Toyota iQ EV User manual

iQ EV
Electric Vehicle
ELECTRIC VEHICLE
DISMANTLING
MANUAL
KPJ10 Series

ii
Foreword
This guide was developed to educate and assist dismantlers in the safe handling of
Scion/Toyota iQ EV electric vehicles. iQ EV dismantling procedures are similar to other
non-electric Scion/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 Scion/Toyota iQ EV electric vehicle, as they may not be familiar to
dismantlers.
High voltage electricity powers the electric motor, DC/DC converter, battery coolant heater, air
conditioning (A/C) compressor, cabin coolant heater and inverter. 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 iQ EV to help
ensure the high voltage, approximately 277.5 Volt, Lithium-ion (Li-ion) Electric Vehicle (EV)
battery assembly is kept safe and secure in an accident.
The Li-ion EV battery assembly 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.
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:
• Scion/Toyota iQ EV identification.
• 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. This book may not be reproduced or
copied, in whole or in part, without the written permission
of Toyota Motor Corporation.

iii
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
Components Powered by the EV Battery Assembly .....................................................................................9
EV Battery Assembly Recovery ..................................................................................................................10
Auxiliary Battery..........................................................................................................................................10
High Voltage Safety ....................................................................................................................................11
High Voltage Safety System........................................................................................................................11
Service Plug Grip........................................................................................................................................12
Precaution to be observed when dismantling the vehicle........................................................................13
Necessary Items.........................................................................................................................................13
Spills.............................................................................................................................................................14
Dismantling the vehicle..............................................................................................................................15
Removal of EV Battery Assembly .............................................................................................................20
HV Battery Caution Label.........................................................................................................................31

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.
The following illustration demonstrates how the iQ EV operates in various driving modes.
nFully charging the EV battery assembly utilizing the charge cable assembly, when the SOC
(State of Charge) warning light has come on, will take approximately 7 (for U.S.A.) or 4
(for General) hours. When the EV battery assembly is charged at charging stations
utilizing charge cable assembly, it will take approximately 3 hours.
oDuring driving, when the Li-ion battery is sufficiently charged, the vehicle will drive using
electric power only.
pDuring deceleration, such as when braking, the vehicle regenerates kinetic energy from the front
wheels to produce electricity that recharges the EV battery assembly.
qWhile the vehicle is stopped, the electric motor is off, however the vehicle remains on and
operational.
oDriving
p
Deceleration
qStopped
nPlug-in Charging
Electricity
Charging batteries
Plug-in Charging
1

iQ 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.
Example VIN: JTNJVXB00C2020211 (for U.S.A.)
JTNJVSB00C2020211 (for General)
An iQ EV is identified by the first 8 alphanumeric characters JTNJVXB0 or JTNJVSB0.
Left Side Windshield Cowl (for U.S.A.) Left Side B Pillar
Right Side Floor
2

iQ EV Identification (Continued)
Exterior
nand logos on the back door.
ologos on the B pillars. (for U.S.A.)
plogo on the recharge inlet door.
qRecharge inlet door located on the driver side front upper grille.
Exterior Left Side View
Exterior Front View
Exterior Rear View
Exterior Rear and Left Side View
o
For General
For U.S.A.
n
q
p
For U.S.A. For General
p
For U.S.A. For General
q
For U.S.A.
o
n
For General
n
n
3

iQ EV Identification (Continued)
Interior
rThe 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.
Hint:
If the vehicle is shut off, the instrument cluster gauges will be “blacked out”, not illuminated.
Interior View
Instrument Cluster View
r
r
READY Indicator
Plug-in Indicator
EV System Indicator, Driving Range and
Battery Gauge
4

iQ EV Identification (Continued)
Motor Compartment
sLogo on the plastic cover.
tOrange colored high voltage power cables.
Motor Compartment View
Power Cables
s
t
t
5

6
Electric Vehicle Component Locations & Descriptions
Component* Location Description
12 Volt Auxiliary
Battery nDriver Side of Motor
Compartment
A lead-acid battery that supplies power to the low voltage devices.
Electric Vehicle
(EV) Battery
Assembly o
Undercarriage 277.5 Volt Lithium-ion (Li-ion) battery assembly consisting of
150 low voltage (3.7 Volt) cells connected in a series-parallel
circuit.
Power Cables pUndercarriage and
Motor
Compartment
Orange colored power cables carry high voltage Alternating
Current (AC) between the charge inlet (for normal charging) and
charger assembly, and high voltage Direct Current (DC) between
the EV battery assembly, inverter/converter,A/C compressor, and
charge inlet (for optional quick charging).
These cables also carry 3-phase Alternating Current (AC) between
the inverter/converter and electric motor.
Inverter /
Converter qMotor Compartment Inverts the high voltage DC electricity from the EV battery assembly to 3-phrase AC electricity to drive the electric motor.
The inverter/converter also converts AC electricity from the
electric motor (regenerative braking) to DC that recharges the EV
battery assembly.
DC/DC
Converter for
12 Volt
Auxiliary
Battery t
Inverter / Converter Converts 277.5 Volts from the EV battery assembly to 12 Volts for
low voltage vehicle power.
Electric Motor r
Motor Compartment 3-phase high voltageAC permanent magnet electric motor contained in the transaxle and drives the front wheels.
A/C Compressor
(with Inverter) sMotor Compartment 3-phase high voltage AC electrically driven motor compressor.
*Numbers in the component column apply to the illustrations on the following page.

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 l
b
s
/
1
,
080 k
g
(
for General
)
Frame Material: Steel Unibody
Body Material: Steel Panels
Seating Capacity: 4 passengers
Electric Vehicle Components
Components (Top View) and High Voltage Power Cables
o
q
tp
s
r
p
so
t
q
r
n
7

Electric Vehicle Operation
Once the READY indicator is illuminated in the instrument cluster, the vehicle may be driven.
However, as there is no gasoline engine, no sound will be produced from the vehicle. 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 motor
compartment is silent.
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.
Instrument Cluster READY Indicator
8

Electric Vehicle (EV) Battery Assembly andAuxiliary 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.
• The EV battery assembly consists of 150 low voltage (3.7 Volt) Li-ion battery cells connected in
series-parallel to produce approximately 277.5 Volts. Each Li-ion battery cell is non-spillable and
sealed in a 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.
EV Battery Assembly
Battery assembly voltage 277.5 V
Number of Li-ion battery cells in the battery 150
Li-ion battery cell voltage 3.7 V
Li-ion battery cell dimensions Length x Width x Height 4.13 x 5.83 x 1.04 in.
(105 x 148 x 27 mm)
Li-ion cell weight 1.60 lbs (726 g)
Li-ion battery assembly dimensions
Length x Width x Height 48 x 53 x 13 in.
(1,226 x 1,355 x 335 mm)
Li-ion battery assembly weight 485 lbs (220 kg)
Components Powered by the EV Battery Assembly
• Electric Motor
•
Power Cables
• Inverter/Converter • A/C Compressor
- DC-DC Converter for 12 Volt Auxiliary Battery
9

Electric Vehicle (EV) Battery Assembly andAuxiliary Battery (Continued)
EV Battery Assembly Recovery
• Contact either your Scion/Toyota Distributor or the nearest Scion/Toyota dealer.
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.
• The auxiliary battery is located in the motor compartment.
277.5 Volt EV Battery Assembly 12 Volt Auxiliary Battery Mounted in Motor
Compartment
EV Battery Assembly Mounted in Undercarriage
EV Battery Assembly
10

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. Power cables are routed from the inverter/converter
to each high voltage motor (electric motor 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
• High voltage fuses nprovide short circuit protection in the EV battery assembly.
• Positive and negative high voltage power cables oconnected to the EV battery assembly are
controlled by 12 Volt normally open relays (system main relays p). When the vehicle is shut off,
the relays stop electrical flow from leaving the EV battery assembly.
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.
• 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 electric vehicle computer qcontinuously monitors for high voltage
leakage to the metal chassis while the vehicle is running. If a malfunction is detected, the electric
vehicle computer qwill illuminate the master warning light in the instrument cluster and
indicate “CHECK EV SYSTEM” on the multi-information display.
• The EV battery assembly contactors will automatically open to stop electricity flow in a collision
sufficient to activate the SRS.
*Numbers apply to the illustration on the following page.
11

High Voltage Safety (Continued)
Service Plug Grip
• The high-voltage circuit is cut by removing the service plug grip (see page 15).
High Voltage Safety System – Vehicle Shut Off (READY-OFF)
High Voltage Safety System – Vehicle On and Operational (READY-ON)
o
q
o
p
A
C 3-Phase
0V
Inverter/
Converter
A
/C
Compressor
Electric Motor
Battery
Charger
Controller
Charger Assembly
p
V
olt DC
00
V
olt DC
n
EV Battery Assembly
EV Battery Assembly
Electric Vehicle Computer
12 Volt Auxiliary Battery
V
olt DC
V
olt DC
277.5
277.5
00
00
V
olt DC
00
V
olt DC
V
olt DC
00
A
/C
Compressor Inverter/
Converter
Electric Motor
V
olt DC
00
00
A
C 3-Phase
270 V
V
olt DC
Char
g
er Assembl
y
Battery
Charger
Controller
V
olt DC
12 Volt Auxiliary Battery
00
Electric Vehicle Computer
12

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.
Necessary Items
• Protective clothing such as insulated gloves (electrically insulated), rubber gloves, safety goggles,
and safety shoes.
• Insulating tape such as electrical tape that has a suitable electrical insulation rating.
• Before wearing insulated gloves, make sure that they are not cracked, ruptured, torn, or damaged in
any way. Do not wear wet insulated gloves.
• An electrical tester that is capable of measuring DC 750 Volts or more.
13

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. 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. Fold down helmet shields are not acceptable for 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.
14

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. To prevent serious injury or death
from severe burns or electric shock, avoid touching, cutting, or opening
any orange high voltage power cable or any high voltage component.
1. Shut off the ignition (READY indicator is off).
Then disconnect the cable from the auxiliary
battery negative (-) terminal.
(1) Open the hood.
(2) Disconnect the auxiliary battery negative (-)
terminal.
2. Remove the center floor hole cover.
(1) Move the front seat assembly LH to the
rearmost position.
(2) Turn back the center floor hole cover carpet.
(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.
15

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.
• All the high voltage wiring connectors are orange.
Notice:
To prevent the EV battery assembly from being damaged by falling objects,
temporarily install the front upper floor cover after removing the service plug grip.
(1) Wear insulating gloves and remove the service
plug grip after sliding up the lever of the
service plug grip as shown in the illustration.
Caution:
• Keep the removed service plug grip in
your pocket to prevent other technicians
from accidentally reconnecting it while
you are servicing the vehicle.
• After removing the service plug grip, wait
for at least 10 minutes before touching
any of the high voltage connectors or
terminals. After waiting for 10 minutes,
check the voltage at the terminals in the
inspection point in the inverter with
converter assembly. The voltage should
be 0 V before beginning work.
Notice:
• Turning the power switch to READY ON
with the service plug grip removed can cause a malfunction, so make sure not to
turn the power switch to READY ON.
• Connect the auxiliary battery on the same day of installing the service plug grip to
allow the battery cell voltage equalization function of the battery smart unit to
operate.
Hint:
Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the
inverter with converter assembly and electric vehicle charger assembly.
16

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. If the service plug grip cannot be removed due to damage to the vehicle, remove the IG2
fuse (10 A red colored).
Caution:
This operation shuts off the EV system. Be sure to wear insulated gloves because
high voltage is not shut off inside the EV battery. When it is possible to remove the
service plug grip, remove it and continue the procedure.
IG2 fuse (10 A Red)
7. After disconnecting or exposing a high-voltage
connector or terminal, insulate it immediately
using insulating tape. Before disconnecting or
touching a bare high-voltage terminal, wear
insulated gloves.
17