Toyota iQ EV Dismantling Manual Download Page 32

Page: 32 / 34

29. REMOVE BATTERY COOLING PLATE

(1) Remove the 2 clips and the battery cooling

plate from the EV battery duct sub-assembly.

30. REMOVE EV BATTERY DUCT

SUB-ASSEMBLY

(1) Remove the nut and disconnect the EV battery

duct sub-assembly from the vehicle.

(2) Loosen the hose clip and remove the EV

battery duct sub-assembly from the No. 6 EV

battery exhaust duct.

31. REMOVE NO. 6 EV BATTERY EXHAUST

DUCT

(1) Remove the bolt and disconnect the No. 6 EV

battery exhaust duct from the No. 2 battery

cooling bracket.

Summary of Contents for iQ EV

Page 1: ...iQ EV Electric Vehicle ELECTRIC VEHICLE DISMANTLING MANUAL KPJ10 Series ...

Page 2: ...re the high voltage approximately 277 5 Volt Lithium ion Li ion Electric Vehicle EV battery assembly is kept safe and secure in an accident The Li ion EV battery assembly contains sealed batteries that are similar to rechargeable batteries used in some battery operated power tools and other consumer products The electrolyte is absorbed in the cell plates and will not normally leak out even if the ...

Page 3: ...tric Vehicle EV Battery Assembly and Auxiliary Battery 9 EV Battery Assembly 9 Components Powered by the EV Battery Assembly 9 EV Battery Assembly Recovery 10 Auxiliary Battery 10 High Voltage Safety 11 High Voltage Safety System 11 Service Plug Grip 12 Precaution to be observed when dismantling the vehicle 13 Necessary Items 13 Spills 14 Dismantling the vehicle 15 Removal of EV Battery Assembly 2...

Page 4: ...e warning light has come on will take approximately 7 for U S A or 4 for General hours When the EV battery assembly is charged at charging stations utilizing charge cable assembly it will take approximately 3 hours o During driving when the Li ion battery is sufficiently charged the vehicle will drive using electric power only p During deceleration such as when braking the vehicle regenerates kine...

Page 5: ...assist in identification The alphanumeric 17 character Vehicle Identification Number VIN is provided in the front windshield cowl for U S A under the right side front seat and on the left side B pillar Example VIN JTNJVXB00C2020211 for U S A JTNJVSB00C2020211 for General An iQ EV is identified by the first 8 alphanumeric characters JTNJVXB0 or JTNJVSB0 Left Side Windshield Cowl for U S A Left Side...

Page 6: ... logo on the recharge inlet door q Recharge inlet door located on the driver side front upper grille Exterior Left Side View Exterior Front View Exterior Rear View Exterior Rear and Left Side View o For General For U S A n q p For U S A For General p For U S A For General q For U S A o n For General n n 3 ...

Page 7: ...ning lights located in the dash behind the steering wheel is different than the one on the conventional non electric iQ Hint If the vehicle is shut off the instrument cluster gauges will be blacked out not illuminated Interior View Instrument Cluster View r r READY Indicator Plug in Indicator EV System Indicator Driving Range and Battery Gauge 4 ...

Page 8: ...iQ EV Identification Continued Motor Compartment s Logo on the plastic cover t Orange colored high voltage power cables Motor Compartment View Power Cables s t t 5 ...

Page 9: ...ck charging These cables also carry 3 phase Alternating Current AC between the inverter converter and electric motor Inverter Converter q Motor Compartment Inverts the high voltage DC electricity from the EV battery assembly to 3 phrase AC electricity to drive the electric motor The inverter converter also converts AC electricity from the electric motor regenerative braking to DC that recharges th...

Page 10: ...axle Automatic Only EV Battery Assembly 277 5 Volt Sealed Li ion Battery Curb Weight 2 425 lbs 1 100 kg for U S A 2 381 lbs 1 080 kg for General Frame Material Steel Unibody Body Material Steel Panels Seating Capacity 4 passengers Electric Vehicle Components Components Top View and High Voltage Power Cables o qt p s r p s o t q r n 7 ...

Page 11: ...r provided in the instrument cluster When lit it informs the driver that the vehicle is on and operational even though the motor compartment is silent Vehicle Operation With the iQ EV the system is operational while the READY indicator is on Never assume that the vehicle is shut off just because the motor compartment is silent Always look for the READY indicator status The vehicle is shut off when...

Page 12: ...trolyte used in the Li ion battery cells is a flammable organic electrolyte The electrolyte is absorbed into the battery cell separator and will not normally leak even in a collision EV Battery Assembly Battery assembly voltage 277 5 V Number of Li ion battery cells in the battery 150 Li ion battery cell voltage 3 7 V Li ion battery cell dimensions Length x Width x Height 4 13 x 5 83 x 1 04 in 105...

Page 13: ...ery This 12 Volt auxiliary battery powers the vehicle electrical system similar to a conventional vehicle As with other conventional vehicles the negative terminal of the auxiliary battery is grounded to the metal chassis of the vehicle The auxiliary battery is located in the motor compartment 277 5 Volt EV Battery Assembly 12 Volt Auxiliary Battery Mounted in Motor Compartment EV Battery Assembly...

Page 14: ...ving the EV battery assembly WARNING The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled To prevent serious injury or death from severe burns or electric shock avoid touching cutting or opening any orange high voltage power cable or high voltage component Both positive and negative power cables o are insulated from the metal body High voltage e...

Page 15: ...nverter Converter A C Compressor Electric Motor Battery Charger Controller Charger Assembly p Volt DC 00 Volt DC n EV Battery Assembly EV Battery Assembly Electric Vehicle Computer 12 Volt Auxiliary Battery Volt DC Volt DC 277 5 277 5 00 00 Volt DC 00 Volt DC Volt DC 00 A C Compressor Inverter Converter Electric Motor Volt DC 00 00 AC 3 Phase 270 V Volt DC Charger Assembly Battery Charger Controll...

Page 16: ...ge high voltage power cable or high voltage component Necessary Items Protective clothing such as insulated gloves electrically insulated rubber gloves safety goggles and safety shoes Insulating tape such as electrical tape that has a suitable electrical insulation rating Before wearing insulated gloves make sure that they are not cracked ruptured torn or damaged in any way Do not wear wet insulat...

Page 17: ...s organic electrolyte Only a small amount may leak from the batteries which may irritate the eyes nose throat and skin Contact with the vapor produced by the electrolyte may irritate the nose and throat To avoid injury by coming in contact with the electrolyte or vapor wear personal protective equipment for organic electrolyte including SCBA or protective mask for organic gases Handle Li ion elect...

Page 18: ...shock avoid touching cutting or opening any orange high voltage power cable or any high voltage component 1 Shut off the ignition READY indicator is off Then disconnect the cable from the auxiliary battery negative terminal 1 Open the hood 2 Disconnect the auxiliary battery negative terminal 2 Remove the center floor hole cover 1 Move the front seat assembly LH to the rearmost position 2 Turn back...

Page 19: ...from accidentally reconnecting it while you are servicing the vehicle After removing the service plug grip wait for at least 10 minutes before touching any of the high voltage connectors or terminals After waiting for 10 minutes check the voltage at the terminals in the inspection point in the inverter with converter assembly The voltage should be 0 V before beginning work Notice Turning the power...

Page 20: ...t be removed due to damage to the vehicle remove the IG2 fuse 10 A red colored Caution This operation shuts off the EV system Be sure to wear insulated gloves because high voltage is not shut off inside the EV battery When it is possible to remove the service plug grip remove it and continue the procedure IG2 fuse 10 A Red 7 After disconnecting or exposing a high voltage connector or terminal insu...

Page 21: ... may leak from the batteries which may irritate the eyes nose throat and skin Contact with the vapor produced by the electrolyte may irritate the nose and throat To avoid injury by coming in contact with the electrolyte or vapor wear personal protective equipment for organic electrolyte including SCBA or protective mask for organic gases 9 If the electrolyte comes into contact with your eye s call...

Page 22: ...19 ...

Page 23: ...ng any high voltage terminals which are not insulated The SRS may remain powered for up to 90 seconds after the vehicle is shut off or disabled To prevent serious injury or death from unintentional SRS deployment avoid cutting the SRS components 1 SHUT OFF IGINITION READY indicator is off 2 REMOVE 12 V AUXILIARY BATTERY 1 Open the hood 2 Disconnect the cable from the auxiliary battery negative ter...

Page 24: ...ally reconnecting it while you are servicing the vehicle After removing the service plug grip wait for at least 10 minutes before touching any of the high voltage connectors or terminals After waiting for 10 minutes check the voltage at the terminals in the inspection point in the inverter with converter assembly The voltage should be 0 V before beginning work Notice Turning the power switch to RE...

Page 25: ...ge inlet terminal Standard voltage 0 V Hint Use measuring range of DC 750 V or more on the voltmeter 7 DISCONNECT DC CHARGER INLET CABLE w Quick Charging Inlet Caution Wear insulated gloves 1 Using a screwdriver move the 2 lock levers as shown in the illustration and disconnect the 2 DC charger inlet cable connectors from the EV charger wire Lock Lever 8 DISCONNECT EV CHARGER WIRE w Quick Charging...

Page 26: ...e inverter with converter assembly Notice Make sure to pull the upper inverter cover sub assembly straight up to remove it because an interlock connector is connected to the bottom of the upper inverter cover sub assembly Interlock Connector 11 CHECK TERMINAL VOLTAGE for Inverter Caution Wear insulated gloves 1 Using a voltmeter measure the voltage of the high voltage inlet terminal Standard volta...

Page 27: ... 1 Remove the 6 clips and the front floor cover RH 15 REMOVE REAR MOTOR SIDE UNDER COVER ASSEMBLY LH 1 Remove the 2 clips and the rear motor side under cover assembly LH 16 REMOVE NO 4 FRAME CROSSMEMBER REINFORCEMENT LH 1 Remove the 2 bolts from the No 4 frame crossmember reinforcement LH 2 Disengage the guide and remove the No 4 frame crossmember reinforcement LH from the electric vehicle battery...

Page 28: ... for the No 2 side as for the No 3 side 20 DISCONNECT WIRE HARNESS CLAMP w o Quick Charging Inlet Caution Wear insulated gloves 1 Separate the 2 wire harnesses of the electric vehicle battery assembly shown in the illustration from the wire harness clamp 21 DISCONNECT WIRE HARNESS CLAMP w Quick Charging Inlet Caution Wear insulated gloves 1 Separate the 3 wire harnesses of the electric vehicle bat...

Page 29: ...lectric vehicle battery assembly connectors from the frame wire Notice Cover the connectors of the frame wire and the electric vehicle battery assembly connector with tape that does not leave adhesive residue to prevent foreign matter or water droplets from entering Lock Lever 24 DISCONNECT NO 2 FRAME WIRE Caution Wear insulated gloves Lock 1 Disengage the clamp and disconnect the electric vehicle...

Page 30: ...n the hose clip and remove the No 3 EV battery intake duct from the battery cooling blower 26 REMOVE REAR BUMPER SIDE SEAL LH 1 Remove the 4 clips and the rear bumper side seal LH 27 REMOVE REAR BUMPER SIDE SEAL RH Hint Use the same procedure as for the LH side 28 REMOVE REAR BUMPER COVER 1 Using a T30 TORX socket wrench remove the 2 rear bumper cushions 27 ...

Page 31: ...ng a screwdriver with its tip wrapped in protective tape disengage the 2 claws Front 4 Disengage the 10 claws and remove the rear bumper cover 5 Disconnect the 2 license plate light connectors and remove the rear bumper cover 28 ...

Page 32: ...T SUB ASSEMBLY 1 Remove the nut and disconnect the EV battery duct sub assembly from the vehicle 2 Loosen the hose clip and remove the EV battery duct sub assembly from the No 6 EV battery exhaust duct 31 REMOVE NO 6 EV BATTERY EXHAUST DUCT 1 Remove the bolt and disconnect the No 6 EV battery exhaust duct from the No 2 battery cooling bracket 29 ...

Page 33: ...tery assembly 32 REMOVE ELECTRIC VEHICLE BATTERY ASSEMBLY Caution Wear insulated gloves Because the electric vehicle battery assembly is extremely heavy make sure to follow the work procedure carefully and maintain proper balance when installing or removing it in order to prevent accidents and injuries 1 Remove the 4 bolts shown in the illustration from the electric vehicle battery assembly 30 ...

Page 34: ... battery assembly 3 Remove the 12 bolts and remove the electric vehicle battery assembly from the vehicle Caution After removing the HV battery do not reinstall the service plug grip to the HV battery Engine Lifter Support Point HV Battery Caution Label 31 ...

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