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Home >> Toyota >> 2015 >> Avalon Hybrid Limited >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Battery Management Systems >> Hybrid Battery Control System (Service Information) (Hybrid) >> HV Relay Assembly >> Removal [10/2014 - ] >> Procedure

Removal [10/2014 - ]: Procedure

  1. PRECAUTION 

    (Refer to PRECAUTION [10/2014 - ] )

  2. CHECK FOR DTCS 
    1. Check for DTCs (Refer to DTC CHECK / CLEAR [10/2014 - 10/2015] or DTC CHECK / CLEAR [10/2015 - ] ).
      NOTE:

      Confirm that P0AA6 (Hybrid Battery Voltage System Isolation Fault) is not output before removing the HV battery. If this DTC is output, perform troubleshooting for this DTC first.

  3. REMOVE SERVICE PLUG GRIP 

    (Refer to REMOVAL [10/2014 - ] )

  4. REMOVE CONNECTOR COVER ASSEMBLY 

    See step  4

  5. CHECK TERMINAL VOLTAGE 

    See step  5

  6. INSTALL CONNECTOR COVER ASSEMBLY 

    See step  20

  7. REMOVE REAR SEAT ASSEMBLY 

    (Refer to REMOVAL [10/2014 - ] )

  8. REMOVE NO. 4 HYBRID BATTERY SHIELD PANEL 
    WARNING:

    Wear insulated gloves.

    1. Using the service plug grip, remove the battery cover lock striker.
      GTY563077Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Service Plug Grip
      *2 Battery Cover Lock Striker
      *3 Button
      *a Projection
      *b Turn

      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. Remove the bolt, 2 nuts and No. 4 hybrid battery shield panel.
      GTY320194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. DISCONNECT NO. 4 FLOOR WIRE 
    WARNING:

    Wear insulated gloves.

    1. Disconnect the shield wire ground from the No. 1 hybrid battery shield sub-assembly.
      GTY564699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Shield Wire Ground
    2. Disconnect the 2 connectors from the hybrid battery junction block assembly.
      NOTE:

      Insulate the disconnected connectors with insulating tape.

  10. REMOVE NO. 1 HYBRID BATTERY SHIELD SUB-ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. Disconnect the connector and wire harness clamp.
      GTY566047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt, 3 nuts and No. 1 hybrid battery shield sub-assembly from the HV battery.
      GTY584782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. Disengage the claw and disconnect the terminal cover.
      GTY320186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an insulated tool, remove the 2 bolts from the hybrid battery junction block assembly.
      GTY320180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Insulate the disconnected terminals with insulating tape.

    3. Disconnect the connector from the hybrid battery junction block assembly.
      GTY320182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 3 bolts and hybrid battery junction block assembly from the HV battery.
      GTY314794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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