COROLLA CROSS

Hybrid
Gasoline-Electric
Hybrid Synergy Drive

ZVG1#/MXGH1# Series
Foreword

This guide was developed to educate and assist dismantlers in the safe handling of Toyota COROLLA
CROSS Hybrid gasoline-electric hybrid vehicles. COROLLA CROSS 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 COROLLA CROSS 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
COROLLA CROSS Hybrid to help ensure the high voltage, approximately 201.6*1, 207.2*2 or 222.0*3.
Volt, Nickel Metal Hydride (NiMH) Hybrid Vehicle (HV) battery pack*1 or Lithium-ion (Li-ion) Hybrid
Vehicle (HV) battery pack*2*3 is kept safe and secure in an accident.
The NiMH HV battery pack*1 or the Lithium-ion (Li-ion) HV battery pack*2*3 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.

*1: for Nickel-Metal hydride battery

*2: for Lithium-ion battery (2ZR-FXE)
*3: for Lithium-ion battery (M20A-FXS)

Additional topics contained in the guide include:

• Toyota COROLLA CROSS Hybrid identification.
• Major hybrid component locations and descriptions.

By following the information in this guide, dismantlers will be able to handle COROLLA CROSS Hybrid
hybrid-electric vehicles as safely as the dismantling of a conventional gasoline engine automobile.

© 2022 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.

ii
 Table of Contents

About the COROLLA CROSS Hybrid ....................................................................................................... 1

COROLLA CROSS Hybrid Identification ................................................................................................ 2

Exterior ......................................................................................................................................................... 3
Interior........................................................................................................................................................... 4
Engine Compartment .................................................................................................................................... 6

Hybrid Component Locations & Descriptions ........................................................................................... 7

Specifications ................................................................................................................................................ 9

Hybrid Synergy Drive Operation .............................................................................................................. 12

Vehicle Operation........................................................................................................................................ 12

Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery ...................................................................... 14

HV Battery Pack.......................................................................................................................................... 14
Components Powered by the HV Battery Pack........................................................................................... 15
HV Battery Pack Recycling ......................................................................................................................... 16
Auxiliary Battery .......................................................................................................................................... 16

High Voltage Safety .................................................................................................................................... 18

High Voltage Safety System ....................................................................................................................... 18
Service Plug Grip ........................................................................................................................................ 19

Precaution to be observed when dismantling the vehicle ........................................................................ 21

Necessary Items ......................................................................................................................................... 22

Spills............................................................................................................................................................. 23

Dismantling a vehicle ................................................................................................................................. 25

Removal of HV battery .............................................................................................................................. 31

iii
About the COROLLA CROSS Hybrid
The COROLLA CROSS Hybrid 5-door wagon joins the hybrid model for Toyota.
Hybrid Synergy Drive means that the vehicle contains a gasoline engine, a front electric
motor and a rear 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 COROLLA CROSS 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 COROLLA CROSS Hybrid operates
in various driving modes.

 During light acceleration at low speeds, the vehicle is powered by the front electric
motor and rear 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, the front
electric motor and rear 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, the front electric motor and rear
electric motor* are off, however the vehicle remains on and operational.

 Starting  Normal Driving  Acceleration  Deceleration  Stopping

Electricity Electricity and gasoline Electricity and gasoline Charging batteries Engine automatically
(additional electricity stopped
extracted from batteries)

*: for AWD

1
COROLLA CROSS Hybrid Identification
In appearance, the COROLLA CROSS Hybrid is nearly identical to the conventional,
non-hybrid Toyota COROLLA CROSS. The COROLLA CROSS Hybrid is a 5-door
wagon. 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:
MR2KZAAG 0000000


A COROLLA CROSS Hybrid is identified by the 5th alphanumeric character of the

VIN.

 Drive Type Engine Series Production Base

TMT
Z 2WD 2ZR-FXE
TDB
Y 2WD 2ZR-FXB TDB
A 2WD 2ZR-FXE KUOZUI
2ZR-FXE ASSB
B 2WD
M20A-FXS TMC
C AWD M20A-FXS TMC
TSAM
D 2WD 2ZR-FXE
TMC

Left Side Windshield Cowl, Under the Right Side Front Seat and Left Side B Pillar

2
Exterior

 logo on the back door and each front fender.

 logo on the back door. (for AWD)
 Gasoline fuel filler door located on the left side rear quarter panel.


●


●

Exterior Front and Left Side View




●

●

Exterior Rear and Left Side View

3
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 COROLLA CROSS.

 A hybrid system indicator can be displayed by selecting menu icons on the multi-information
display.

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


●

This illustration is for an LHD model

Interior View

 for 4.2 Inch Multi-information Display


●

READY Indicator

Combination Meter View

4
 for 7 Inch Multi-information Display


● 
●

READY Indicator READY Indicator

 for Full Digital Meter Display


●

READY Indicator

Combination Meter View

5
Engine Compartment

 1.8-liter or 2.0-liter aluminum alloy gasoline engine.

 Orange colored high voltage power cables.

for Nickel-Metal hydride battery


●

●

for Lithium-ion battery (2ZR-FXE)


● 
●

for Lithium-ion battery (M20A-FXS)

Rear Electric Motor


● 
●

This illustration is for an AWD model

Power Cables

6
Hybrid Component Locations & Descriptions

Component Location Description

12 Volt Auxiliary Engine Supplies electricity to the electrical components.
Battery  Compartment
Hybrid Vehicle Cabin Area, • Supplies electrical power to MG1, MG2 and MGR*1 in
(HV) Battery Pack Mounted Under accordance with the driving conditions of the vehicle.
 Rear Seat • Recharged by MG1, MG2 and MGR*1 in accordance
with the SOC and the driving conditions of the vehicle.
Power Cables  Undercarriage and Connects the HV battery, inverter with converter
Engine assembly, hybrid vehicle transaxle assembly, rear drive
Compartment unit (rear traction motor with transaxle assembly)*1 and
compressor with motor assembly.
Inverter/Converter Engine • Converts the direct current from the boost converter into
 Compartment alternating current for MG1 and MG2, and vice versa
(from AC to DC).
• Boosts the HV battery nominal voltage of DC 201.6
V*2 / DC 207.2 V*3 / DC 222.0 V*4 up to a maximum
voltage of DC 600 V and vice versa (steps down DC
600 V to DC 201.6 V*2 DC 207.2 V*3 / DC 222.0
V*4).
Gasoline Engine  Engine Provides two functions:
Compartment 1) Powers vehicle.
2) Powers generator to recharge the HV battery pack.
The engine is started and stopped under control of the
vehicle computer.
Front Electric Engine • MG2, which is driven by electrical power from MG1
Motor  Compartment 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.

7
 Component Location Description
Electric Generator Engine MG1, which is driven by the engine, generates high-
 Compartment voltage electricity in order to operate MG2, MGR*1 and
charge the HV battery. Also, it functions as a starter to
start the engine.
A/C Compressor Engine 3-phase high voltage AC electrically driven motor
(with Inverter)  Compartment compressor.
DC-DC Converter Engine Steps down the HV battery nominal voltage of DC 201.6
for 12 Volt Compartment V*2 / DC 207.2 V*3 / DC 222.0 V*4 to approximately
Auxiliary Battery DC 14 V in order to supply electricity to the electrical
 components, as well as to recharge the auxiliary battery.
Fuel Tank and Fuel Undercarriage and The fuel tank provides gasoline via a fuel line to the
Line  Center engine. The fuel line is routed under the center of
vehicle.
Rear Electric Under the Luggage MGR, which is driven by electrical power from MG1 and
Motor *1 Compartment the HV battery, generates motive force for the drive
wheels.
*Numbers in the component column apply to the illustrations on the following page.

*1: for AWD Models

*2: for Nickel-Metal hydride battery
*3: for Lithium-ion battery (2ZR-FXE)
*4: for Lithium-ion battery (M20A-FXS)

8
Specifications

Gasoline Engine: 72 kW, 1.8-liter Aluminum Alloy Engine*1*2

112 kW, 2.0-liter Aluminum Alloy Engine*3
Electric Motor: 53 kW, Permanent Magnet Motor*1
70 kW, Permanent Magnet Motor*2
83 kW, Permanent Magnet Motor*3
Transmission: Automatic Only
HV Battery: 201.6 Volt Sealed NiMH Battery*1
207.2 Volt Sealed Li-ion Battery*2
222.0 Volt Sealed Li-ion Battery*3
Curb Weight: 3,053 - 3,439 lbs / 1,385 - 1,560 kg
Fuel Tank: 36.0 – 43.0 liters / 9.5 – 11.4 Us. gals / 7.9 – 9.5 Imp. gals
Frame Material: Steel Unibody
Body Material: Steel Panels
Seating Capacity: 5 passenger

*1: for Nickel-Metal hydride battery

*2: for Lithium-ion battery (2ZR-FXE)
*3: for Lithium-ion battery (M20A-FXS)

for Nickel-Metal hydride battery



● 
 


●




 

 
 

9
for Lithium-ion battery (2ZR-FXE)


●

●

●

● 
●

●

●

●

●


●

●

●

●●

●

●

● 
●

10
for Lithium-ion battery (M20A-FXS)


●


●


● 
●

● 
●

●


●●


This illustration is for an AWD model


●

●

●

●●

●

●

●

●

This illustration is for an AWD model

11
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 COROLLA CROSS 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.

for 4.2 Inch Multi-information Display

12
for 7 Inch Multi-information Display

for Full Digital Meter Display

Combination Meter READY Indicator

13
Hybrid Vehicle (HV) Battery Pack and Auxiliary Battery
The COROLLA CROSS Hybrid features a high voltage Hybrid Vehicle (HV) battery pack that
contains sealed Nickel Metal Hydride (NiMH) battery modules*1 or Lithium-ion (Li-ion)
battery cells*2.
*1: for Nickel-Metal hydride battery
*2: for Lithium-ion battery

HV Battery Pack
for Nickel-Metal hydride battery:
• 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

for Lithium-ion battery:

• 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 covers in the cabin area.

• The HV battery pack consists of 56*1 or 60*2 low voltage (3.7 Volt) Li-ion battery
cells connected in series to produce approximately 207.2*1 or 222.0*2 Volts. Each
Li-ion battery cell is non-spillable and in a sealed case.

• The electrolyte used in the Li-ion battery cells is a flammable organic electrolyte.
The electrolyte is absorbed into the battery cell separator and will not normally leak,
even in a collision.

14
 HV Battery Pack
Battery pack voltage 207.2 V*1 / 222.0 V*2
Number of Li-ion battery cells in the pack 56*1 / 60*2
Li-ion battery cell voltage 3.7 V
*1: for 2ZR-FXE
*2: for M20A-FXS

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

15
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 COROLLA CROSS 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 (for 2ZR-FXE or 2ZR-FXB)
or luggage compartment area (for M20A-FXS).

for Nickel-Metal hydride battery: for Lithium-ion battery:

HV Battery Pack

for Nickel-Metal hydride battery: for Lithium-ion battery:

HV Battery Pack Mounted in Cabin Area

16
for 2ZR-FXE or 2ZR-FXB: for M20A-FXS:

12 Volt Auxiliary Battery Mounted in Engine 12 Volt Auxiliary Battery Mounted in Luggage
Compartment Area Compartment Area (Right Side)

17
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*1, 207.2*2 or 222.0*3 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:
*1: for Nickel-Metal hydride battery
*2: for Lithium-ion battery (2ZR-FXE)
*3: for Lithium-ion battery (M20A-FXS)

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 Volts normally open relays *. When the vehicle is shut off, the relays
stop electricity 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 electricity flow in a collision
sufficient to activate the SRS.

*Numbers apply to the illustration on the following page.

18
Service Plug Grip
• The high-voltage circuit is cut by removing the service plug grip (see page 25).

for 2ZR-FXE or 2ZR-FXB

Hybrid Vehicle Computer

0.0

Volts DC

A/C
Compressor


Inverter/
Electric Converter
Generator

0.0  
12 Volts Electric Volts DC
Auxiliary Motor
Battery 

0 Volts AC HV Battery Pack

3-Phase

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

Hybrid Vehicle Computer

201.6*1
207.2*2
Volts DC

A/C
Compressor

Electric Inverter/
Generator Converter

201.6*1
207.2*2
12 Volts Electric Volts DC
Auxiliary Motor
Battery

600 Volts AC HV Battery Pack

Max 3-Phase

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

*1: for Nickel-Metal hydride battery
*2: for Lithium-ion battery (2ZR-FXE)

19
for M20A-FXS

Hybrid Vehicle Computer

0.0
Volts DC 

A/C
Compressor
 Electric
 Motor
(Rear)
Inverter/
Electric Converter
Generator

0.0
Volts DC
 
12 V
Electric Motor Auxiliary
(Front) Battery


0 V AC HV Battery assembly
3-Phase

This illustration is for an AWD model

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

Hybrid Vehicle Computer

222.0
Volts DC

A/C
Compressor Electric
Motor
(Rear)
Inverter/
Electric Converter
Generator

222.0
Volts DC 12 V
Electric Motor Auxiliary
(Front) Battery

600 V AC Max HV Battery assembly

3-Phase

This illustration is for an AWD model

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

20
Precaution to be observed when dismantling the vehicle

• To prevent electric shock, wear insulated gloves when working on wire harnesses and components
of the high voltage system. Before using insulated gloves, be sure to check them for cracks, tears
and other types of damage.
• When servicing the vehicle, do not carry metal objects like mechanical pencils or rulers that can be
dropped accidentally and cause a short circuit.
• To reduce the risk of electric shock, make sure to remove the service plug grip to cut off the high
voltage circuit before servicing the vehicle.
• To reduce the risk of electric shock, make sure to wait at least 10 minutes after removing the service
plug grip to fully discharge the high voltage capacitor inside the inverter with converter assembly.
• Do not touch any high voltage wire harnesses, connectors or parts with bare hands.
• Do not touch the terminals of the service plug grip.
• Make sure to insulate the high-voltage connectors and terminals of the HV battery with insulating
tape after removing them.
• After removing the service plug grip, put it in your pocket to prevent other technicians from accident
ally reconnecting it while you are working on the high-voltage system.
• Before touching a bare high-voltage terminal, wear insulated gloves and use a tester to make sure
that the terminal voltage is 0 V.
• If the vehicle catches on fire, use an ABC fire extinguisher to extinguish the fire. Trying to
extinguish a fire using only a small amount of water can be more dangerous than effective. Use a
substantial amount of water or wait for firefighters.
• Do not allow any foreign matter or water to enter the HV battery.

for Nickel-Metal hydride battery:

• If the electrolyte comes in contact with your skin, use a saturated boric acid solution or a large
amount of water to wash it off. If the electrolyte comes in contact with an article of clothing, take
it off immediately.
• If the electrolyte comes in contact with your eyes, call out loudly for help. Do not rub your eyes.
Wash them immediately with a large amount of water and seek medical care.
• If the electrolyte is swallowed, seek medical care immediately. Do not induce vomiting, unless
instructed by the doctor.

21
for Lithium-ion battery:
• Electrolyte leaks may cause acute poisoning if a high concentration of the vapor from the electrolyte
is inhaled. In case of inhalation, move the affected person to a place with ample fresh air and let
them lie quietly. Seek medical care.
• If the electrolyte comes in contact with your skin, wash the area thoroughly with soap and plenty of
water, and seek medical care. If the electrolyte comes in contact with an article of clothing, take it
off immediately. Prolonged contact with the electrolyte may cause skin irritation.
• If the electrolyte comes in contact with your eyes, call out loudly for help. Do not rub your eyes.
Immediately flush them with a large amount of water for at least 15 minutes and seek medical care.
• If electrolyte is swallowed, seek medical care immediately. Do not induce vomiting, unless
instructed by the doctor.

Necessary Items
• Protective clothing such as insulated gloves (electrically insulated), rubber gloves, helmet, safety
goggles, safety shoes and SCBA or protective mask.
• Insulating tape such as electrical tape that has a suitable electrical insulation rating and insulation
tool set.
• An electrical tester that is capable of measuring DC 750 Volts or more.

22
Spills

for Nickel-Metal hydride battery:

The COROLLA CROSS 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.

23
for Lithium-ion battery:
The COROLLA CROSS Hybrid contains the same common automotive fluids used in other non-hybrid
Toyota vehicles, with the exception of the Li-ion electrolyte used in the HV battery pack. 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. Any liquid electrolyte that leaks from a Li-ion battery cell quickly
evaporates.

WARNING:
・ The Li-ion battery contains organic electrolyte. Only a small
amount may leak from the batteries which may irritate the eyes,
nose, throat, and skin.
・ Contact with the vapor produced by the electrolyte may irritate
the nose and throat.
・ To avoid injury by coming in contact with the electrolyte or vapor,
wear personal protective equipment for organic electrolyte
including SCBA or protective mask for organic gases.

• Handle Li-ion electrolyte spills using the following Personal Protective Equipment (PPE):
• Splash shield or safety goggles. A fold down face shield is not acceptable for acid or
electrolyte spills.
• Rubber gloves or gloves suitable for organic solvents.
• Apron suitable for organic solvents.
• Rubber boots or boots suitable for organic solvents.
• Protective mask for organic gases or SCBA.

24
Dismantling a vehicle

The following 6 pages contain general instructions for use when working on a COROLLA
CROSS Hybrid.
Read these instructions before proceeding to the HV battery removal instructions on page 31.

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 any high voltage component.

Shut off the ignition (READY indicator is off). Then disconnect the cable from the
negative auxiliary battery terminal.
a.

for 2ZR-FXE or 2ZR-FXB: for M20A-FXS:

25
 Remove battery service hole cover.
a.

26
Remove service plug grip.
CAUTION:
• Be sure to wear insulated gloves.
• Do not inspect or service
the high voltage system
with the service plug grip
installed.
• To reduce the risk of electric
shock, make sure to remove
the service plug grip to cut
off the high voltage circuit
before servicing the vehicle.

• To reduce the risk of electric

shock, make sure to wait at
least 10 minutes after
removing the service plug
grip to fully discharge the
high voltage capacitor
inside the inverter with
converter assembly.
• Keep the removed service
plug grip in your pocket to
prevent other technicians from accidentally installing it while you are
servicing the vehicle.

NOTICE:
• After removing the service plug grip, turning the power switch on (READY) may
cause a malfunction. Do not turn the power switch on (READY) unless
instructed by the repair manual.
• Do not touch the terminals of the service plug grip.
• If the service plug grip has been struck or dropped, replace it.

HINT:
Waiting for at least 10 minutes is required to discharge the high voltage
capacitor inside the inverter with converter assembly.

27
a.

(1)

2
3
1

While wearing insulated gloves, rotate the handle of the service plug grip and remove
the service plug grip as indicated by the arrows, in the order shown in the illustration.

Carry the removed service plug grip in your pocket to prevent other staff from
accidentally reinstalling it while you are dismantling the vehicle.
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 30).
If the service plug grip cannot be
removed due to damage to the vehicle,
remove the IG2-MAIN fuse (20 A).
Caution:
This operation shuts off the HV
system. Be sure to wear insulated
gloves because high voltage is not
shut off inside the HV battery. When
IG2-MAIN Fuse
it is possible to remove the service
plug grip, remove it and continue the procedure.

28
After disconnecting or exposing a high-
voltage connector or terminal, insulate it
immediately using insulating tape.
Before touching a bare high-voltage
terminal, wear insulated gloves.

Check the HV battery and nearby area for leakage. If you find any liquid, it may be
strong alkaline electrolyte. Wear rubber gloves and goggles and neutralize the
liquid using a saturated boric acid solution or vinegar. Then wipe up the liquid
using waste rags etc.
If the electrolyte comes into contact with your skin, wash the skin immediately using
a saturated boric acid solution or a large amount of water. If the electrolyte adheres
to any article of clothing, take the clothing off immediately.
If the electrolyte comes into contact with your eye(s), call out loudly for help. Do
not rub your eye(s). Instead, wash the eye(s) with a dilute boric acid solution or a
large amount of water and seek medical care.
With the exception of the HV battery, remove parts by following procedures which
are similar to conventional Toyota vehicles. For the removal of the HV battery,
refer to the following pages.

29
30
Removal of HV battery

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.
・ Power remains in the high voltage electrical system for 10
minutes even after the HV battery pack is shut off because the
circuit has a condenser that stores power.
・ Make sure that the tester reading is 0 V before touching any high-
voltage terminals which are not insulated.
・ The SRS may remain powered for up to 90 seconds after the
vehicle is shut off or disabled. To prevent serious injury or
death from unintentional SRS deployment, avoid cutting the SRS
components.

SHUT OFF IGNITION (READY indicator is off)

DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY

TERMINAL
a.

for 2ZR-FXE or 2ZR-FXB: for M20A-FXS:

31
 REMOVE BATTERY SERVICE HOLE COVER
a.

32
REMOVE SERVICE PLUG GRIP
CAUTION:
• Be sure to wear insulated gloves.
• Do not inspect or service
the high voltage system
with the service plug grip
installed.
• To reduce the risk of electric
shock, make sure to remove
the service plug grip to cut
off the high voltage circuit
before servicing the vehicle.

• To reduce the risk of electric

shock, make sure to wait at
least 10 minutes after
removing the service plug
grip to fully discharge the
high voltage capacitor
inside the inverter with
converter assembly.
• Keep the removed service
plug grip in your pocket to
prevent other technicians from accidentally installing it while you are
servicing the vehicle.

NOTICE:
• After removing the service plug grip, turning the power switch on (READY) may
cause a malfunction. Do not turn the power switch on (READY) unless
instructed by the repair manual.
• Do not touch the terminals of the service plug grip.
• If the service plug grip has been struck or dropped, replace it.

HINT:
Waiting for at least 10 minutes is required to discharge the high voltage
capacitor inside the inverter with converter assembly.

33
a.

(1)

3
2
1

(1) While wearing insulated gloves, rotate the handle of the service plug grip and remove
the service plug grip as indicated by the arrows, in the order shown in the illustration.

DISCONNECT ENGINE WIRE (for NICKEL METAL HYDRIDE BATTERY)

CAUTION:
Be sure to wear insulated gloves.
NOTICE:
Do not allow any foreign matter or water to enter the inverter with converter
assembly.
a.

(1)

(2)

(3)

34
 Move each lock lever as shown in the illustration and disconnect the 2 inverter with
converter assembly connectors.
Notice:
・Do not touch the waterproof seal or terminals of the connector.
・Do not damage the terminals, connector housing or inverter with converter
assembly during disconnection.
・Cover the hole where the cable was connected with tape (non-residue type) or
equivalent to prevent entry of foreign matter.
・Insulate the disconnected terminals with insulating tape.
Remove the bolt.
Disengage the clamp and disconnect the engine wire.

REMOVE CONNECTOR COVER ASSEMBLY

CAUTION:
Be sure to wear insulated gloves.
a.
for Nickel-Metal hydride battery: for Lithium-ion battery:

(1) Bolt (B)

(1) Bolt (B)

(2) Bolt (A)

(3) Bolt (C)

(1) Remove the bolt (B).

(2) for Nickel-Metal hydride battery:
a) Using a T25 "TORX" socket wrench, remove the bolt (A) and connector cover
assembly from the inverter with converter assembly.
(3) for Lithium-ion battery:
a) Using a T30 "TORX" socket wrench, remove the bolt (C) and connector cover
assembly from the inverter with converter assembly.
Notice:
・Do not touch the connector cover assembly waterproof seal.
・Do not allow any foreign matter or water to enter the inverter with converter
assembly.

35
 CHECK TERMINAL VOLTAGE
CAUTION:
Be sure to wear insulated gloves.
NOTICE:
Do not allow any foreign matter or water to enter the inverter with converter
assembly.
a.
for Nickel-Metal hydride battery: for Lithium-ion battery:
(1) (1)

(1) Using a voltmeter, measure the voltage between the terminals of the 2 phase
connectors.
Standard voltage: 0 V
Hint:
Use measuring range of DC 750 V or more on the voltmeter.

DISCONNECT REAR CENTER SEAT OUTER BELT ASSEMBLY

a.

36
 REMOVE BENCH TYPE REAR SEAT CUSHION ASSEMBLY
a.

(1)
Rear Seat Cushion Frame
Hook Front Side

80 mm (3.15 in.)

(2)

60 mm
(2.36 in.)

Place Hands Here Rear Seat Cushion Frame Hook Rear Side

(1) Lift the front edge of the bench type rear seat cushion assembly as shown in the
illustration and disengage the rear seat cushion frame hooks on the front side of
the bench type rear seat cushion assembly from the rear seat cushion lock
hooks.
Notice:
Be sure to hold the parts of the seat cushion assembly directly next to the rear seat
cushion frame hooks when lifting it. Lifting a different part of the cushion may deform
the rear seat cushion frame.
(2) Disengage the rear seat cushion frame hook on the rear side of the bench type rear seat
cushion assembly as shown in the illustration.
Notice:
Be careful not to damage the bench type rear seat cushion assembly, body exterior or
interior parts.

37
 REMOVE REAR SEAT CUSHION LOCK HOOK
a.

REMOVE REAR DOOR SCUFF PLATE LH

a.

Place Hand Here

REMOVE REAR UNDER SIDE COVER LH

a.

REMOVE REAR DOOR SCUFF PLATE RH

Hint:
Use the same procedure for the LH side.

38
 REMOVE REAR UNDER SIDE COVER RH
a.

REMOVE REAR UNDER COVER

a.

REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY

a.

39
 REMOVE NO. 1 EV BATTERY INTAKE DUCT (for LITHIUM-ION BATTERY)
a.

REMOVE BATTERY COOLING BLOWER ASSEMBLY

NOTICE:
・Be sure not to touch the fan part of the battery cooling blower assembly.
・Do not lift the battery cooling blower assembly using the wire harness.
a.

REMOVE HYBRID BATTERY HOSE ASSEMBLY (for LITHIUM-ION

BATTERY)
a.

40
 REMOVE NO. 2 HYBRID BATTERY INTAKE DUCT (for LITHIUM-ION
BATTERY)
CAUTION:
Be sure to wear insulated gloves.
a.

REMOVE NO. 3 HV BATTERY PACK WIRE (for LITHIUM-ION BATTERY)

a.

41
 REMOVE NO. 1 HV BATTERY COVER PANEL RH
CAUTION:
Be sure to wear insulated gloves.
a.
for Nickel-Metal hydride battery: for Lithium-ion battery:

(3)
*1
*b
*1
*c *a
*b
(1) *2
*c *a

(2) (1) *2

*1 Service Plug Grip *2 Battery Cover Lock Striker

*a Projection *b Turn
*c Button - -
(1) Using the service plug grip, remove the battery cover lock striker.
Hint:
Insert the projection of the service plug grip and turn the button of the battery cover lock
striker counterclockwise to release the lock.
(2) for Nickel-Metal hydride battery:
a) Remove the 3 bolts, 2 nuts and No. 1 HV battery cover panel RH from the HV
battery.
(3) for Lithium-ion battery:
a) Remove the 5 nuts and HV battery upper cover panel from the HV battery.

42
 DISCONNECT HV FLOOR UNDER WIRE
CAUTION:
Be sure to wear insulated gloves.
a.

for Nickel-Metal hydride battery: for Lithium-ion battery:

(1) (1)

(2) Shield Ground (2) Shield Ground

(1) Disconnect the 2 HV battery junction block assembly connectors.

Notice:
Insulate each disconnected high-voltage connector with insulating tape. Wrap the
connector from the wire harness side to the end of the connector.
(2) Disconnect the shield ground from the HV battery.

DISCONNECT FLOOR WIRE

CAUTION:
Be sure to wear insulated gloves.
a.

for Nickel-Metal hydride battery: for Lithium-ion battery:

43
 REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT (for NICKEL METAL
HYDRIDE BATTERY)
a.

DISCONNECT FLOOR WIRE (for NICKEL METAL HYDRIDE BATTERY)

CAUTION:
Be sure to wear insulated gloves.
a.

REMOVE HV BATTERY (for NICKEL METAL HYDRIDE BATTERY)

CAUTION:
Be sure to wear insulated gloves.
NOTICE:
・To prevent the wire harness from being caught, make sure to bundle the wire
harness using insulating tape or equivalent.
・Since the HV battery is very heavy, 2 people are needed to remove it. When
removing the HV battery, be careful not to damage the parts around it.
・When removing/installing/moving the HV battery, make sure not to tilt it more
than 80°.
・Insulate the disconnected terminals or connectors with insulating tape.

44
a.

REMOVE HV SUPPLY BATTERY ASSEMBLY (for LITHIUM-ION BATTERY)

CAUTION:
Be sure to wear insulated gloves.
NOTICE:
・To prevent the wire harness from being caught, make sure to bundle the wire
harness using insulating tape or equivalent.
・Since the HV battery is very heavy, 2 people are needed to remove it. When
removing the HV battery, be careful not to damage the parts around it.
・When removing/installing/moving the HV battery, make sure not to tilt it more
than 80°.
・Insulate the disconnected terminals or connectors with insulating tape.

a.

45