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Table of Contents
Related Manuals for Toyota iQ EV
Summary of Contents for Toyota iQ EV
- Page 1 EV Electric Vehicle ELECTRIC VEHICLE DISMANTLING MANUAL KPJ10 Series...
- Page 2 • 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.
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Page 3: Table Of Contents
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 Vehicle Operation ...........................8 Vehicle Operation............................8 Electric Vehicle (EV) Battery Assembly and Auxiliary Battery ...............9 EV Battery Assembly ............................9... -
Page 4: About The Iq Ev
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. -
Page 5: Iq Ev Identification
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. -
Page 6: Exterior
EV Identification (Continued) Exterior logos on the back door. logos on the B pillars. (for U.S.A.) logo on the recharge inlet door. Recharge inlet door located on the driver side front upper grille. For General For U.S.A. Exterior Left Side View For U.S.A. -
Page 7: Interior
EV Identification (Continued) Interior 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. -
Page 8: Motor Compartment
EV Identification (Continued) Motor Compartment Logo on the plastic cover. Orange colored high voltage power cables. Motor Compartment View Power Cables... -
Page 9: Electric Vehicle Component Locations & Descriptions
Electric Vehicle Component Locations & Descriptions Component* Location Description 12 Volt Auxiliary Driver Side of A lead-acid battery that supplies power to the low voltage devices. Battery Motor Compartment Electric Vehicle Undercarriage 277.5 Volt Lithium-ion (Li-ion) battery assembly consisting of (EV) Battery 150 low voltage (3.7 Volt) cells connected in a series-parallel Assembly... -
Page 10: Specifications
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 kg (for General) Frame Material: Steel Unibody Body Material: Steel Panels Seating Capacity: 4 passengers... -
Page 11: Electric Vehicle Operation
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. -
Page 12: Electric Vehicle (Ev) Battery Assembly And Auxiliary Battery
Electric Vehicle (EV) Battery Assembly and Auxiliary Battery The iQ EV features a high voltage Electric Vehicle (EV) battery assembly that contains sealed Lithium-ion (Li-ion) battery cells. EV Battery Assembly • The EV battery assembly is enclosed in a case and is rigidly mounted under the floor. The case is isolated from high voltage. -
Page 13: Ev Battery Assembly Recovery
Auxiliary Battery • The iQ EV 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. -
Page 14: High Voltage Safety
High Voltage Safety The EV battery assembly powers the high voltage electrical system with DC electricity. Positive and negative orange colored high voltage power cables are routed from the EV battery assembly, under the vehicle floor pan, and to the inverter/converter. The inverter/converter creates 3-phase AC to power the motor. -
Page 15: Service Plug Grip
High Voltage Safety (Continued) Service Plug Grip • The high-voltage circuit is cut by removing the service plug grip (see page 15). Volt DC Volt DC EV Battery Assembly Compressor Inverter/ Converter Electric Motor AC 3-Phase Volt DC Volt DC Charger Assembly Battery Charger... -
Page 16: Precaution To Be Observed When Dismantling The Vehicle
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 opening any orange high voltage power cable or high voltage component. -
Page 17: Spills
Spills The iQ EV contains some of the same common automotive fluids used in other non-electric Scion/Toyota vehicles, with the exception of the Li-ion electrolyte used in the EV battery assembly. The electrolyte used in the Li-ion battery cells is a flammable organic electrolyte. The electrolyte is absorbed into the battery cell separators, even if the battery cells are crushed or cracked, it is unlikely that liquid electrolyte will leak. -
Page 18: Dismantling The Vehicle
Dismantling the vehicle The following 4 pages contain general instructions for use when working on an iQ EV. Read these instructions before proceeding to the EV battery removal instructions on page 20. WARNING: • The high voltage system may remain powered for up to 10 minutes after the vehicle is shut off or disabled. - Page 19 3. Remove the service plug grip. Caution: • Wear insulating gloves and protective goggles. • After removing the service plug grip, attach a note to it to prevent other technicians from mistakenly reconnecting it while you are servicing the vehicle. •...
- Page 20 4. Carry the removed service plug grip in your pocket to prevent other staff from accidentally reinstalling it while you are dismantling the vehicle. 5. Make other staff aware that a high-voltage system is being dismantled by using the following sign: CAUTION: HIGH-VOLTAGE. DO NOT TOUCH (see page 19). 6.
- Page 21 10. With the exception of the EV battery assembly, remove parts by following procedures which are similar to conventional Scion/Toyota vehicles. For the removal of the EV battery assembly, refer to the following pages.
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Page 23: Removal Of Ev Battery Assembly
Removal of EV Battery Assembly WARNING: • Be sure to wear insulated gloves when handling high-voltage parts. • Even if the vehicle is shut off and the relays are off, be sure to remove the service plug grip before performing any further work. •... - Page 24 (3) Remove the 2 bolts from the center floor hole cover. (4) Disengage the guide and remove the center floor hole cover from the front floor panel. 4. REMOVE SERVICE PLUG GRIP Caution: • Wear insulating gloves and protective goggles. •...
- Page 25 5. REMOVE INVERTER COVER ASSEMBLY (1) Remove the 3 clips and the inverter cover assembly RH from the inverter with converter assembly. 6. CHECK TERMINAL VOLTAGE (w/ Quick Charging Inlet) Caution: Wear insulated gloves. (1) Open the charge lid. (2) Open the cap of the DC charger inlet cable. (3) Using a voltmeter, measure the voltage of the high voltage inlet terminal.
- Page 26 9. REMOVE INVERTER SERVICE COVER (1) Remove the 3 clips and the inverter service cover from the inverter with converter assembly. 10. REMOVE UPPER INVERTER COVER SUB-ASSEMBLY Caution: Wear insulated gloves. (1) Remove the 9 bolts and the upper inverter cover sub-assembly from the inverter with converter assembly.
- Page 27 12. DISCONNECT FLOOR WIRE (1) Move the lock lever as shown in the illustration, and disconnect the connector of the floor wire from the electric vehicle battery assembly. Lock Lever 13. REMOVE NO. 1 MOTOR UNDER COVER ASSEMBLY (1) Remove the 4 bolts, 6 clips and the No. 1 motor under cover assembly.
- Page 28 18. DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY (1) Remove the 3 bolts and disconnect the No. 3 parking brake cable assembly from the electric vehicle battery assembly and rear axle beam assembly. 19. DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY Hint: Use the same procedure for the No.
- Page 29 22. DISCONNECT EV CHARGER WIRE (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 electric vehicle battery assembly connectors Lock Lever from the EV charger wire. Notice: Cover the connectors of the EV charger wire and the electric vehicle battery assembly...
- Page 30 25. REMOVE NO. 3 EV BATTERY INTAKE DUCT (1) Loosen the hose clip and disconnect the No. 3 EV battery intake duct from the electric vehicle battery assembly. (2) Loosen the hose clip and remove the No. 3 EV battery intake duct from the battery cooling blower.
- Page 31 (2) Remove the 2 clips. (3) Using 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.
- Page 32 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.
- Page 33 Disengage the claw and separate the No. 6 EV battery exhaust duct from the battery cooling clamp. (3) Loosen the hose clip and remove the No. 6 EV battery exhaust duct from the electric vehicle battery assembly. 32. REMOVE ELECTRIC VEHICLE BATTERY ASSEMBLY Caution: •...
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Page 34: Hv Battery Caution Label
Using an engine lifter, support the electric vehicle battery assembly. 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.