Last Modified: 08-21-2023 6.11:8.1.0 Doc ID: RM100000001YOJK
Model Year Start: 2022 Model: Avalon HV Prod Date Range: [08/2021 -           ]
Title: HYBRID / BATTERY CONTROL: HV RELAY ASSEMBLY (for LITHIUM-ION BATTERY): REMOVAL; 2022 MY Avalon HV [08/2021 -        ]

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 battery junction block assembly 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)

2022 MY Avalon Avalon HV [08/2021 -        ]; PRE-COLLISION: PRE-COLLISION SYSTEM: 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 HV battery junction block assembly

Current sensor offset learning

DTCs are stored

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

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 2022 MY Avalon HV [08/2021 -        ]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for LITHIUM-ION BATTERY): PRECAUTION

  • To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.

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 2022 MY Avalon HV [08/2021 -        ]; HYBRID / BATTERY CONTROL: SERVICE PLUG GRIP: REMOVAL

2. DISCONNECT ENGINE ROOM MAIN WIRE

Click here 2022 MY Avalon HV [08/2021 -        ]; HYBRID / BATTERY CONTROL: FRAME WIRE: REMOVAL+

3. REMOVE CONNECTOR COVER ASSEMBLY

Click here 2022 MY Avalon HV [08/2021 -        ]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER: REMOVAL+

4. CHECK TERMINAL VOLTAGE

Click here 2022 MY Avalon HV [08/2021 -        ]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER: REMOVAL+

5. INSTALL CONNECTOR COVER ASSEMBLY

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

6. CONNECT ENGINE ROOM MAIN WIRE

Click here 2021 - 2022 MY Avalon HV [08/2020 -        ]; HYBRID / BATTERY CONTROL: FRAME WIRE: INSTALLATION+

7. DISCONNECT REAR CENTER SEAT OUTER BELT ASSEMBLY

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

8. REMOVE REAR SEAT CUSHION ASSEMBLY

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

9. REMOVE REAR SEAT CUSHION LOCK HOOK

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

10. REMOVE REAR DOOR SCUFF PLATE LH

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

17. DISCONNECT 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.

18. DISCONNECT FLOOR WIRE

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

19. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Disengage the 2 claws and open the wiring harness protector.

(b) Disconnect the HV battery junction block assembly connector.

NOTICE:

Insulate the disconnected high-voltage connector with insulating tape.

(c) Disconnect the hybrid battery terminal block connector.

NOTICE:

Insulate the disconnected high-voltage connector with insulating tape.

(d) Remove the bolt and electric vehicle battery plug assembly from the HV battery.

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

NOTICE:

Insulate the disconnected high-voltage connectors with insulating tape.

(f) Using a screwdriver with its tip wrapped with protective tape, disengage the 2 claws and remove the wiring harness protector.

*a

Protective Tape

(g) Remove the 4 nuts and HV battery junction block assembly from the HV battery.

NOTICE:

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