HV RELAY ASSEMBLY INSTALLATION

PROCEDURE

1. INSTALL HV BATTERY JUNCTION BLOCK ASSEMBLY

   CAUTION:

   Be sure to wear insulated gloves and protective goggles.

   
   

   1. No. 2 HV battery junction block assembly:

      
      

      1. Install the No. 2 HV battery junction block assembly to the HV battery with the 4 nuts.

         Torque:

         7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

         Note

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

      2. Engage the 2 clamps.

      3. Connect the 4 No. 2 HV battery junction block assembly connectors.

         Note

         Make sure that the connectors are connected securely.

   2. No. 1 HV battery junction block assembly:

      
      

      1. Install the No. 1 HV battery junction block assembly to the HV battery with the 5 nuts.

         Torque:

         7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

         Note

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

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

         Note

         Make sure that the connectors are connected securely.

2. CONNECT WIRE HARNESS

   CAUTION:

   Be sure to wear insulated gloves and protective goggles.

   
   

   1. 

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

      Note

      Make sure that the connectors are connected securely.

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

      Note

      Make sure that the connectors are connected securely.

3. INSTALL UPPER HYBRID BATTERY COVER SUB-ASSEMBLY

   CAUTION:

   Be sure to wear insulated gloves and protective goggles.

   
   

   1. Install the upper hybrid battery cover sub-assembly to the HV battery with the 12 bolts and 8 nuts.

      Torque:

      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

4. INSTALL NO. 2 HV BATTERY SHIELD PANEL

   Click here

5. INSTALL NO. 3 HV BATTERY SHIELD PANEL

   Click here

6. INSTALL NO. 1 HV BATTERY SHIELD PANEL

   Click here

7. INSTALL REAR FLOOR FRONT BATTERY COVER BOARD

   Click here

8. INSTALL REAR SEAT CONSOLE BOX ASSEMBLY

   Click here

9. INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH

   Click here

10. INSTALL NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY

    Click here

11. INSTALL TONNEAU COVER HOOK A (for RH Side with Toyota Safety Sense)

    Click here

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

    Click here

13. INSTALL NO. 2 ROPE HOOK (for RH Side without Toyota Safety Sense)

    Click here

14. INSTALL ROPE HOOK (for RH Side without Toyota Safety Sense)

    Click here

15. INSTALL REAR SEAT SIDE GARNISH LH

    Click here

16. INSTALL REAR SEATBACK HINGE SUB-ASSEMBLY LH

    Click here

17. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP LH

    Click here

18. INSTALL REAR SEAT SIDE GARNISH RH

    Click here

19. INSTALL REAR SEATBACK HINGE SUB-ASSEMBLY RH

    Click here

20. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH

    Click here

21. INSTALL REAR SEATBACK ASSEMBLY LH

    Click here

22. INSTALL REAR SEATBACK ASSEMBLY RH

    Click here

23. INSTALL REAR SEATBACK HINGE COVER

    Click here

24. INSTALL REAR SEAT HEADREST ASSEMBLY (for LH Side)

    Click here

25. INSTALL REAR SEAT HEADREST ASSEMBLY (for RH Side)

    Click here

26. INSTALL REAR DECK TRIM COVER

    Click here

27. INSTALL DECK TRIM SERVICE HOLE COVER

    Click here

28. INSTALL DECK FLOOR BOX LH

    Click here

29. INSTALL DECK FLOOR BOX RH

    Click here

30. INSTALL REAR NO. 4 FLOOR BOARD

    Click here

31. INSTALL REAR NO. 3 FLOOR BOARD

    Click here

32. INSTALL TONNEAU COVER ASSEMBLY

    Click here

33. INSTALL SERVICE PLUG GRIP

    Click here

34. PERFORM CURRENT SENSOR OFFSET LEARNING

    Tech Tips

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

    
    

    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (READY).

    3. Perform a road test.

       Note

       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.

          Tech Tips

          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).

          Note

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

          Tech Tips

          
          

          • 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.