Toyota iQ EV Dismantling Manual
iQ EV
Electric Vehicle
ELECTRIC VEHICLE
DISMANTLING
MANUAL
KPJ10 Series
ii
Foreword
This guide was developed to educate and assist dismantlers in the safe handling of
Scion/Toyota iQ EV electric vehicles. iQ EV dismantling procedures are similar to other
non-electric Scion/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 Scion/Toyota iQ EV electric vehicle, as they may not be familiar to
dismantlers.
High voltage electricity powers the electric motor, DC/DC converter, battery coolant heater, air
conditioning (A/C) compressor, cabin coolant heater and inverter. 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 iQ EV to help
ensure 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 battery is
cracked.
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:
• Scion/Toyota iQ EV identification.
• Major electric vehicle component locations and descriptions.
By following the information in this guide, dismantlers will be able to handle iQ EV electric
vehicles as safely as the dismantling of a conventional non-electric 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.
iii
Table of Contents
About the iQ EV ...........................................................................................................................................1
iQ EV Identification.....................................................................................................................................2
Exterior .........................................................................................................................................................3
Interior...........................................................................................................................................................4
Motor Compartment......................................................................................................................................5
Electric Vehicle Component Locations & Descriptions.............................................................................6
Specifications................................................................................................................................................7
Electric V ehic le Operation...........................................................................................................................8
Vehicle Operation..........................................................................................................................................8
Electric 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 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 EV Battery Assembly .............................................................................................................20
HV Battery Caution Label.........................................................................................................................31
About the iQ EV
The iQ EV 3-door hatchback is the first electric vehicle for Scion/Toyota. Electric Vehicle
means that the vehicle contains only an electric motor and does not have a gasoline engine for
power. Electricity is stored in a high voltage Electric Vehicle (EV) battery assembly for the
electric motor.
The following illustration demonstrates how the iQ EV operates in various driving modes.
n
Fully charging the EV battery assembly utilizing the charge cable assembly, when the SOC
(State of Charge) 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 kinetic energy from the front
wheels to produce electricity that recharges the EV battery assembly.
q While the vehicle is stopped, the electric motor is off, however the vehicle remains on and
operational.
o Driving
p
Deceleration
q Stopped
n Plug-in Charging
Electricity
Charging batteries
Plug-in Charging
1
iQ EV Identification
In appearance, the 2012 model iQ EV is nearly identical to the conventional, non-electric Scion/Toyota
iQ. The iQ EV is a 3-door hatchback. Exterior, interior, and motor compartment illustrations are
provided to 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.)
JTNJVSB0
0C2020211 (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 B Pillar
Right Side Floor
2
iQ EV Identification (Continued)
Exterior
n and logos on the back door.
o
logos on the B pillars. (for U.S.A.)
p
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
iQ EV Identification (Continued)
Interior
r The instrument cluster (power meter, driving range & battery gauge, READY indicator, plug-in
indicator and warning 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 V iew
Instrument Cluster View
r
r
READY Indicator
Plug-in Indicator
EV System Indicator, Driving Range and
Battery Gauge
4
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
6
Electric Vehicle Component Locations & Descriptions
Component* Location Description
12 Volt Auxiliary
Battery n
Driver Side of
Motor
Compartment
A lead-acid battery that supplies power to the low voltage devices.
Electric Vehicle
(EV) Battery
Assembly o
Undercarriage 277.5 Volt Lithium-ion (Li-ion) battery assembly consisting of
150 low voltage (3.7 Volt) cells connected in a series-parallel
circuit.
Power Cables p Undercarriage and
Motor
Compartment
Orange colored power cables carry high voltage Alternating
Current (AC) between the charge inlet (for normal charging) and
charger assembly, and high voltage Direct Current (DC) between
the EV battery assembly, inverter/converter, A/C compressor, and
charge inlet (for optional quick 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 the EV
battery assembly.
DC/DC
Converter for
12 Volt
Auxiliary
Battery t
Inverter / Converter Converts 277.5 Volts from the EV battery assembly to 12 Volts for
low voltage vehicle power.
Electric Motor r Motor
Compartment
3-phase high voltage AC permanent magnet electric motor
contained in the transaxle and drives the front wheels.
A/C Compressor
(with Inverter) s
Motor
Compartment
3-phase high voltage AC electrically driven motor compressor.
*Numbers in the component column apply to the illustrations on the following page.
Electric Vehicle Component Locations & Descriptions (Continued)
Specifications
Electric Motor: 63 hp (47 kW), AC Permanent Magnet Motor
Transaxle: 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 k
g
(
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
q
t
p
s
r
p
s
o
t
q
r
n
7
Electric Vehicle Operation
Once the READY indicator is illuminated in the instrument cluster, the vehicle may be driven.
However, as there is no gasoline engine, no sound will be produced from the vehicle. It is
important to recognize and understand the READY indicator 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 the READY indicator is off.
Instrument Cluster READY Indicator
8
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