Part 1 of 2

PRECAUTION

1. WORK PRECAUTIONS
a. VEHICLE PROTECTION







1. When welding, cover glass, seats, carpets, etc. with heat resistant fireproof covers to protect them.

b. SAFETY







1. Never stand in the path of the chain when using a puller on the body or frame, and be sure to attach a safety cable.







2. If it is necessary to use a frame in the area of the fuel tank, first remove the tank and plug the fuel line.

c. SAFETY WORK CLOTHES







1. In addition to the usual mechanic's wear, cap and safety shoes, the appropriate gloves, head protector, welder's glasses, ear plugs, face protector, dust mask, etc. should be worn as the situation demands.

2. PRECAUTIONS WHEN REPAIRING BODY FRAME PARTS (INCLUDING CRUSH BOX)
a. PROHIBITION OF HEAT REPAIR FOR BODY FRAME PARTS







1. Rustproof high strength steel sheets are used for the body frame. Therefore, if these parts are heat repaired using an acetylene torch or equivalent, the crystalline structure changes, causing the strength of the steel sheets to decrease. Also, the zinc coating which is used to protect the body from rust will be damaged. This causes the surface of the steel sheets to become oxidized, which reduces their ability to resist rust.

b. NOTES ON ULTRA HIGH STRENGTH STEEL PANEL REPAIR
1. Make sure that the frame aligning machine does not affect undamaged areas when aligning the frame.







2. Do not butt weld because the heat decreases the strength of the steel.
3. Use a spot cutter suitable for high strength steel when removing spot welds. The cutter should be able to cut welding nuggets smoothly.
4. Always follow the welding instructions when welding.







5. Do not heat the panel when repairing.

c. WHEN TO REPLACE FRAME PARTS







NOTICE: Replace the sections of the frame where kinks have occurred.

HINT: What is kink?

A deformation on a steel sheet that cannot be returned to its original shape by pulling or hammering due to the deformation angle being sharp.

d. REPAIR OF DOOR SIDE IMPACT BEAM IS PROHIBITED










1. The impact beam is designed so that it performs at 100% in its original shape.
However, if the impact beam is repaired, its performance may not be the same as before the accident.

PARTS WHICH ARE PROHIBITED TO BE REPAIRED:
Door side impact beam

e. REPAIR OF BUMPER REINFORCEMENT IS PROHIBITED







1. The bumper reinforcement is designed so that it performs at 100% in its original shape.
However, if the bumper reinforcement is repaired, its performance may not be the same as before the accident.

PARTS WHICH ARE PROHIBITED TO BE REPAIRED:
Bumper reinforcement

3. NOTICE FOR HYBRID SYSTEM
a. 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 manual to handle the system correctly. Failure to do so may result in serious injury or electrocution.

1. Technicians must undergo special training to be able to service and inspect the high-voltage system.
2. 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.
3. 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.
4. 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.

5. After removing the service plug, 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.

6. Before using insulated gloves, be sure to check them for cracks, tears and other types of damage by performing the following procedure.







7. When servicing the vehicle, do not carry metal objects like mechanical pencils or rulers that can be dropped accidentally and cause a short circuit.
8. Before touching a bare high-voltage terminal, wear insulated gloves and use a tester to make sure that the terminal voltage is 0 V.







9. After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulating tape.
10. Bolts and nuts high-voltage terminals should be tightened firmly to the specified torque. Both insufficient and excessive torque can cause failure.
11. Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION" sign to notify other technicians that the high-voltage system is being inspected and/or repaired.







12. 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.
13. When installing hybrid system components such as the HV battery, make sure that the polarity of all connections is correct.

b. ACTIONS TO BE TAKEN FOR VEHICLES DAMAGED BY IMPACT

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 manual to handle the system correctly. Failure to do so may result in serious injury or electrocution.

1. Items to be prepared for the accident site
- Protective clothing (insulated gloves, rubber gloves, goggles, and safety shoes)
- Saturated boric acid solution 20 L (obtain 800 g 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 cable)
- Electrical tester

2. 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 highly alkaline electrolyte.
- Work on the vehicle only after the vehicle has been pulled out of the water.

1. Check the vicinity of the hybrid vehicle battery for any leakage of the electrolyte.

CAUTION: Do not touch any leaked liquid because it could be highly alkaline electrolyte. Wear rubber gloves and goggles, neutralize the liquid with saturated boric acid solution, and then apply red litmus paper to the liquid. Check that the paper does not turn blue. Wipe the neutralized liquid with a shop rag or piece of cloth.

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.










3. Turn the power switch off.

HINT: If the power switch cannot be turned off, remove the IGCT fuse and AM2 fuse from the engine room junction block assembly. Confirm that the READY Light is OFF.

4. Disconnect the cable from the negative terminal of the auxiliary battery.
5. 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.

3. Moving the damaged vehicle
If any of the following conditions are met, tow the vehicle away using a tow truck.
- 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 (-) terminal of the auxiliary battery and remove the service plug.

NOTICE: Perform the procedure below if the READY light turns off, or there are abnormal noises, unusual smells, or strong vibrations while driving:
1. Park the vehicle in a safe place.
2. Push the "P" position switch, and apply the parking brake, and apply the parking brake.
3. Turn the power switch off, and disconnect the power cable from the negative (-) terminal of the auxiliary battery.
4. Remove the service plug while wearing insulated gloves.

4. Actions required after moving the damaged vehicle
1. Procedure
If you see any liquid on the road surface, it could be highly alkaline electrolyte leakage. Wear rubber gloves and goggles, neutralize the liquid with saturated boric acid solution, and then apply red litmus paper to the liquid. Check that the paper does not turn blue. Wipe the neutralized liquid with a shop rag or piece of cloth.

5. Items to be prepared (when repairing a damaged vehicle)
- Protective clothing (Insulated gloves, rubber gloves, goggles, and safety shoes)
- Saturated boric acid solution 20 L (obtain 800 g of boric acid powder, put it into a container, and dissolve it in water)
- Red litmus paper
- A shop rag or piece of cloth (for wiping off the electrolyte)
- Insulating tape (for insulating cables)
- Electrical tester

6. Precautions to be observed when servicing a damaged vehicle

CAUTION: Always follow instructions to ensure safety.

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 highly alkaline electrolyte. Wear rubber gloves and goggles, neutralize the liquid with saturated boric acid solution, and then apply red litmus paper to the liquid. Check that the paper does not turn blue. Wipe the neutralized liquid with a shop rag or piece of cloth.
- If the electrolyte comes in contact with your skin, use a saturated boric acid solution or a large amount of water to wash it off. If the electrolyte comes in contact with an article of clothing, take it off immediately.
- If the electrolyte comes in contact with your eyes, call out loudly for help. Do not rub your eyes. Wash them immediately with a large amount of water and seek medical care.

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 highvoltage 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.

HINT: If the power switch cannot be turned off, remove the IGCT fuse and AM2 fuse from the engine room junction block assembly. Confirm that the READY Light is OFF.

6. Disconnect the cable from the negative terminal of the auxiliary battery.
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.

7. Precautions to be taken when disposing of the vehicle
1. Disposing of HV battery
When scrapping the vehicle, remove the HV battery from the vehicle and return it to the location specified by the manufacturer. Any damaged HV battery should also be returned to the specified location.

CAUTION:
- After removing the HV battery, keep it away from water. Water may heat the battery, resulting in a fire.
- Accidents such as electric shocks could result if the vehicle and its HV battery are disposed of improperly or abandoned. Therefore, make sure to return any HV battery using the prescribed recovery route through a TOYOTA dealer.

8. 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 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.

9. 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) and move the shift lever to N.
- If any abnormality is present in the damaged vehicle during towing, stop towing immediately.

HINT: Park (N) cannot be selected if the auxiliary battery is disconnected.

c. WHEN TOWING VEHICLES
1. Use one of the following methods to tow the vehicle.
2. If the vehicle has trouble with the chassis or drive train, use method 1 (flatbed truck).







3. If a tow truck is not available, in an emergency vehicle may be temporarily towed using a cable or chain secured to the emergency towing eyelet(s). This should only be attempted on hard surfaced roads for short distances below 30 km/h (19 mph).
A driver must be in the vehicle to steer and operate the brakes. The vehicle's wheels, drive train, axles, steering and brakes must be in good condition.
1. Emergency towing procedure
i. Turn the power switch on (IG).
ii. Depress the brake pedal and move the selector lever to N.
iii. Release the parking brake.
iV. Release the brake pedal slowly.

NOTICE:
- Use extreme caution when towing the vehicle.
Avoid sudden starts or erratic driving maneuvers which place excessive stress on the emergency towing eyelet and the cables or chains.
- If the hybrid system is off, the power assist for the brakes and steering will not function, making steering and braking more difficult.







4. The following towing methods shown below are dangerous and can damage the vehicle, so do not use them.
1. Do not tow the vehicle with only front wheels on the ground.
2. Do not use a sling-type towing method either from the front or rear.

NOTICE:
- If these towing methods are used either from the front or rear, the following may occur.
- The drive train may overheat and be damaged.
- If a sling-type tow truck is used, damage may occur to the vehicle body.

4. PRECAUTIONS FOR CORRECT REPAIR
a. REMOVAL OF ADJACENT COMPONENTS







1. To prevent damage to the body and parts, apply protective tape to the body and tools before removing the parts.

NOTICE: If the paint film is damaged, make sure to refinish the paint.


b. ANTI-RUST TREATMENT BEFORE WELDING







1. Apply welding primer to the contact surfaces of the welding areas to protect them from rust.

NOTICE: Do not apply welding primer outside of the contact surfaces.

c. WELDING WORK

1. Follow the welding conditions below when welding ultra high strength steel to assure sufficient weld strength.







When welding 2 panels together including 980 MPa ultra high strength steel.







NOTICE: Be sure to use Metal active gas (Ar 80% + CO2 20%) as the shield gas when plug welding. Sufficient weld strength cannot be assured when using 100% CO2 shield gas.







When welding more than 3 panels together including 980 MPa ultra high strength steel. (When plug welding a panel to the welded panels with the weld condition above.)







NOTICE: Be sure to use Metal active gas (Ar 80% + CO2 20%) as the shield gas when plug welding. Sufficient weld strength cannot be assured when using 100% CO2 shield gas.

2. Standard Number of Welds







NOTICE: Inspect the welds after spot welding. For points with insufficient weld strength join the panels using plug welds.







3. Spot weld locations
Avoid welding over previously welded areas.


d. MAKING HOLES FOR PLUG WELDING







1. For areas where a spot welder cannot be used, use a puncher or drill to make holes for plug welding.







5. ANTI- RUST TREATMENT AFTER INSTALLATION
a. BODY SEALER APPLICATION







PURPOSE:
For water-proofing and anti-rust measures, always apply the body sealer to the body panel seams and hems of the doors, hood, etc.

NOTICE: Apply body sealer neatly to parts that require a high quality appearance.

b. UNDERCOAT APPLICATION







PURPOSE:
To prevent corrosion and protect the body from gravel, always apply a sufficient undercoating to the areas indicated.

c. VEHICLE BODY ANTI- RUST AGENT APPLICATION







PURPOSE:
The purpose is to protect areas from rust which are difficult to paint such as the backside of the box-shaped cross section frame parts.
METHOD:
Apply anti-rust agent through the service holes and/or installation holes of the parts.