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 battery junction block assembly 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.

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

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3. REMOVE CONNECTOR COVER ASSEMBLY

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4. CHECK TERMINAL VOLTAGE

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5. INSTALL CONNECTOR COVER ASSEMBLY

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6. CONNECT ENGINE ROOM MAIN WIRE

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7. REMOVE NO. 1 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY

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8. REMOVE REAR DOOR SCUFF PLATE LH

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9. REMOVE REAR UNDER SIDE COVER LH

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10. REMOVE REAR DOOR SCUFF PLATE RH

HINT:

Use the same procedure as for the LH side.

11. REMOVE REAR UNDER SIDE COVER RH

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12. REMOVE REAR UNDER COVER

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13. REMOVE REAR SEAT CUSHION LEG SUB-ASSEMBLY

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14. REMOVE NO. 1 HV BATTERY COVER PANEL RH

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15. DISCONNECT HV FLOOR UNDER WIRE

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16. DISCONNECT FLOOR WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Disengage the clamp.

(b) Disconnect the electric vehicle battery plug assembly connector.

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

(d) Disengage the 2 clamps to disconnect the floor wire.

17. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT

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18. REMOVE UPPER HV BATTERY COVER SUB-ASSEMBLY

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19. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Remove the bolt and disconnect the electric vehicle battery plug assembly.

(b) Disconnect the HV battery junction block assembly connector. NOTICE: Insulate the disconnected connectors with insulating tape.

(c) Disengage the clamp.

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

(e) Disconnect the HV battery junction block assembly connector. NOTICE: Insulate the disconnected 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) Disconnect the HV battery junction block assembly connector.

(h) 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.