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Home >> Toyota >> 2016 >> Prius Two >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Battery Management Systems >> Hybrid Battery Control System - Service Information (3 Of 3) >> HV RELAY ASSEMBLY (for NICKEL METAL HYDRIDE BATTERY) >> Removal [11/2015 - 12/2018] >> Procedure

Removal [11/2015 - 12/2018]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    Refer to PRECAUTION [11/2015 - 11/2017] Refer to PRECAUTION [11/2017 - 12/2018]

  2. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [11/2015 - 12/2018] 

  3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [11/2015 - ]

  4. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL 

    Refer to PROCEDURE - Step 3

  5. REMOVE WATER GUARD PLATE LH 

    Refer to PROCEDURE - Step 4

  6. REMOVE COWL BODY MOUNTING REINFORCEMENT LH 

    Refer to PROCEDURE - Step 5

  7. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  8. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 13 [11/2015 - 08/2016] Refer to PROCEDURE - Step 13 [08/2016 - 12/2018]

  9. DISCONNECT ENGINE WIRE 

    Refer to PROCEDURE - Step 9

  10. REMOVE CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 16

  11. CHECK TERMINAL VOLTAGE 

    Refer to PROCEDURE - Step 17

  12. INSTALL CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 12

  13. CONNECT ENGINE WIRE 

    See step  17

  14. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 72 [11/2015 - 08/2016] Refer to PROCEDURE - Step 72 [08/2016 - 12/2018]

  15. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 14

  16. INSTALL COWL BODY MOUNTING REINFORCEMENT LH 

    Refer to PROCEDURE - Step 15

  17. INSTALL WATER GUARD PLATE LH 

    Refer to PROCEDURE - Step 16

  18. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL 

    Refer to PROCEDURE - Step 17

  19. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to INSTALLATION [11/2015 - ]

  20. REMOVE REAR SEAT CUSHION ASSEMBLY 

    Refer to PROCEDURE - Step 7

  21. REMOVE REAR SEAT CUSHION LOCK HOOK 

    Refer to PROCEDURE - Step 8

  22. REMOVE REAR DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 18

  23. REMOVE REAR UNDER SIDE COVER LH 

    Refer to PROCEDURE - Step 35

  24. REMOVE REAR DOOR SCUFF PLATE RH 

    HINT: 

    Use the same procedure as for the LH side.

    Refer to PROCEDURE - Step 28

  25. REMOVE REAR UNDER SIDE COVER RH 

    HINT: 

    Use the same procedure as for the LH side.

    Refer to PROCEDURE - Step 46

  26. REMOVE REAR UNDER COVER 

    Refer to PROCEDURE - Step 26

  27. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 27

  28. REMOVE BATTERY COOLING BLOWER ASSEMBLY 

    See step  9

  29. REMOVE NO. 1 HV BATTERY COVER PANEL RH 

    Refer to PROCEDURE - Step 29

  30. DISCONNECT HV FLOOR UNDER WIRE 

    Refer to PROCEDURE - Step 30

  31. DISCONNECT FLOOR WIRE 

    Refer to PROCEDURE - Step 31

  32. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT 

    Refer to PROCEDURE - Step 32

  33. DISCONNECT FLOOR WIRE 

    Refer to PROCEDURE - Step 33

  34. REMOVE UPPER NO. 1 HYBRID BATTERY COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 34

  35. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    1. Remove the bolt and disconnect the electric vehicle battery plug assembly.
      GTY552036Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the HV battery junction block assembly connector.
      GTY563782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Insulate the disconnected connectors with insulating tape.

    3. Disengage the clamp.
    4. Disengage the 2 claws and open the wiring harness protector.
      GTY552037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the HV battery junction block assembly connector.
      NOTE:

      Insulate the disconnected connectors with insulating tape.

      GTY552038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a screwdriver with its tip wrapped with protective tape, disengage the 2 claws and remove the wiring harness protector.
      GTY570486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
    7. Disconnect the HV battery junction block assembly connector.
      GTY552033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the 4 nuts and HV battery junction block assembly from the No. 1 hybrid battery shield sub-assembly.
      NOTE:

      If the HV battery junction block assembly has been struck or dropped, replace it with a new one.

      GTY552034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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