Toyota Avalon (XX50): Hv Battery Thermistor

Components

COMPONENTS

ILLUSTRATION

*1	UPPER HV BATTERY COVER SUB-ASSEMBLY	*2	HV BATTERY JUNCTION BLOCK ASSEMBLY
*3	ELECTRIC VEHICLE BATTERY PLUG ASSEMBLY	*4	WIRING HARNESS PROTECTOR
	N*m (kgf*cm, ft.*lbf): Specified torque	-	-

ILLUSTRATION

*1	NO. 2 HYBRID BATTERY SHIELD SUB-ASSEMBLY	*2	NO. 1 HYBRID BATTERY PACKING
*3	NO. 1 HV BATTERY INTAKE DUCT LH	*4	HYBRID BATTERY THERMISTOR
	N*m (kgf*cm, ft.*lbf): Specified torque	-	-

Installation

INSTALLATION

PROCEDURE

1. INSTALL HYBRID BATTERY THERMISTOR

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Engage the 3 claws of the hybrid battery thermistor (sensor portions) to install the hybrid battery thermistor to the HV battery. HINT: Install each hybrid battery thermistor (sensor portion) to the appropriate location shown in the illustration.

*a 1st Module from the HV Battery Junction Block Assembly Side (Wire harness color: Blue) *b 14th Module from the HV Battery Junction Block Assembly Side (Wire harness color: White) *c 34th Module from the HV Battery Junction Block Assembly Side (Wire harness color: Red)

(b) Engage the 4 clamps in the locations shown in the illustration.

*a 4th Module from the HV Battery Junction Block Assembly Side *b 10th Module from the HV Battery Junction Block Assembly Side *c 18th Module from the HV Battery Junction Block Assembly Side *d 28th Module from the HV Battery Junction Block Assembly Side

(c) Connect the battery voltage sensor connector.

(d) Engage the clamp.

(e) Engage the 2 claws to install the No. 1 hybrid battery packing to the HV battery. NOTICE: Align each piece of tape on the wire harness of the hybrid battery thermistor with the edge of the No. 1 hybrid battery packing as shown in the illustration and then engage the 2 claws to install the No. 1 hybrid battery packing to the HV battery.

*1 No. 1 Hybrid Battery Packing *a Tape *b Hybrid Battery Thermistor Wire Harness

(f) Engage the clamp.

2. INSTALL NO. 1 HV BATTERY INTAKE DUCT LH

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Install the No. 1 HV battery intake duct LH to the HV battery with the clip.

(b) Engage the claw of hybrid battery thermistor (sensor portion) to connect the hybrid battery thermistor to the No. 1 HV battery intake duct LH.

3. INSTALL NO. 2 HYBRID BATTERY SHIELD SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Pull back the rear No. 1 HV battery shield and install the No. 2 hybrid battery shield sub-assembly to the HV battery.

HINT:

Pull back the rear No. 1 HV battery shield until there is sufficient clearance for the stud bolt of the No. 2 hybrid battery shield sub-assembly.

(b) Install the 5 nuts.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

4. INSTALL HV BATTERY JUNCTION BLOCK ASSEMBLY

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5. INSTALL UPPER HV BATTERY COVER SUB-ASSEMBLY

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6. INSTALL HV BATTERY

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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 hybrid battery thermistor 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 HV BATTERY

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2. REMOVE UPPER HV BATTERY COVER SUB-ASSEMBLY

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3. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY

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4. REMOVE NO. 2 HYBRID BATTERY SHIELD SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Remove the 5 nuts.

(b) Pull back the rear No. 1 HV battery shield and remove the No. 2 hybrid battery shield sub-assembly from the HV battery.

*1	Rear No. 1 HV Battery Shield
*2	No. 2 Hybrid Battery Shield Sub-assembly
	Pull Back

HINT:

Pull back the rear No. 1 HV battery shield until it is separated from the stud bolt of the No. 2 hybrid battery shield sub-assembly.

5. REMOVE NO. 1 HV BATTERY INTAKE DUCT LH

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Remove the clip to disconnect the No. 1 HV battery intake duct LH from the HV battery.

(b) Disengage the claw of hybrid battery thermistor (sensor portion) and remove the No. 1 HV battery intake duct LH.

6. REMOVE HYBRID BATTERY THERMISTOR

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Disengage the clamp.

(b) Disengage the 2 claws and remove the No. 1 hybrid battery packing from the HV battery.

(c) Disengage the clamp.

(d) Disconnect the battery voltage sensor connector.

(e) Disengage the 4 clamps.

(f) Disengage the 3 claws of the hybrid battery thermistor (sensor portions) and remove the hybrid battery thermistor from the HV battery.