Toyota AVALON Hybrid Dismantling Manual page 2

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 high voltage electrical 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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