Toyota AVALON Hybrid Dismantling Manual
AVALON Hybrid
Gasoline-Electric
Hybrid Synergy Drive
AVX40 Series
ii
Foreword
This guide was developed to educate and assist dismantlers in the safe handling of Toyota
AVALON Hybrid gasoline-electric hybrid vehicles. AVALON 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 hi gh volt age ele ctri cal system features and
specifications of the Toyota AVALON 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 AVALON Hybrid to help ensure the high voltage, approximately 244.8 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 AVALON Hybrid identification.
Major hybrid component locations and descriptions.
By following the information in this guide, dismantlers will be able to handle AVALON Hybrid
hybrid-electric vehicles as safely as the dismantling of a conventional non-hybrid automobile.
2012 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.
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Table of Contents
About the AVALON Hybrid.........................................................................................................................1
AVALON 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 V oltage 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 HV battery..............................................................................................................................19
HV Battery Caution Label.........................................................................................................................29
1
About the AVALON Hybrid
The AVALON Hybrid 4-door sedan joins the hybrid model lineup 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 AVALON 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 AVALON 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
AVALON Hybrid Identification
In appearance, the 2013 model year AVALON Hybrid is nearly identical to the conventional,
non-hybrid Toyota AVALON. The AVALON Hybrid is a 4-door sedan. Exterior, interior,
and engine compartment illustrations are provided to assist in identification.
The alphanumeric 17 character Vehicle Identification Number (VIN) is provided in the front
windshield cowl and on the driver side B pillar.
Example VIN: 4T1BD1EB0E2000101
An AVALON Hybrid is identified by the first 8 alphanumeric characters
4T1BD1EB.
Driver Side Windshield Cowl
Driver Side B Pillar
3
AVALON Hybrid Identification (Continued)
Exterior
and logos on the trunk.
logo on the driver and front passenger door.
Gasoline fuel filler door located on the driver side rear quarter panel.
Exterior Driver Side View
Exterior Front and Rear View
Exterior Rear and Driver Side View
4
AVALON Hybrid Identification (Continued)
Interior
The instrument cluster (READY indicator, and warning lights) located in the dash behind the
steering wheel, is different than the one on the conventional, non-hybrid AVALON.
Instead of a tachometer, a hybrid system indicator is used.
Hint:
If the vehicle is shut off, the instrument cluster gauges will be “blacked out”, not illuminated.
Interior V iew
Instrument Cluster View
READY Indica t or
5
AVALON Hybrid Identification (Continued)
Engine Compartment
2.5-liter aluminum alloy gasoline engine.
Logo on the plastic engine cover.
Orange colored high voltage power cables.
Engine Compartment View
Power Cables
6
Hybrid Component Locations & Descriptions
Component Location Description
12 Volt Auxiliary
Battery
Passenger Side of
Trunk
A lead-acid battery that supplies power to the low voltage
devices.
Hybrid Vehicle
(HV) Battery
Pack
Trunk Area,
Mounted behind
Rear Seat
244.8 Volt Nickel Metal Hydride (NiMH) battery pack
consisting of 34 low voltage (7.2 Volt) modules connected
in series.
Power Cables Undercarriage
and Engine
Compartment
Orange colored power cables carry high voltage Direct
Current (DC) between the HV battery pack,
inverter/converter, and A/C compressor. These cables also
carry 3-phase Alternating Current (AC) between the
inverter/converter, electric motor, and generator.
Inverter/
Converter
Engine
Compartment
Boosts and inverts the high voltage electricity from the HV
battery pack to 3-phase AC electricity that drives the
electric motor. The inverter/converter also converts AC
electricity from the electric generator and electric motor
(regenerative braking) to DC that recharges the HV battery
pack.
DC-DC
Converter
for 12 Volt
Auxiliary
Battery
Inverter/
Converter
Converts 244.8 Volts from the HV battery pack to 12 Volts
for low voltage vehicle power.
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
3-phase high voltage A C motor co nta in ed in the transax le. It
is used to power the front wheels.
Electric Generator Engine
Compartment
3-phase high voltage A C ge nerator that is contained in the
transaxle and recharges the HV battery pack.
A/C Compressor
(with Inverter)
Engine
Compartment
3-phase high voltage AC electrically driven motor
compressor.
Fuel Tank and
Fuel Line
Undercarriage
and Driver Side
and Center
The fuel tank provides gasoline via a fuel line to the engine.
The fuel line is routed along the driver side and center
tunnel under the floor pan.
*Numbers in the component column apply to the illustrations on the following page.
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