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Foreword

This guide was developed to educate and assist dismantlers in the safe handling of Toyota C-HR Hybrid

gasoline-electric hybrid vehicles. C-HR Hybrid dismantling procedures are similar to other non-hybrid

Toyota vehicles with the exception of the high voltage electrical system. It is important to recognize

and understand the high voltage electrical system features and specifications of the Toyota C-HR Hybrid,

as they may not be familiar to dismantlers.

High voltage electricity powers the electric motor, generator, Air Conditioning (A/C) compressor and

inverter/converter. All other automotive electrical devices such as the head lights, radio, and gauges

are powered from a separate 12 Volt auxiliary battery. Numerous safeguards have been designed into

the C-HR Hybrid to help ensure the high voltage, approximately 201.6 Volt, Nickel Metal Hydride

(NiMH) Hybrid Vehicle (HV) battery pack is kept safe and secure in an accident.

The NiMH HV battery pack 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 battery is cracked. In the unlikely event the electrolyte

does leak, it can be easily neutralized with a dilute boric acid solution or vinegar.

High voltage cables, identifiable by orange insulation and connectors, are isolated from the metal chassis

of the vehicle.

Additional topics contained in the guide include:

Toyota C-HR Hybrid identification.

Major hybrid component locations and descriptions.

By following the information in this guide, dismantlers will be able to handle C-HR Hybrid

hybrid-electric vehicles as safely as the dismantling of a conventional gasoline engine automobile.

2017 Toyota Motor Corporation All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of Toyota Motor Corporation.

iii

Table of Contents

About the C-HR Hybrid ............................................................................................................................ 1

C-HR Hybrid Identification ..................................................................................................................... 2 Exterior ......................................................................................................................................................... 3 Interior ........................................................................................................................................................... 4 Engine Compartment .................................................................................................................................... 5

Hybrid Component Locations & Descriptions ........................................................................................ 6 Specifications ................................................................................................................................................ 7

Hybrid Synergy Drive Operation ............................................................................................................. 8 Vehicle Operation .......................................................................................................................................... 8

Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery ..................................................................... 9 HV Battery Pack ............................................................................................................................................ 9 Components Powered by the HV Battery Pack............................................................................................. 9 HV Battery Pack Recycling ......................................................................................................................... 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 a vehicle............................................................................................................................... 15

Removal of HV battery ........................................................................................................................... 20

1

About the C-HR Hybrid The C-HR Hybrid 5-door hatchback joins the hybrid model for Toyota. Hybrid Synergy Drive means that the vehicle contains a gasoline engine and an electric motor for power. The two hybrid power sources are stored on board the vehicle:

1. Gasoline stored in the fuel tank for the gasoline engine. 2. Electricity stored in a high voltage Hybrid Vehicle (HV) battery pack for the

electric motor. The result of combining these two power sources is improved fuel economy and reduced emissions. The gasoline engine also powers an electric generator to recharge the battery pack; unlike a pure all electric vehicle, the C-HR Hybrid never needs to be recharged from an external electric power source. Depending on the driving conditions one or both sources are used to power the vehicle. The following illustration demonstrates how the C-HR Hybrid operates in various driving modes. During light acceleration at low speeds, the vehicle is powered by the electric motor.

The gasoline engine is shut off. During normal driving, the vehicle is powered mainly by the gasoline engine.

The gasoline engine also powers the generator to recharge the battery pack and to drive the motor.

During full acceleration, such as climbing a hill, both the gasoline engine and the

electric motor power the vehicle. During deceleration, such as when braking, the vehicle regenerates kinetic energy

from the front wheels to produce electricity that recharges the battery pack. While the vehicle is stopped, the gasoline engine and electric motor are off, however

the vehicle remains on and operational.

Starting Normal Driving Acceleration Deceleration Stopping

Electricity Electricity and gasoline Electricity and gasoline (additional electricity extracted from batteries)

Charging batteries Engine automatically stopped

2

C-HR Hybrid Identification In appearance, the 2017 model year C-HR Hybrid is nearly identical to the conventional, non-hybrid Toyota C-HR. The C-HR Hybrid is a 5-door hatchback. Exterior, interior, and engine compartment illustrations are provided to assist in identification. The alphanumeric 15 character Vehicle Identification Number (VIN) is provided on the floor under the right side front seat and on the left side B pillar.

Example VIN: MR2KZ3BX3000000 A C-HR Hybrid is identified by the first 8 alphanumeric characters MR2KZ3BX.

Under the Right Side Front Seat and Left Side B Pillar

C-H Exter

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ar quarter pan

Side View

Side View

fender.

nel.

4

C-HR Hybrid Identification (Continued) Interior

The instrument cluster (hybrid system indicator, READY indicator, and warning lights) located in the dash behind the steering wheel, is different than the one on the conventional, non-hybrid C-HR.

In place of a tachometer, a hybrid system indicator is used to show power output.

Notice: If the vehicle is shut off, the instrument cluster gauges will be “blacked out”, not illuminated.

Interior View

Combination Meter View

READY Indicator

C-HR Engi 1.8 Or

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6

Hybrid Component Locations & Descriptions

Component Location Description

12 Volt Auxiliary Battery

Engine Compartment

Supplies electricity to the electrical components.

Hybrid Vehicle (HV) Battery Pack

Cabin Area, Mounted Under Rear Seat

• Supplies electrical power to MG1 and MG2 in accordance with the driving conditions of the vehicle.

• Recharged by MG1 and MG2 in accordance with the SOC and the driving conditions of the vehicle.

Power Cables Undercarriage and Engine Compartment

Connects the HV battery, inverter with converter assembly, hybrid vehicle transaxle assembly and compressor with motor assembly.

Inverter/ Converter

Engine Compartment

• Converts the direct current from the boost converter into alternating current for MG1 and MG2, and vice versa (from AC to DC).

• Boosts the HV battery nominal voltage of DC 201.6 V up to a maximum voltage of DC 600 V and vice versa (steps down DC 600 V to DC 201.6 V).

Gasoline Engine

Engine Compartment

Provides two functions: 1) Powers vehicle. 2) Powers generator to recharge the HV battery pack. The engine is started and stopped under control of the vehicle computer.

Electric Motor Engine Compartment

• MG2, which is driven by electrical power from MG1 and the HV battery, generates motive force for the drive wheels.

• During braking, or when the accelerator pedal is not depressed, it generates high-voltage electricity to recharge the HV battery.

Electric Generator

Engine Compartment

MG1, which is driven by the engine, generates high-voltage electricity in order to operate MG2 and charge the HV battery. Also, it functions as a starter to start the engine.

A/C Compressor (with Inverter)

Engine Compartment

3-phase high voltage AC electrically driven motor compressor.

DC-DC Converter for 12 Volt Auxiliary Battery

Engine Compartment

Steps down the HV battery nominal voltage of DC 201.6 V to approximately DC 14 V in order to supply electricity to the electrical components, as well as to recharge the auxiliary battery.

Fuel Tank and Fuel Line

Undercarriage and Center

The fuel tank provides gasoline via a fuel line to the engine. The fuel line is routed under the center of vehicle.

*Numbers in the component column apply to the illustrations on the following page.

7

Hybrid Component Locations & Descriptions (Continued) Specifications Gasoline Engine: 70 kW, 1.8-liter Aluminum Alloy Engine

Electric Motor: 53 kW, Permanent Magnet Motor Transmission: Automatic Only

HV Battery: 201.6 Volt Sealed NiMH Battery Curb Weight: 3,042 – 3,219 lbs / 1,380 - 1,460 kg

Fuel Tank: 9.5 gals / 43.0 liters

Frame Material: Steel Unibody

Body Material: Steel Panels

Seating Capacity: 5 passenger

8

Hybrid Synergy Drive Operation Once the READY indicator is illuminated in the instrument cluster, the vehicle may be driven. However, the gasoline engine does not idle like a typical automobile and will start and stop automatically. It is important to recognize and understand the READY indicator provided in the instrument cluster. When illuminated, it informs the driver that the vehicle is on and operational even though the gasoline engine may be off and the engine compartment is silent. Vehicle Operation With the C-HR Hybrid, the gasoline engine may stop and start at any time while the

READY indicator is on. Never assume that the vehicle is shut off just because the engine is off. Always look for

the READY indicator status. The vehicle is shut off when the READY indicator is off. The vehicle may be powered by:

1. The electric motor only. 2. A combination of both the electric motor and the gasoline engine.

Combination Meter READY Indicator

9

Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery The C-HR Hybrid features a high voltage Hybrid Vehicle (HV) battery pack that contains sealed Nickel Metal Hydride (NiMH) battery modules. HV Battery Pack The HV battery pack is enclosed in a metal case and is rigidly mounted to the cabin area

under the rear seat. The metal case is isolated from high voltage and concealed by carpet in the cabin area.

The HV battery pack consists of 28 low voltage (7.2 Volt) NiMH battery modules

connected in series to produce approximately 201.6 Volts. Each NiMH battery module is non-spillable and sealed in a metal case.

The electrolyte used in the NiMH battery module is an alkaline mixture of potassium and

sodium hydroxide. The electrolyte is absorbed into the battery cell plates and will not normally leak, even in a collision.

HV Battery Pack Battery pack voltage 201.6 V Number of NiMH battery modules in the pack 28 NiMH battery module voltage 7.2 V

Components Powered by the HV Battery Pack

Electric Motor Inverter/Converter Power Cables A/C Compressor Electric Generator DC-DC Converter for 12 Volt Auxiliary Battery

10

Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery (Continued) HV Battery Pack Recycling The HV battery pack is recyclable. Contact either your Toyota distributor as mentioned on

HV Battery Caution Label or the nearest Toyota dealer. Auxiliary Battery The C-HR Hybrid contains a sealed lead-acid 12 Volt battery. 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 engine compartment area. It is concealed by a

plastic cover on the left side in the battery compartment.

201.6 Volt HV Battery Pack 12 Volt Auxiliary Battery Mounted in Engine

Compartment Area

HV Battery Pack Mounted in Cabin Area

11

High Voltage Safety The HV battery pack powers the high voltage electrical system with DC electricity. Positive and negative orange colored high voltage power cables are routed from the battery pack, under the vehicle floor pan, to the inverter/converter. The inverter/converter contains a circuit that boosts the HV battery voltage from 201.6 to 600 Volts DC. The inverter/converter creates 3-phase AC to power the motor. Power cables are routed from the inverter/converter to each high voltage motor (electric motor, electric generator, and A/C compressor). The following systems are intended to help keep occupants in the vehicle and emergency responders safe from high voltage electricity: High Voltage Safety System A high voltage fuse * provides short circuit protection in the HV battery pack. Positive and negative high voltage power cables * connected to the HV battery pack are

controlled by 12 Volt normally open relays *. When the vehicle is shut off, the relays stop electrical flow from leaving the HV battery pack.

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 breaching any orange high voltage power cable or high voltage component.

Both positive and negative power cables * are insulated from the metal body. High

voltage electricity flows through these cables and not through the metal vehicle body. The metal vehicle body is safe to touch because it is insulated from the high voltage components.

A ground fault monitor in the hybrid vehicle computer * continuously monitors for high

voltage leakage to the metal chassis while the vehicle is running. If a malfunction is

detected, the hybrid vehicle computer * will illuminate the master warning light in the instrument cluster and a message indicating that the hybrid system is malfunctioning will be displayed on the multi-information display.

The HV battery pack relays will automatically open to stop electrical flow in a collision

sufficient to activate the SRS. *Numbers apply to the illustration on the following page.

12

High Voltage Safety (Continued) Service Plug Grip The high-voltage circuit is cut by removing the service plug grip (see page 15).

High Voltage Safety System – Vehicle Shut Off (READY-OFF)

High Voltage Safety System – Vehicle On and Operational (READY-ON)

HV Battery Pack

Hybrid Vehicle Computer

Volts DC

A/C Compressor

Electric Generator

Electric Motor

0 Volts AC 3-Phase

Inverter/ Converter

12 Volts Auxiliary Battery

Volts DC0.0

➊

➋

➋

❸ ❸

➍0.0

HV Battery Pack

Hybrid Vehicle Computer

Volts DC

A/C Compressor

Electric Generator

201.6

600 Volts AC Max 3-Phase

Inverter/ Converter

201.6Volts DC

12 Volts Auxiliary Battery

Electric Motor

13

Precaution to be observed when dismantling the vehicle

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 breaching any orange 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 insulated gloves. An electrical tester that is capable of measuring DC 750 Volts or more.

14

Spills

The C-HR Hybrid contains the same common automotive fluids used in other non-hybrid Toyota

vehicles, with the exception of the NiMH electrolyte used in the HV battery pack. The NiMH battery

electrolyte is a caustic alkaline (pH 13.5) that is damaging to human tissues. The electrolyte, however,

is absorbed in the cell plates and will not normally spill or leak out even if a battery module is cracked.

A catastrophic crash that would breach both the metal battery pack case and a metal battery module

would be a rare occurrence.

A caustic alkaline is at the opposite end of the pH scale from a strong acid. A safe (neutral) substance

is approximately in the middle of this scale. Adding a weak acidic mixture, such as a dilute boric acid

solution or vinegar, to the caustic alkaline electrolyte will cause the electrolyte to be neutralized. This

is similar but opposite to the use of baking soda to neutralize a lead-acid battery electrolyte spill.

A Toyota Product Safety Data Sheets (PSDS) is attached to this document.

Handle NiMH electrolyte spills using the following Personal Protective Equipment (PPE):

• Splash shield or safety goggles. Fold down helmet shields are not acceptable for acid or

electrolyte spills.

• Rubber, latex or nitrile gloves.

• Apron suitable for alkaline.

• Rubber boots.

Neutralize NiMH electrolyte.

• Use a boric acid solution or vinegar.

• Boric acid solution - 800 grams boric acid to 20 liters water or 5.5 ounces boric acid to 1

gallon of water.

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high voltage

service plug

rder shown in

rter with con

(non-residu

EADY) may

ss instructed

capacitor in

grip and rem

n the illustrat

nverter assem

ue type) or

(3)

d by

nside

move

tion.

mbly

(

(

R6.

A

C

W

(

(2

N

・

C7.

C

W

N

D

th

(

S

H

U

Remove(2)

Disenga(3)

the engi

REMOVE C

ASSEMBL

Caution:

Wear insula

1) Remove

2) Using a T

remove t

assembly

assembly

Notice:

・Do not tou

・Do not allow

CHECK TE

Caution:

Wear insula

Notice:

Do not allow

he inverter w

Using a(1)

between

connect

Standard vo

Hint:

Use measuri

e the bolt.

age the 2 clam

ine wire.

CONNECTO

Y

ated gloves

the bolt (B).

T25 "TORX

the bolt (A) a

y from the in

y.

uch the conn

w any foreig

RMINAL V

ated gloves

any foreign

with convert

a voltmeter, m

n the termina

tors.

oltage: 0 V

ing range of

mps and disc

OR COVER

s.

.

X" socket wre

and connecto

nverter with c

nector cover

gn matter or

VOLTAGE

s.

matter or w

er assembly

measure the v

als of the 2 ph

f DC 750 V o

23

connect

R

ench,

or cover

converter

r assembly w

water to ent

water to ente

y.

voltage

hase

or more on t

waterproof s

ter the inver

er

the voltmete

eal.

ter with conv

er.

verter assem

(B)

(A)

mbly.

R8.

C

(

N

B

a

fr

p

S

(

R9.

H

(

H

U

L

REMOVE B

CUSHION

Lift the (1)

cushion

illustrati

cushion

bench ty

the rear

Notice:

Be sure to ho

assembly dir

rame hooks

part of the cu

Standard M

Area

A

Disenga(2)

seat cus

REMOVE R

HOOK

(1) Disenga

cushion

illustrati

Hint:

Use the sam

LH side.

BENCH TY

ASSEMBL

front edge o

assembly as

ion and disen

frame hooks

ype rear seat

seat cushion

old the parts

rectly next to

when lifting

ushion may

Measureme

age the rear s

hion assemb

REAR SEAT

age the claws

lock hook a

ion.

me procedur

YPE REAR S

LY

f the bench t

s shown in th

ngage the rea

s on the fron

cushion asse

n lock hooks.

s of the seat

o the rear se

g it. Lifting a

deform the r

ent:

Measu

135 mm

seat cushion

bly as shown

T CUSHION

s to remove t

s shown in th

e for the RH

24

SEAT

type rear sea

he

ar seat

nt side of the

embly from

.

t cushion

eat cushion

different

rear seat cu

urement

m (5.31 in.)

frame hook

in the illustr

N LOCK

the rear seat

he

H side and

at

ushion frame

on the rear s

ration.

Place Ha

e.

ide of the be

ands Here

A

Frame Hook

(1)

(2

ench type rea

A

2)

Place Han

ar

nds Here

R10.

(

R11.

(

(

R12.

H

U

R13.

H

U

R14.

(

(

REMOVE R

1) Disengag

scuff pla

REMOVE R

Remove(1)

Disenga(2)

remove

shown i

REMOVE R

Hint:

Use the sam

REMOVE R

Hint:

Use the sam

REMOVE R

Disenga(1)

Disenga(2)

under co

sub-asse

REAR DOO

ge the claws

ate LH as sho

REAR UND

e the 2 crips.

age the clips,

the rear und

in the illustra

REAR DOO

me procedur

REAR UND

me procedur

REAR UND

age the 2 clip

age the 2 gui

over from th

embly.

OR SCUFF P

to remove th

own in the ill

DER SIDE C

, claw and gu

der side cover

ation.

OR SCUFF P

re for the LH

DER SIDE C

re for the LH

DER COVER

ps.

des to remov

e rear seat cu

25

PLATE LH

he rear door

lustration.

COVER LH

uide to

r LH as

PLATE RH

H side.

COVER RH

H side.

R

ve the rear

ushion leg

H

H

H

H

Placee Hands Here

R15.

S

(

R16.

B

(

(

(

(

N

・

R17.

P

C

W

(

H

In

a

s

(

REMOVE R

SUB-ASSE

Remove(1)

leg sub-

REMOVE B

BLOWER A

Disconn(1)

assembl

Disenga(2)

Remove(3)

Disenga(4)

battery c

Notice:

・Be sure no

battery coo

・Do not lift

assembly

REMOVE N

PANEL RH

Caution:

Wear insula

Using th(1)

battery c

Hint:

nsert the pro

and turn the

striker counte

Remove(2)

battery c

battery.

REAR SEAT

EMBLY

e the 6 bolts

-assembly.

BATTERY C

ASSEMBLY

nect the batte

ly connector.

age the 2 clam

e the 3 bolts.

age the 2 claw

cooling blow

ot to touch th

oling blower

the battery c

using the w

NO. 1 HV B

H

ated gloves

he service plu

cover lock st

ojection of th

button of the

erclockwise

e the 3 bolts,

cover panel R

T CUSHION

and rear seat

COOLING

Y

ery cooling b

.

mps.

ws to remove

wer assembly

he fan part o

r assembly.

cooling blow

ire harness.

BATTERY C

s.

ug grip, remo

triker.

he service p

e battery co

to release t

2 nuts and N

RH from the

26

N LEG

t cushion

blower

e the

y.

of the

wer

COVER

move the

plug grip

over lock

the lock.

No. 1 HV

e HV

Button

Turn

Batt

Pr

Service Plug

ttery Cover Lo

rojection

g Grip

ock Striker

D18.

W

C

W

N

In

c

c

e

(

(

D19.

C

W

(

(2

(3

R20.

E

(

(

D21.

C

W

(

(

DISCONNE

WIRE

Caution:

Wear insula

Notice:

nsulate each

connector wi

connector fro

end of the co

Disconn(1)

Disconn(2)

DISCONNE

Caution:

Wear insula

1) Disengag

2) Disconne

assembly

3) Disconne

assembly

REMOVE N

EXHAUST

Remove(1)

Disenga(2)

hybrid b

battery.

DISCONNE

Caution:

Wear insula

Disenga(1)

Disconn(2)

connect

ECT HV FL

ated gloves

h disconnec

ith insulating

om the wire

onnector.

nect the 2 HV

nect the shiel

ECT FLOOR

ated gloves

ge the clamp.

ect the electri

y connector.

ect the HV ba

y connector.

NO. 1 HYBR

T DUCT

e the clip.

age the claw

battery exhau

ECT FLOOR

ated gloves

age the clamp

nect the batte

tor.

LOOR UND

s.

cted high-vol

g tape. Wrap

harness sid

V battery jun

ld ground fro

R WIRE

s.

ic vehicle batt

attery junction

RID BATT

to remove th

ust duct from

R WIRE

s.

p.

ery voltage s

27

DER

ltage

p the

de to the

nction block

om the HV b

tery plug

n block

TERY

he No. 1

m the HV

ensor

assembly co

battery.

nnectors.

Shield Ground

R22.

C

W

(

N

REMOVE H

Caution:

Wear insula

Remove(1)

the vehi

Notice:

Do not a

grease o

HV batte

To preve

harness

Use card

body fro

Since th

removin

When re

vehicle.

When re

80°.

Insulate

HV BATTE

ated gloves

e the 5 bolts

icle.

allow foreign

or oil, to adh

ery.

ent the wire

using insula

dboard or an

om damage.

e HV battery

g the HV ba

emoving the

emoving/inst

the disconn

RY

s.

and HV batt

n matter, suc

here to the b

harness from

ating tape o

nother simila

y is very hea

attery, be car

HV battery

talling/movin

nected termi

28

tery from

ch as

bolts of the

m being cau

r equivalent

ar material t

avy, 2 peopl

reful not to d

from the ve

ng the HV ba

nals or conn

ught, make s

t.

to protect the

le are neede

damage the

hicle, do no

attery, make

nectors with

sure to bund

e HV battery

ed to remove

parts aroun

t allow it to c

e sure not to

insulating ta

dle the wire

y and vehicl

e it. When

nd it.

contact the

o tilt it more t

ape.

e

than