More Toyota EV, Hybrid and Hydrogen Vehicles - BodyShop Business

More Toyota EV, Hybrid and Hydrogen Vehicles

Sponsored by Toyota


As Toyota moves forward with the production of Electric Vehicles (EVs), Hydrogen Fuel Cell Vehicles (FCVs), and Hybrid Vehicles (HVs), the question is: Is your collision repair facility prepared for the challenges that these vehicles present?

To make vehicles more efficient, Toyota is making vehicles lighter and more sophisticated:

  • Reduced weight means the vehicle requires less power to get moving.
  • More sophistication means implementing technology that makes the powertrain more efficient.

What does that mean for your collision repair facility?

It means that estimating, diagnosing, and repairing an EV, FCV or HV damaged in a collision presents new challenges that shops have never seen, including:

  • Disarming the high voltage systems
  • Additional refinishing time

Toyota’s Technical Information System (TIS) provides you with assets that will help you get up-to-speed on these high-tech vehicles. When a Toyota EV, FCV or HV comes into your shop for collision repairs, Toyota has a bulletin that outlines how to protect yourself during repairs and provides precautions that need to be taken prior to the inspection and service of the high-voltage circuit.

When an EV, FCV or HV has been in a collision, there’s a chance that the battery and its contents have been compromised. The major dangers of damaged batteries and wiring are electrocution and combustion. As a precaution, all high-voltage batteries should be treated as though they are unstable.

Here are some procedures technicians need to be aware of when working on an EV, FCV or HV:

  • Wait at least 10 minutes to discharge the high-voltage capacitor inside the inverter.
  • If the battery has been damaged or punctured, the vehicle should be isolated in a place at least 50 feet away from other flammable or combustible materials (due to some batteries being extremely difficult to extinguish once they are on fire).
  • Place any object that could start the engine or hybrid system, including key fobs, away from the vehicle. They should be locked in a container and moved out of range from the vehicle.
  • Once a high-voltage battery is disabled and discharged, the vehicle should never be rolled on its wheels, as this can generate voltage to the battery system.
  • High-voltage personal protection equipment may be necessary, including gloves (rubber and leather), boots, face shield, and safety glasses.
  • Check insulated gloves to be sure they are free of cracks, tears, and other types of damage before starting your work.
  • When servicing the vehicle, do not carry any metal objects—like mechanical pencils or rulers — that can be dropped accidentally and cause a short circuit.
  • Before touching a bare high-voltage terminal, wear insulated gloves and use a tester to make sure that the terminal voltage is 0 V.
  • After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulating tape.
  • Bolts and nuts used for high-voltage terminals should be tightened to the specified torque — insufficient or excessive torque could cause a failure.
  • Use the “CAUTION: HIGH VOLTAGE DO NOT TOUCH” sign to notify others that the high-voltage system is being inspected and/or repaired.
  • When welding on an EV, FCV, or HV, follow the same precautions as when welding on a conventional vehicle; as a best practice, disconnect both the 12 V battery and the high-voltage battery service disconnect.
  • After servicing a high-voltage system and before reinstalling the service plug grip, check that you haven’t left any parts or tools inside, that the high-voltage terminals are firmly tightened, and that the connectors are correctly connected.
  • When working on a high-voltage circuit, use either a tool wrapped with vinyl insulation tape or use an insulated tool.

There are additional guidelines and cautions, so be sure to read the appropriate bulletin before starting repairs.

Before starting repairs on a Mirai, an FCV-Qualified Toyota Dealership and Technician must be consulted to assess the damage to the hydrogen fuel system components (i.e., the fuel cell stack, fuel system piping, receptacle, tube joints, sensors, regulator, and tank assemblies) prior to collision repairs. Please contact the Toyota Customer Experience Center for FCV-Qualified Dealers: 800 331-4331.

Many of the precautions for EVs and HVs are the same for the Mirai, but you must remember you are dealing with compressed hydrogen stored in tanks.

Before touching a bare high-voltage terminal, wear insulated gloves and use a tester to make sure that the terminal voltage is 0 V. After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulating tape.

  • The tanks on Mirai store hydrogen at high pressures and the hydrogen must be released prior to removing the tanks from the vehicle. Have an FCV-Qualified Toyota Technician assist in the releasing of the hydrogen.
  • High-pressure hydrogen pipes have red insulation for identification purposes.
  • Toyota genuine fuel cell stack coolant cannot be reused — refill only with new Toyota Genuine FC Stack Coolant Full Service Kit-20L (P/N 08889-80350).
  • When cutting and welding, do not allow sparks or hot fragments to contact the hydrogen fuel components. If that occurs, remove the hydrogen tanks before proceeding.
  • Do not allow solvents to contact the hydrogen fuel tanks.

Safety is key. Always be sure to do your research and take the appropriate precautions prior to working on one of these sophisticated vehicles.

Here’s where you can find the Toyota High-Voltage Disable Procedures:

  1. Go to
  2. Enter your username and password
  3. Click Login
  4. Click on TIS Tab
  5. From the dropdown, select the Division, Model, and Year
  6. Click the Search Button
  7. Click on the RM Tab
  8. Click on the blue text
  9. A new page will open in a popup window
  10. Click the dropdown menu for Engine/Hybrid System and select Hybrid/Battery Control
  11. Click the dropdown menu for Service Plug Grip and select Removal

For more of the latest news, product information and best practices from Toyota, visit

You May Also Like

Restoring Beauty to America’s Roadways

By Steve Calitri

To many in America, particularly automobile buffs, the car is like a beautiful model designed and engineered by man; purely functional, yet designed with sleek and sensual contours. When the bodies of these gorgeous models are decaying or damaged, the auto body shop is called on to restore the vehicle to its original beauty. The best plastic surgeon wishes he could restore beauty with the precision of a body man.

Use Less, Make More in the Paint Shop

One of the challenges we face every day is how can we be more competitive in the marketplace. Collision Centers must be efficient and profitable if they want to remain in the game long term. It is critical that we identify the steps to becoming more efficient by using less to make more money. Step

From Truck Beds to RVs: How GLADIATOR™ XC Elevates Protective Coatings

Explore the all new matte extreme coating


By Steve Calitri

Encouraging Continued Education Through Your Trusted Distribution Partner

In today’s collision repair industry, it’s crucial to acknowledge the fact that vehicles have undergone significant changes. These changes have been so extensive that they can no longer be compared to our parents’ or grandparents’ vehicles. We were used to straightening metal, sanding, and spraying paint, but now we have to be computer technicians, metallurgy

Other Posts

Lucid Group Debuts New EV with 516-mile Range

Lucid claims the 2024 Air Grand Touring starting at $109,900 is the longest-range EV available today.

Electric Vehicles and ADAS

Jason Stahl and Jason Wong discuss the similarities and differences in calibrating ADAS systems in EVs vs. ICE vehicles.

Autel Releases the AC Elite G2 Charging Series 

The charger can be used in various settings, such as public commercial parking areas, residential areas, hospitals and service areas.

Tesla Model 3 TPMS Service

Resetting and programming TPMS sensors for a Tesla is a lot like any other vehicle, and the challenge is still the same: keeping the light off.