2018 Toyota Prius Prime AdvancedFACTORY OEM SERVICE PROCEDURE

Precaution [07/2020 - ]

  1. PRECAUTIONS FOR INSPECTING PLUG-IN CHARGE CONTROL SYSTEM 
    1. Before the following operations are conducted, take precautions to prevent electric shock by turning the power switch off, wearing insulated gloves, and removing the service plug grip from HV battery.
      Fig 1: Wear Insulated Gloves
      GTY588386Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Inspecting the high-voltage system
      • Disconnecting the low voltage connector of the inverter with converter assembly
      • Disconnecting the low voltage connector of the HV battery
      • Disconnecting the low voltage connector of the electric vehicle charger assembly
      GTY730777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

        Refer to PRECAUTION [05/2019 - ]

      • 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 information.
    2. To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.
      Fig 2: Do Not Service The Vehicle Before Cutting Of The High-Voltage Circuit
      GTY687067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.
      Fig 3: Do Not Leave Service Plug Grip Accessible To Other Technicians
      GTY703958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. After removing the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals.

      HINT: 

      Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

      Fig 4: Do Not Service Vehicle Before Waiting At Least 10 Minutes After Discharging High Voltage Capacitor
      GTY698431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Without waiting for 10 minutes
    5. Check the voltage at the terminals in the inspection point in the inverter with converter assembly.
      WARNING:

      Be sure to wear insulated gloves.

      1. Remove the connector cover assembly from the inverter with converter assembly.

        Refer to REMOVAL [07/2020 - ]

        GTY729487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Do not touch the connector cover assembly waterproof seal.
        • Do not allow any foreign matter or water to enter the inverter with converter assembly.
      2. Measure the voltage according to the value(s) in the table below.
        Fig 5: Measuring Voltage Between Terminals Of Phase Connectors
        GTY541774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard Voltage

        Tester Connection Condition Specified Condition
        Inspection point At least 10 minutes after removing the service plug grip 0 V

        HINT: 

        Set the tester to DC750 V or more to measure the voltage.

      3. Reinstall the connector cover assembly.
    6. When turning the power switch on (IG) during an inspection, do not press the power switch with the brake pedal depressed.
      WARNING:

      Pressing the power switch with the brake pedal depressed causes the system to enter the READY-on state. This is very dangerous because high voltage may be applied to the inspection area.

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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