Toyota Avalon (XX50) 2019-2022 Service & Repair Manual: Removal

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.

CAUTION:

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

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• 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.

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PROCEDURE

1. REMOVE SERVICE PLUG GRIP

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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

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4. CHECK TERMINAL VOLTAGE

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5. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

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6. DISCONNECT HV FLOOR UNDER WIRE

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7. DISCONNECT REAR CENTER SEAT OUTER BELT ASSEMBLY

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8. REMOVE REAR SEAT CUSHION ASSEMBLY

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9. REMOVE REAR SEAT CUSHION LOCK HOOK

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10. REMOVE REAR DOOR SCUFF PLATE LH

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11. REMOVE REAR UNDER SIDE COVER LH

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12. REMOVE REAR DOOR SCUFF PLATE RH

HINT:

Use the same procedure as for the LH side.

13. REMOVE REAR UNDER SIDE COVER RH

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14. REMOVE REAR UNDER COVER

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15. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY

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16. REMOVE NO. 1 HV BATTERY COVER PANEL RH

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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.

18. REMOVE FRONT EXHAUST PIPE ASSEMBLY

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19. REMOVE EXHAUST MANIFOLD

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20. REMOVE NO. 1 FLOOR UNDER COVER

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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.