Last Modified: 08-21-2023 6.11:8.1.0 Doc ID: RM100000001PZ6V
Model Year Start: 2021 Model: Avalon HV Prod Date Range: [08/2020 -           ]
Title: HYBRID / BATTERY CONTROL: HV RELAY ASSEMBLY (for LITHIUM-ION BATTERY): INSTALLATION; 2021 - 2022 MY Avalon HV [08/2020 -        ]

INSTALLATION

PROCEDURE

1. INSTALL HV BATTERY JUNCTION BLOCK ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Install the HV battery junction block assembly to the HV battery with the 4 nuts.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

NOTICE:

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

(b) Engage the 2 claws to install the wiring harness protector.

(c) Connect the 2 HV battery junction block assembly connectors.

NOTICE:

Make sure that the connectors are connected securely.

(d) Install the electric vehicle battery plug assembly to the HV battery with the bolt.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

(e) Connect the hybrid battery terminal block connector.

NOTICE:

Make sure that the connector is connected securely.

(f) Connect the HV battery junction block assembly connector.

NOTICE:

Make sure that the connector is connected securely.

(g) Engage the 2 claws to close the wiring harness protector.

2. CONNECT FLOOR WIRE

Click here 2021 - 2022 MY Avalon HV [08/2020 -        ]; HYBRID / BATTERY CONTROL: HV BATTERY (for LITHIUM-ION BATTERY): INSTALLATION+

3. CONNECT HV FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Connect the shield ground to the HV battery.

(b) Connect the 2 HV battery junction block assembly connectors.

NOTICE:

Make sure that the connectors are connected securely.

4. INSTALL NO. 1 HV BATTERY COVER PANEL RH

Click here 2021 - 2022 MY Avalon HV [08/2020 -        ]; HYBRID / BATTERY CONTROL: HV BATTERY (for LITHIUM-ION BATTERY): INSTALLATION+

5. INSTALL REAR SEAT CUSHION LEG SUB-ASSEMBLY

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

6. INSTALL REAR UNDER COVER

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

7. INSTALL REAR UNDER SIDE COVER LH

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

8. INSTALL REAR DOOR SCUFF PLATE LH

Click here 2021 - 2022 MY Avalon Avalon HV [08/2020 -        ]; INTERIOR PANELS / TRIM: ROOF HEADLINING: INSTALLATION+

9. INSTALL REAR UNDER SIDE COVER RH

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

10. INSTALL REAR DOOR SCUFF PLATE RH

HINT:

Use the same procedure as for the LH side.

11. INSTALL REAR SEAT CUSHION LOCK HOOK

Click here 2021 - 2022 MY Avalon Avalon HV [08/2020 -        ]; SEAT: REAR SEAT ASSEMBLY: INSTALLATION+

12. INSTALL REAR SEAT CUSHION ASSEMBLY

Click here 2021 - 2022 MY Avalon Avalon HV [08/2020 -        ]; SEAT: REAR SEAT ASSEMBLY: INSTALLATION+

13. CONNECT REAR CENTER SEAT OUTER BELT ASSEMBLY

Click here 2021 - 2022 MY Avalon Avalon HV [08/2020 -        ]; SEAT: REAR SEAT ASSEMBLY: INSTALLATION+

14. INSTALL SERVICE PLUG GRIP

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; HYBRID / BATTERY CONTROL: SERVICE PLUG GRIP: INSTALLATION

15. PERFORM CURRENT SENSOR OFFSET LEARNING

HINT:

Perform this procedure when the HV battery junction block assembly or battery ECU assembly has been replaced.

(a) Connect the Techstream to the DLC3.

(b) Turn the power switch on (READY).

(c) Perform a road test.

NOTICE:

Accelerate and decelerate gently. Avoid rapid acceleration and deceleration.

(1) Enter the following menus: Powertrain / HV Battery / Data List / Hybrid Battery Current.

Powertrain > HV Battery > Data List

Tester Display

Hybrid Battery Current

(2) Drive the vehicle with the value of Data List item "Hybrid Battery Current" between -50 A and 50 A.

HINT:

Distance and driving time are not specified.

(3) Turn the power switch off and leave the vehicle for 30 seconds or more.

(4) Turn the power switch on (IG).

(5) Enter the following menus: Powertrain / HV Battery / Data List / Hybrid Battery Current.

Powertrain > HV Battery > Data List

Tester Display

Hybrid Battery Current

(6) Check that the value of "Hybrid Battery Current" is between -0.5 A and 0.5 A with the power switch on (IG).

NOTICE:

If the value is outside the specified range, perform the road test again.

HINT:

  • When the power switch is on (IG), if value of "Hybrid Battery Current" is between -0.5 A and 0.5 A, current sensor offset learning has been completed.
  • Even if the current sensor offset learning is not complete, the current sensor value will be corrected by repeating the road test a maximum of 7 times.