Toyota AVALON HYBRID 2013 User manual

AVALON Hybrid
Hybrid
2013 Model
© 2012 Toyota Motor Corporation
All rights reserved. This document may not be
altered without the written permission of Toyota Motor Corporation.
13 Toyota AVALON Hybrid ERG REV – (12/9/28)

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Foreword
In November 2012, Toyota released the 2013 Toyota AVALON Hybrid
gasoline-electric hybrid vehicle in North America. To educate and
assist emergency responders in the safe handling of the AVALON
Hybrid technology, Toyota published this AVALON Hybrid
Emergency Response Guide.
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 AVALON Hybrid utilizes the following electrical systems:
•Maximum 650 Volts AC
•Nominal 244.8 Volts DC
•Nominal 12 Volts DC
AVALON Hybrid Features:
•A boost converter in the inverter/converter that boosts the available
voltage to the electric motor to 650 Volts.
•A high voltage Hybrid Vehicle (HV) battery pack rated at 244.8
Volts.
•A high voltage motor driven Air Conditioning (A/C) compressor
rated at 244.8 Volts.
•A body electrical system rated at 12 Volts, negative chassis ground.
•Supplemental Restraint System (SRS) – dual stage frontal airbags,
knee airbags, front and rear seat side airbags, side curtain airbags,
and front outer seat belt pretensioners.
High voltage electrical safety remains an important factor in the
emergency handling of the AVALON Hybrid Hybrid Synergy Drive. It
is important to recognize and understand the disabling procedures and
warnings throughout the guide.
Additional topics in the guide include:
•AVALON Hybrid identification.
•Major Hybrid Synergy Drive component locations and descriptions.
•Extrication, fire, recovery, and additional emergency response
information.
•Roadside assistance information.
2013 Model Year AVALON Hybrid
This guide is intended to assist emergency responders in the safe
handling of an AVALON Hybrid vehicle during an incident.
NOTE:
Emergency Response Guides for Toyota hybrid and alternative fuel
vehicles may be viewed at http://techinfo.toyota.com.

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Table of Contents Page
About the AVALON Hybrid 1
AVALON Hybrid Identification 2
Hybrid Synergy Drive Component Locations & Descriptions 5
SmartKeySystem 8
Hybrid Synergy Drive Operation 10
Hybrid Vehicle (HV) Battery Pack 12
Low Voltage Battery 13
High Voltage Safety 14
SRS Airbags & Seat Belt Pretensioners 15
Emergency Response 17
Extrication 18
Fire 23
Overhaul 24
Recovering/Recycling of NiMH HV Battery Pack 24
Spills 25
First Aid 25
Submersion 26
Roadside Assistance 27

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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.
nDuring light acceleration at low speeds, the vehicle is powered by
the electric motor. The gasoline engine is shut off.
oDuring 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.
pDuring full acceleration, such as climbing a hill, both the gasoline
engine and the electric motor power the vehicle.
qDuring deceleration, such as when braking, the vehicle regenerates
kinetic energy from the front wheels to produce electricity that
recharges the battery pack.
rWhile the vehicle is stopped, the gasoline engine and electric motor
are off, however the vehicle remains on and operational.

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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
Exterior
nand logos on the trunk.
ologo on the driver and front passenger door.
pGasoline 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
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AVALON Hybrid Identification (Continued)
Interior
qThe 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.
rInstead of a tachometer, a hybrid system indicator is used.
NOTE:
If the vehicle is shut off, the instrument cluster gauges will be “blacked
out”, not illuminated.
Interior View
Instrument Cluster View
qREADY Indicator
q
r

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AVALON Hybrid Identification (Continued)
Engine Compartment
s2.5-liter aluminum alloy gasoline engine.
tLogo on the plastic engine cover.
Engine Compartment View
t
s

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Hybrid Synergy Drive Component Locations &
Descriptions
Component Location Description
12 Volt
Auxiliary
Battery n
Passenger Side of
Trunk A lead-acid battery that supplies power to the low voltage devices.
Hybrid
Vehicle (HV)
Battery Pack
o
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 pUndercarriage 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 qEngine 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 r
Inverter/
Converter Converts 244.8 Volts from the HV battery pack to 12 Volts for low voltage vehicle
power.
Gasoline
Engine sEngine 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 tEngine Compartment 3-phase high voltage AC motor contained in the transaxle. It is used to power the front
wheels.
Hybrid Synergy Drive Components
Components (Top View) and High Voltage Power Cables
n
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Hybrid Synergy Drive Component Locations &
Descriptions (Continued)
Component Location Description
Electric
Generator uEngine Compartment 3-phase high voltage AC generator that is contained in the transaxle and recharges the
HV battery pack.
A/C
Compressor
(with
Inverter) v
Engine
Compartment 3-phase high voltage AC electrically driven motor compressor.
Fuel Tank
and Fuel Line
w
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.
Fuel Tank and Fuel Line
w

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Hybrid Synergy Drive Component Locations &
Descriptions (Continued)
Key Specifications:
Gasoline Engine: 156 hp (116 kW), 2.5-liter Aluminum Alloy Engine
Electric Motor: 141 hp (105 kW), Permanent Magnet Motor
Transmission: Automatic Only
HV Battery: 244.8 Volt Sealed NiMH Battery
Curb Weight: 3,594 - 3,638 lbs/1,630 - 1,650 kg
Fuel Tank: 17 gals/64 liters
Frame Material: Steel Unibody
Body Material: Steel Panels
Seating Capacity: 5 passenger
Steel Unibody

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Smart Key System
The AVALON Hybrid smart key system consists of a smart key
transceiver that communicates bi-directionally, enabling the vehicle to
recognize the smart key in proximity to the vehicle. Once recognized,
the smart key will allow the user to lock and unlock the doors without
pushing smart key buttons, and start the vehicle without inserting it into
an ignition switch.
Smart key features:
•Passive (remote) function to lock/unlock the doors, unlock the trunk,
and start the vehicle.
•Wireless transmitter buttons to lock/unlock all 4 doors and unlock the
trunk.
•Hidden metal cut key to lock/unlock the doors and glove box.
Door (Lock/Unlock)
There are several methods available to lock/unlock the doors.
•Pushing the smart key lock button will lock all doors.
Pushing the smart key unlock button once unlocks the driver door, twice
unlocks all doors.
•If the touch sensor is provided on both the driver and front passenger door
exterior handles, touching the sensor on the backside of the driver door
exterior handle, with the smart key in close proximity to the vehicle,
unlocks the driver door. Touching the sensor on the backside of the front
passenger door exterior handle, with the smart key in close proximity to the
vehicle, unlocks all the doors.
•If the touch sensor is provided on the driver door exterior handle only,
touching the unlock touch sensor on the backside of the driver door exterior
handle, with the smart key in close proximity to the vehicle, unlocks the
driver door. Touching the lock touch sensor on the front side of the driver
door exterior handle locks all the doors.
•Inserting the hidden metal cut key in the driver door lock and turning
clockwise once unlocks the driver door, twice unlocks all doors. To lock
all doors turn the key counterclockwise once. Only the driver door contains
an exterior door lock for the metal cut key.
Trunk (Unlock)
There are several methods available to open the trunk.
•Pushing the smart key trunk opener button.
•Pushing the trunk opener switch on the lower dash panel.
•Pushing the trunk opener switch with the smart key in proximity to the
vehicle.
Smart Key (Fob) Hidden Metal Cut Key for Door Lock
Driver Door Unlock Touch Sensor and
Lock Touch Sensor Front Driver Door Lock
Trunk Opener Switch (Trunk) Trunk Opener Switch
(Lower Dash Panel)
Release Button
Lock Touch Sensor
Unlock Touch
Sensor
Lock Touch Sensor Use the Hidden Metal Cut Key

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Smart Key System (Continued)
Vehicle Starting/Stopping
The smart key uses a power button to start and stop the vehicle. The smart key
only needs to be in proximity to the vehicle to allow the system to function.
•With the brake pedal released, the first push of the power button operates
the accessory mode, the second push operates the ignition-on mode, and the
third push turns the ignition off again.
Ignition Mode Sequence (brake pedal released):
•Starting the vehicle takes priority over all other ignition modes and is
accomplished by depressing the brake pedal and pushing the power button
once. To verify the vehicle has started, check that the READY indicator is
illuminated in the instrument cluster.
•If the internal smart key battery is dead, use the following method to start
the vehicle.
1. Touch the Toyota emblem side of the smart key to the power button.
2. Within the 10 seconds after the buzzer sounds, push the power button
with the brake pedal depressed (the READY indicator will illuminate).
•Once the vehicle has started and is on and operational (READY-ON), the
vehicle is shut off by bringing the vehicle to a complete stop, placing the
gearshift lever in Park and then depressing the power button once.
•To shut off the vehicle before coming to a stop in an emergency, push and
hold down the power button for more than 2 seconds or push the power
button 3 times or more in a row. This procedure may be useful at an
accident scene in which the READY indicator is on, Park cannot be
selected, and the drive wheels remain in motion.
Ignition Mode Multi-information Display
(Instrument Cluster)
Off -
Accessory POWER ON
Ignition-On POWER ON
Brake Pedal Depressed Smart Key Symbol
Vehicle Started (READY-ON) -
Malfunction Warning Message
POWER ON & Smart Key Symbol
(Multi-information Display) Ignition Modes (Brake Pedal Released)
Starting Sequence
(Brake Pedal Depressed) Smart Key Recognition (When Smart Key Battery is Dead)
Vehicle Off Accessor
y
Ignition-On
Button Push Button Push
Button Push

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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 lit, 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 AVALON 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.
•The vehicle computer determines the mode in which the vehicle operates in
order to help enhance fuel economy and reduce emissions. Three features
on the 2013 AVALON Hybrid are EV (Electric Vehicle) mode, ECO
(Economy) mode and Sport mode:
1. EV Mode: When activated, and certain conditions have been met,
the vehicle operates with the electric motor powered by the HV
battery.
2. ECO Mode: When activated, ECO mode helps enhance fuel
economy on trips that involve frequent braking and acceleration.
3. Sport Mode: When activated, Sport mode optimizes acceleration
feel by increasing the power output more quickly at the beginning
of accelerator pedal operation.
Instrument Cluster READY Indicator
EV Mode Switch, ECO Switch and Sport Switch

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Hybrid Synergy Drive Operation (Continued)
Vehicle Proximity Notification System
The AVALON Hybrid has a vehicle proximity notification system that emits
a sound when the vehicle is driven using only the electric motor at speeds less
than 12 mph. The sound is intended to notify pedestrians that the vehicle is
approaching.
Vehicle Proximity Notification System

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Hybrid Vehicle (HV) Battery Pack
The AVALON Hybrid features a high voltage Hybrid Vehicle (HV)
battery pack that contains sealed Nickel Metal Hydride (NiMH) battery
modules.
HV Battery Pack
•The HV battery pack is enclosed in a metal case and is rigidly mounted to
the trunk area behind the rear seat. The metal case is isolated from high
voltage and concealed by fabric covers in the trunk.
•The HV battery pack consists of 34 low voltage (7.2 Volt) NiMH battery
modules connected in series to produce approximately 244.8 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 244.8 V
Number of NiMH battery modules in the pack 34
NiMH battery module voltage 7.2 V
NiMH battery module dimensions
(Width x Length x Height) 10.9 x 0.8 x 4.2 in
(276 x 19.6 x 106 mm)
NiMH module weight 2.2 lbs (1 kg)
NiMH battery pack dimensions
(Width x Length x Height) 32.1 x 17.5 x 12.9 in (817 x 445 x 325 mm)
NiMH battery pack weight 102.5 lbs (46.5 kg)
Note: Values in inches have been rounded
Components Powered by the HV Battery Pack
HV Battery Pack Recycling
•The HV battery pack is recyclable. Contact the nearest Toyota dealer or:
United States: [phone]
Canada: (888) TOYOTA 8 [[phone]]
HV Battery Pack
HV Battery Pack (Viewed From The Trunk)
•Electric Motor •Power Cables
•Electric Generator •A/C Compressor
•Inverter/Converter
- DC-DC Converter for 12 Volt Auxiliary Battery

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Low Voltage Battery
Auxiliary Battery
•The AVALON 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 trunk. It is concealed by a plastic
resin cover on the passenger side in the rear quarter panel well.
NOTE:
An under hood label shows the location of the HV battery (traction battery)
and 12 Volt auxiliary battery.
Remove Luggage Compartment Side
Trim Cover 12 Volt Auxiliary Battery Mounted in the Trunk (Passenger Side)
Battery Location Label

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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 244.8 to 650 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:
High Voltage Safety System
•A high voltage fuse nprovides short circuit protection in the HV battery
pack.
•Positive and negative high voltage power cables oconnected to the HV
battery pack are controlled by 12 Volt normally open relays p. When the
vehicle is shut off, the relays stop electrical 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 oare 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 qcontinuously
monitors for high voltage leakage to the metal chassis while the vehicle is
running. If a malfunction is detected, the hybrid vehicle computer qwill
illuminate the master warning light in the instrument cluster and
indicate “Check Hybrid System” on the multi-information display.
High Voltage Safety System – Vehicle Shut Off (READY-OFF)
High Voltage Safety System – Vehicle On and Operational (READY-ON)
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12 Volt
Auxiliary
Battery
HV Battery Assembly
0 Volts AC
3-Phase
A/C
Compressor
Electric
Generator
Electric
Moto
r
Inverter/
Converter
Volt DC
Volt DC
00
00
12 Volt
Auxiliary
Battery
HV Battery Assembly
650 Volts
AC Max.
3-Phase
A/C
Compressor
Electric
Generator
Electric
Moto
r
Inverter/
Converter
Volt DC
Volt DC
244.8
Hybrid Vehicle Computer
Hybrid Vehicle Computer
244.8

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SRS Airbags & Seat Belt Pretensioners
Standard Equipment
•Electronic frontal impact sensors (2) are mounted in the engine
compartment nas illustrated.
•Front seat belt pretensioners are mounted near the base of the B-pillars o.
•A frontal dual stage driver airbag pis mounted in the steering wheel hub.
•A frontal dual stage passenger airbag qis integrated into the dashboard
and deploys through the top of the dashboard.
•The SRS computer r, which contains an impact sensor, is mounted on the
floor pan underneath the instrument panel, forward of the shift lever.
•Front door electric side impact sensors (2) are mounted inside the base of
the front doors s.
•Front electronic side impact sensors (2) are mounted near the base of the B-
pillars. t
•Rear electronic side impact sensors (2) are mounted near the base of the C-
pillars. u
•Front seat side airbags vare mounted in the front seatbacks.
•Rear seat side airbags ware mounted in the rear seatbacks.
•Side curtain airbags are mounted along the outer edge inside the roof
rails.
•Front knee airbags (2) are mounted on the lower portion of the dash.
Optional Equipment
•The optional pre-collision system contains a radar sensory system and
an electric motor-pyrotechnic pretensioner system. During a pre-
collision event, an electric motor in the pretensioners retracts the front
seatbelts. When conditions stabilize the electric motor will reverse
itself. When the airbags deploy, or as necessary, the pyrotechnic
pretensioners function normally.
WARNING:
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 breaching the SRS components.
Electronic Impact Sensors and Side Airbags
Standard Frontal Airbags, Seat Belt Pretensioners, Knee Airbags,
Side Curtain Airbags
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Side Curtain Airbag Inflators
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SRS Airbags & Seat Belt Pretensioners (Continued)
Standard Equipment (Continued)
NOTE:
The front seatback mounted side airbags and the side curtain airbags may
deploy independently of each other.
The knee airbags deploy simultaneously with the frontal airbags and seat
belt pretensioners.
The AVALON Hybrid is equipped with a standard front passenger
occupant classification system that may prohibit the deployment of the
front passenger frontal airbag, knee airbag, and seat belt pretensioner. If
the front passenger occupant classification system prohibits deployment
during an SRS event, the front passenger SRS will not re-arm nor deploy.
Electronic side impact sensors are installed in each front door to aid in side
collision detection accuracy.
SRS System Diagram
Frontal, Knee, Front and Rear Seatback Mounted Side, Side Curtain Airbags
Driver Knee Airbag and Inflator
Frontal Impact
Sensors
Knee Airbag
Passenger Frontal Airbag
Front Seat Side Airbag
Front Seat Side Airbag
Driver Frontal Airbag
Front Seat Belt Pretensione
r
Front Side Impact Sensor
Front Seat Belt Pretensioner
Side Curtain Airbag
Side Curtain Airbag
Rear Side Impact Sensor
Rear Side Impact Sensor
Rear Seat Side Airbag
Knee Airbag
Rear Seat Side Airbag
SRS Computer
Front Side Impact Sensor
Front Door Impact Sensor
Front Door Impact Sensor

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Emergency Response
On arrival, emergency responders should follow their standard
operating procedures for vehicle incidents. Emergencies involving the
AVALON Hybrid may be handled like other automobiles except as
noted in these guidelines for Extrication, Fire, Overhaul, Recovery,
Spills, First Aid, and Submersion.
WARNING:
•Never assume the AVALON Hybrid is shut off simply because it is
silent.
•Always observe the instrument cluster for the READY indicator
status to verify whether the vehicle is on or shut off. The vehicle is
shut off when the READY indicator is off.
•Failure to shut off the vehicle before emergency response
procedures are performed may result in serious injury or death
from the unintentional deployment of the SRS or severe burns and
electric shock from the high voltage electrical system.
Extrication
•Immobilize Vehicle
Chock wheels and set the parking brake.
Move the shift lever to the Park position.
•Disable Vehicle
Performing either of the following two procedures will shut the
vehicle off and disable the HV battery pack, SRS, and gasoline fuel
pump.
Chock Wheels Shift Lever in Park
Set Parking Brake