Last Modified: 08-21-2023 6.11:8.1.0 Doc ID: RM100000001B3SM
Model Year Start: 2019 Model: Avalon HV Prod Date Range: [04/2018 - 08/2020]
Title: HYBRID / BATTERY CONTROL: FRAME WIRE: REMOVAL; 2019 - 2020 MY Avalon HV [04/2018 - 08/2020]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during HV floor under wire removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedure

Effect/Inoperative Function when Necessary Procedure not Performed

Link
*: When performing learning using the Techstream.

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; PARK ASSIST / MONITORING: INTELLIGENT CLEARANCE SONAR SYSTEM (for HV Model): CALIBRATION

Auxiliary battery terminal is disconnected/reconnected

Perform steering sensor zero point calibration

Lane departure alert system (w/ Steering Control)

2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; PRE-COLLISION: PRE-COLLISION SYSTEM (for HV Model): INITIALIZATION

Pre-collision system

Intelligent clearance sonar system*

Lighting System (for HV Model with Cornering Light)

Memorize steering angle neutral point

Parking assist monitor system

2019 - 2022 MY Avalon HV [04/2018 -        ]; PARK ASSIST / MONITORING: PARKING ASSIST MONITOR SYSTEM(for HV Model): INITIALIZATION

Panoramic view monitor system

2019 - 2022 MY Avalon HV [04/2018 -        ]; PARK ASSIST / MONITORING: PANORAMIC VIEW MONITOR SYSTEM (for HV Model): INITIALIZATION

  • Replacement of air fuel ratio sensor
  • Gas leak from exhaust system is repaired

Inspection After Repair
  • Poor idle, etc.
  • Engine start function, etc.

2019 MY Avalon HV [04/2018 - 08/2019]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION

CAUTION:

  • Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.

    Click here 2019 - 2020 MY Avalon HV [04/2018 - 08/2020]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for NICKEL METAL HYDRIDE BATTERY): PRECAUTION

  • To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.
  • To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.
  • To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

NOTICE:

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.

Click here 2019 - 2022 MY Avalon Avalon HV [04/2018 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

PROCEDURE

1. REMOVE SERVICE PLUG GRIP

Click here 2019 - 2020 MY Avalon HV [04/2018 - 08/2020]; HYBRID / BATTERY CONTROL: SERVICE PLUG GRIP: REMOVAL

2. DISCONNECT ENGINE ROOM MAIN WIRE

CAUTION:

Be sure to wear insulated gloves.

NOTICE:

Do not allow any foreign matter or water to enter the inverter with converter assembly.

(a) Move the lock lever while pushing the lock on the connector, and disconnect the inverter with converter assembly connector.

NOTICE:

  • Do not damage the terminals, connector housing or inverter with converter assembly during disconnection.
  • Cover the hole where the cable was connected with tape (non-residue type) or equivalent to prevent entry of foreign matter.
  • Insulate the disconnected terminals with insulating tape.
  • Do not touch the waterproof seal or terminals of the connector.

3. REMOVE CONNECTOR COVER ASSEMBLY

Click here 2019 - 2020 MY Avalon HV [04/2018 - 08/2020]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER: REMOVAL+

4. CHECK TERMINAL VOLTAGE

Click here 2019 - 2020 MY Avalon HV [04/2018 - 08/2020]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER: REMOVAL+

5. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

Click here 2019 - 2020 MY Avalon HV [04/2018 - 08/2020]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER: REMOVAL+

6. DISCONNECT HV FLOOR UNDER WIRE

Click here 2019 - 2020 MY Avalon HV [04/2018 - 08/2020]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER: REMOVAL+

7. DISCONNECT REAR CENTER SEAT OUTER BELT ASSEMBLY

Click here 2019 - 2020 MY Avalon Avalon HV [04/2018 - 08/2020]; SEAT: REAR SEAT ASSEMBLY: REMOVAL+

8. REMOVE REAR SEAT CUSHION ASSEMBLY

Click here 2019 - 2020 MY Avalon Avalon HV [04/2018 - 08/2020]; SEAT: REAR SEAT ASSEMBLY: REMOVAL+

9. REMOVE REAR SEAT CUSHION LOCK HOOK

Click here 2019 - 2020 MY Avalon Avalon HV [04/2018 - 08/2020]; SEAT: REAR SEAT ASSEMBLY: REMOVAL+

10. REMOVE REAR DOOR SCUFF PLATE LH

Click here 2019 - 2020 MY Avalon Avalon HV [04/2018 - 08/2020]; INTERIOR PANELS / TRIM: ROOF HEADLINING: REMOVAL+

11. REMOVE REAR UNDER SIDE COVER LH

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; HYBRID / BATTERY CONTROL: BATTERY BLOWER: REMOVAL+

12. REMOVE REAR DOOR SCUFF PLATE RH

HINT:

Use the same procedure as for the LH side.

13. REMOVE REAR UNDER SIDE COVER RH

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; HYBRID / BATTERY CONTROL: BATTERY BLOWER: REMOVAL+

14. REMOVE REAR UNDER COVER

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; HYBRID / BATTERY CONTROL: BATTERY BLOWER: REMOVAL+

15. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; HYBRID / BATTERY CONTROL: BATTERY BLOWER: REMOVAL+

16. REMOVE NO. 1 HV BATTERY COVER PANEL RH

Click here 2019 - 2020 MY Avalon HV [04/2018 - 08/2020]; HYBRID / BATTERY CONTROL: HV BATTERY (for NICKEL METAL HYDRIDE BATTERY): REMOVAL+

17. DISCONNECT HV FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Disconnect the 2 HV battery junction block assembly connectors.

NOTICE:

Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

*a

Shield Ground

(b) Disconnect the shield ground from the HV battery.

(c) Disconnect the floor wire connector.

18. REMOVE FRONT EXHAUST PIPE ASSEMBLY

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (INTAKE / EXHAUST): EXHAUST PIPE: REMOVAL

19. REMOVE EXHAUST MANIFOLD

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (INTAKE / EXHAUST): EXHAUST MANIFOLD: REMOVAL

20. REMOVE NO. 1 FLOOR UNDER COVER

Click here 2019 - 2020 MY Avalon Avalon HV [04/2018 - 08/2020]; REAR SUSPENSION: REAR TRAILING ARM: REMOVAL+

21. REMOVE CENTER NO. 2 FLOOR HEAT INSULATOR

(a) Remove the 3 nuts and center No. 2 floor heat insulator.

22. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Remove the 2 nuts and disconnect the transmission control cable assembly.

23. REMOVE HV FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves.

NOTICE:

Insulate the disconnected connectors with insulating tape.

(a) Remove the 2 nuts.

(b) Remove the 2 clamps.

NOTICE:

If the clamps are removed forcibly, the stud bolts may be damaged.

(c) Disengage the grommet and pull out the HV floor under wire from the floor panel hole.

(d) Remove the 3 nuts.

(e) Remove the 2 nuts and clamp.

NOTICE:

If the clamp is removed forcibly, the stud bolt may be damaged.

(f) Disengage the clamp.

(g) Disconnect the HV floor under wire connector.

(h) Remove the nut and HV floor under wire.