HV RELAY ASSEMBLY 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 Procedures Effect/Inoperative Function when Necessary Procedure not Performed Link
Auxiliary battery terminal is disconnected/reconnected Memorize steering angle neutral point Lane departure alert system (w/ Steering Control)

Click here

Intelligent clearance sonar system*1
Simple intelligent parking assist system*1
Pre-crash safety system
Adaptive high beam system
Parking assist monitor system

Click here

Initialize back door lock Power door lock control system

Click here

Replacement of HV battery junction block assembly Current sensor offset learning DTCs are stored

Click here

*1: When performing learning using the GTS.
Click here Click here

CAUTION:


  • B006HTF

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

    Click here

  • B006HUP

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

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.

    Click here

  2. REMOVE SERVICE PLUG GRIP

    Click here

  3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  4. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)

    Click here

  5. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

    Click here

  6. REMOVE WATER GUARD PLATE

    Click here

  7. REMOVE COWL BODY MOUNTING REINFORCEMENT LH

    Click here

  8. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

    Click here

  9. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (w/o Canister Pump Module)

    Click here

  10. DISCONNECT ENGINE WIRE (w/o Canister Pump Module)

    Click here

  11. DISCONNECT ENGINE WIRE (w/ Canister Pump Module)

    Click here

  12. REMOVE CONNECTOR COVER ASSEMBLY

    Click here

  13. CHECK TERMINAL VOLTAGE

    Click here

  14. INSTALL CONNECTOR COVER ASSEMBLY

    Click here

  15. CONNECT ENGINE WIRE (w/ Canister Pump Module)

    Click here

  16. CONNECT ENGINE WIRE (w/o Canister Pump Module)

    Click here

  17. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (w/o Canister Pump Module)

    Click here

  18. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

    Click here

  19. INSTALL COWL BODY MOUNTING REINFORCEMENT LH

    Click here

  20. INSTALL WATER GUARD PLATE

    Click here

  21. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)

    Click here

  22. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

    Click here

  23. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  24. REMOVE TONNEAU COVER ASSEMBLY

    Click here

  25. REMOVE REAR NO. 3 FLOOR BOARD

    Click here

  26. REMOVE REAR NO. 4 FLOOR BOARD

    Click here

  27. REMOVE DECK FLOOR BOX LH

    Click here

  28. REMOVE DECK FLOOR BOX RH

    Click here

  29. REMOVE DECK TRIM SERVICE HOLE COVER

    Click here

  30. REMOVE REAR DECK TRIM COVER

    Click here

  31. REMOVE REAR SEAT HEADREST ASSEMBLY (for LH Side)

    Click here

  32. REMOVE REAR SEAT HEADREST ASSEMBLY (for RH Side)

    Click here

  33. REMOVE REAR SEATBACK ASSEMBLY LH

    Click here

  34. REMOVE REAR SEATBACK HINGE COVER

    Click here

  35. REMOVE REAR SEATBACK ASSEMBLY RH

    Click here

  36. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP LH

    Click here

  37. REMOVE REAR SEATBACK HINGE SUB-ASSEMBLY LH

    Click here

  38. REMOVE REAR SEAT SIDE GARNISH LH

    Click here

  39. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH

    Click here

  40. REMOVE REAR SEATBACK HINGE SUB-ASSEMBLY RH

    Click here

  41. REMOVE REAR SEAT SIDE GARNISH RH

    Click here

  42. REMOVE ROPE HOOK (for RH Side without Toyota Safety Sense)

    Click here

  43. REMOVE NO. 2 ROPE HOOK (for RH Side without Toyota Safety Sense)

    Click here

  44. REMOVE NO. 1 TONNEAU COVER HOLDER CAP (for RH Side with Toyota Safety Sense)

    Click here

  45. REMOVE TONNEAU COVER HOOK A (for RH Side with Toyota Safety Sense)

    Click here

  46. REMOVE NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY

    Click here

  47. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH

    Click here

  48. REMOVE REAR SEAT CONSOLE BOX ASSEMBLY

    Click here

  49. REMOVE REAR FLOOR FRONT BATTERY COVER BOARD

    Click here

  50. REMOVE NO. 1 HV BATTERY SHIELD PANEL

    Click here

  51. REMOVE NO. 3 HV BATTERY SHIELD PANEL

    Click here

  52. REMOVE NO. 2 HV BATTERY SHIELD PANEL

    Click here

  53. REMOVE UPPER HYBRID BATTERY COVER SUB-ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. B006HVMC02
      *a Bolt
      *b Nut

      Remove the 12 bolts, 8 nuts and upper hybrid battery cover sub-assembly from the HV battery.

  54. DISCONNECT WIRE HARNESS

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.

    Note

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


    1. B006I8YN01

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

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

  55. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.

    Note

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


    1. No. 1 HV battery junction block assembly:


      1. B006JA8

        Disconnect the 4 No. 1 HV battery junction block assembly connectors.

      2. B006IZP

        Remove the 5 nuts and No. 1 HV battery junction block assembly from the HV battery.

        Note

        If the No. 1 HV battery junction block assembly has been struck or dropped, replace it.

    2. B006HL3

      No. 2 HV battery junction block assembly:


      1. Disconnect the 4 No. 2 HV battery junction block assembly connectors.

      2. Disengage the 2 clamps.

      3. B006HGN

        Remove the 4 nuts and No. 2 HV battery junction block assembly from the HV battery.

        Note

        If the No. 2 HV battery junction block assembly has been struck or dropped, replace it.