voltage wire harness connectors are colored orange: the HV battery and other high-voltage components are identified by the "High Voltage" caution labels. Do not carelessly touch these wires and components.
      Fig 1: Removing Service Plug
      G02805514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Before inspecting or servicing the high-voltage system, be sure to take 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 reinstalling it while you are servicing the vehicle.
      4. NOTE: The 5 minutes are required to discharge the high-voltage condenser inside the inverter.
    4. After removing the service plug, wait 5 minutes before touching any of the high-voltage connectors and terminals.
    5. Before wearing insulated gloves, make sure that they are not cracked, ruptured, torn, or damaged in any other way. Do not wear wet insulated gloves.
    6. When servicing the vehicle, do not wear a metal object like a mechanical pencil or scale that may drop accidentally and cause a short circuit.
    7. Before touching a bare high-voltage terminal, wear insulated gloves and ensure that the terminal is not charged with electricity (approx. 0 V) using an electrical tester.
      Fig 2: Insulating High Voltage Connector With Tape
      G02805516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulation tape.
    9. The screw of a high-voltage terminal should be tightened firmly to the specified torque. Both insufficient and excessive tightening torque can cause failure.
    10. Call other engineers' attention to the vehicle which high-voltage system is being inspected or repaired by hanging a "High Voltage Operation in Progress. Do Not Touch" sign (See Fig 3).
    11. 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 terminal screws are firmly tightened, and that the connectors are correctly engaged.
    Fig 3: High Voltage Circuit Inspection And Service
    G02805517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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  • • You are missing required tools, torque specs, or safe lifting equipment.
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