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
o
n
nn
o
n
p
p

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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
o
p
u
q
v
s
t
r
n
o
p
q
r
s
t
u
v

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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