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Home >> Toyota >> 2018 >> Prius One >> Repair and Diagnosis >> External Pages >> Different car >> Section 147 (Hybrid Battery Control System (Service Information) (1 Of 2)) >> HV RELAY ASSEMBLY (for NICKEL METAL HYDRIDE BATTERY) >> Removal [04/2018 - 08/2020] >> Procedure

Removal [04/2018 - 08/2020]: Procedure

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  1. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [04/2018 - 08/2020] 

  2. DISCONNECT ENGINE ROOM MAIN WIRE 

    See step  2

  3. REMOVE CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 9

  4. CHECK TERMINAL VOLTAGE 

    Refer to PROCEDURE - Step 10

  5. INSTALL CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 5

  6. CONNECT ENGINE ROOM MAIN WIRE 

    See step  19

  7. REMOVE NO. 1 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY 

    Refer to REMOVAL [04/2018 - 08/2020]

  8. REMOVE REAR DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 8

  9. REMOVE REAR UNDER SIDE COVER LH 

    See step  5

  10. REMOVE REAR DOOR SCUFF PLATE RH 

    HINT: 

    Use the same procedure as for the LH side.

  11. REMOVE REAR UNDER SIDE COVER RH 

    See step  7

  12. REMOVE REAR UNDER COVER 

    See step  8

  13. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY 

    See step  9

  14. REMOVE NO. 1 HV BATTERY COVER PANEL RH 

    Refer to PROCEDURE - Step 8

  15. DISCONNECT HV FLOOR UNDER WIRE 

    Refer to PROCEDURE - Step 9

  16. DISCONNECT FLOOR WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Disengage the clamp.
      GTY762800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the electric vehicle battery plug assembly connector.
    3. Disconnect the HV battery junction block assembly connector.
    4. Disengage the 2 clamps to disconnect the floor wire.
      GTY773437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT 

    Refer to PROCEDURE - Step 13

  18. REMOVE UPPER HV BATTERY COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  19. 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.
      GTY762990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the HV battery junction block assembly connector.
      GTY762992Courtesy 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.
      GTY762987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the HV battery junction block assembly connector.
      NOTE:

      Insulate the disconnected connectors with insulating tape.

      GTY762988Courtesy 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.
      GTY753646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
    7. Disconnect the HV battery junction block assembly connector.
      GTY773479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the 4 nuts and HV battery junction block assembly from the HV battery.
      NOTE:

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

      GTY762984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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