Toyota Avalon (XX50): Hv Battery

Charging

CHARGING

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced when charging the HV battery 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.

  Click here

• 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. INSPECT AUXILIARY BATTERY VOLTAGE

(a) Measure the auxiliary battery voltage.

Standard Voltage:

Approximately 11 V or more

HINT:

• The horn should sound clearly.
• If the voltage is 10 V or less, either charge the auxiliary battery (charging usually takes about 1 hour), or replace it with an auxiliary battery that is already charged.

2. PREPARATION FOR HV BATTERY CHARGING

CAUTION:

• The hybrid system has high-voltage circuits. Accidents, such as electric shock, or electric leaks may result if the hybrid system is not operated in a correct manner. Make sure to follow the correct procedure.

  Click here

• Be sure to wear insulated gloves.

HINT:

• Removing the service plug grip interrupts the high voltage circuit.
• High voltage wiring connectors are orange.

(a) Check the charge level of the HV battery.

(1) If the hybrid system fails to start and "Traction Battery Needs to be Protected Shift into P to Restart" or "Traction Battery Needs to be Protected Refrain From the Use of N Position" is displayed on the multi-information display, the HV battery may be discharged.

(2) Confirm if the engine starts. If the engine starts, leave it idling with the shift lever in P until the engine stops (self charge has completed).

If the engine cannot start, charge the HV battery.

HINT:

• Before performing external charging, always use the Techstream to perform troubleshooting.
• Charging time using the THS charger is 10 minutes per charge cycle. The charging time when using a THS charger is a short charging time (when the HV battery temperature is 25°C (77°F), 10 minutes may be sufficient, if the HV battery temperature is 0°C (32°F), then three 10 minute charge cycles may be required) for putting the engine in a condition where it can be started (the system can enter the READY-on state). (The THS charger will automatically stop 10 minutes after charging starts.)

(b) Remove the service plug grip.

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(c) Check the terminal voltage.

(1) Disconnect the engine room main wire.

Click here

(2) Remove the connector cover assembly.

Click here

(3) Check the terminal voltage.

Click here

(4) Install the connector cover assembly.

Click here

(5) Connect the engine room main wire.

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(d) Disconnect the rear center seat outer belt assembly.

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(e) Remove the rear seat cushion assembly.

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(f) Remove the rear seat cushion lock hook.

Click here

(g) Remove the rear door scuff plate LH.

Click here

(h) Remove the rear under side cover LH.

Click here

(i) Remove the rear door scuff plate RH.

HINT:

Use the same procedure as for the LH side.

(j) Remove the rear under side cover RH.

Click here

(k) Remove the rear under cover.

Click here

(l) Remove the rear seat cushion leg sub-assembly.

Click here

(m) Remove the No. 1 HV battery cover panel RH.

Click here

(n) Disconnect the HV floor under wire.

(1) 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

(2) Disconnect the shield ground from the HV battery.

(o) Inspect the electrical insulation of the HV battery.

(1) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below. NOTICE: Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected. Standard Resistance: Tester Connection Condition Specified Condition 1 - Body ground Power switch off 10 MΩ or higher 2 - Body ground Power switch off 10 MΩ or higher

*a Service Plug Grip Removed (Service Plug Grip Connecting Terminals)

(2) Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below. NOTICE: Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected. Standard Resistance: Tester Connection Condition Specified Condition S2-1 (CBI) - Body ground Power switch off 10 MΩ or higher S3-1 (CEI) - Body ground Power switch off 10 MΩ or higher

*a Component without harness connected (HV Battery Junction Block Assembly)

(p) Connect the THS charger in the order shown in the illustration.

NOTICE:

Connect all of the THS charger cables in the order shown in the illustration to prevent electrical shock.

(q) Connect the 2 SST (high voltage cable) connectors to the HV battery junction block assembly. SST: 09882-10090

(r) Temporarily install the No. 1 HV battery cover panel RH with the bolt and nut. Torque: 7.5 N·m {76 kgf·cm, 66 in·lbf} NOTICE: Be careful not to pinch SST (high voltage cable).

(s) Connect the SST (high voltage cable) terminal to the position shown in the illustration with the nut.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

(t) Connect the SST (EV bonding cable (green cable)) terminal to the position shown in the illustration with the nut. SST: 09882-10070 Torque: 7.5 N·m {76 kgf·cm, 66 in·lbf}

(u) Connect the SST (EV bonding cable (green cable)) terminal to SST (THS charger). SST: 09880-10021 09881-10041

*a EV Bonding Cable (Green Cable) *b THS Charger

(v) Connect the SST (low voltage cable) terminal to the position shown in the illustration with the bolt. Torque: 7.5 N·m {76 kgf·cm, 66 in·lbf}

(w) Connect SST (low voltage cable) and SST (high voltage cable) to SST (THS charger) in the order shown in the illustration.

*a Low Voltage Cable *b High Voltage Cable *c THS Charger *d Power Input Plug

(x) Install the service plug grip.

Click here

(y) Connect the cable to the negative (-) auxiliary battery terminal.

Click here

(z) Connect SST (power input plug) of SST (THS charger) to a grounded AC 100 to 240 V receptacle.

SST: 09881-10081

SST: 09881-10090

SST: 09881-10050

NOTICE:

Always use an AC 100 to 240 V receptacle with a properly functioning ground. The ground is designed to reduce the chance of electric shock if a malfunction occurs. Do not use the charger if any of the pins on its plug have been damaged or removed.

3. HV BATTERY CHARGING

(a) Connect the Techstream to the DLC3.

(b) Turn the power switch on (IG).

(c) Enter the following menus: Powertrain / Hybrid Control / Active Test / Hybrid Battery Charge

HINT:

• While performing the "Battery Charge" Active Test, check the Data List items "System Main Relay Status - SMRB" and "System Main Relay Status - SMRG".
• If the values of the Data List items are not as specified in the table below, turn the Techstream and the power switch off and then perform the HV battery charging procedure again.

"System Main Relay Status - SMRB" and "System Main Relay Status - SMRG" in Data List during "Battery Charge" Active Test:

(d) Make sure that the EMERGENCY STOP switch is in the reset condition (the switch is turned clockwise and released).

(e) Make sure that the BREAKER is in the ON position.

(f) Turn the THS charger MAIN switch on. HINT: The MAIN indicator will illuminate (green).

(g) Press the START switch.

HINT:

• When the START switch is turned on, the INITIAL CHECK indicator illuminates and an initial check starts. When the initial check completes successfully, the INITIAL CHECK indicator turns off, the CHARGING indicator illuminates and charging will start at the same time.
• While the INITIAL CHECK indicator is illuminated, the insulation, 400 V output, emergency stop switch, connector connections and ground connection are inspected.

(h) Repeat the charge cycle 3 times. When the last cycle has finished, turn the THS charger MAIN switch off.

HINT:

• Charging time using the THS charger is 10 minutes per charge cycle. The charging time when using a THS charger is a short charging time (when the battery temperature is 25°C (77°F), 10 minutes may be sufficient, if the battery temperature is 0°C (32°F), then three 10 minute charge cycles may be required) for putting the engine in a condition where it can be started (the system can enter the READY-on state). (The THS charger will automatically stop 10 minutes after charging starts.)
• There is very little chance of overcharging the HV battery during the second or third charging cycle. The SOC will not likely increase beyond the upper limit because it was low enough to prevent the engine from starting. Even if the SOC was to increase enough to exceed the limit, the hybrid vehicle control ECU will stop the Active Test to prevent overcharging.
• Cranking the engine once causes the SOC to drop approximately 1%.
• Charging the HV battery once (10 minutes) using the THS charger restores the SOC approximately 2%.

(i) Turn the power switch off.

(j) Remove the THS charger and connect the HV floor under wire (for HV Battery).

(1) Disconnect SST (power inlet plug) of SST (THS charger) from the grounded AC 100 to 240 V receptacle.

(2) Disconnect the cable from the negative (-) auxiliary battery terminal.

Click here

(3) Remove the service plug grip.

Click here

(4) Disconnect SST (high voltage cable) and SST (low voltage cable) from SST (THS charger) in the order shown in the illustration.

*a Low Voltage Cable *b High Voltage Cable *c THS Charger

(5) Remove the bolt and disconnect the SST (low voltage cable) terminal.

(6) Disconnect the SST (EV bonding cable (green cable)) terminal from SST (THS charger).

*a EV Bonding Cable (Green Cable) *b THS Charger

(7) Remove the nut and disconnect the SST (EV bonding cable (green cable)) terminal.

(8) Remove the nut and disconnect the SST (high voltage cable) terminal.

(9) Remove the bolt, nut and No. 1 HV battery cover panel RH.

(10) Disconnect the 2 SST (high voltage cable) connectors from the HV battery junction block assembly.

(11) Connect the shield ground to the HV battery.

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

NOTICE:

Make sure that the connectors are connected securely.

(13) Install the No. 1 HV battery cover panel RH.

Click here

(14) Install the service plug grip.

Click here

(k) Turn the power switch on (READY) and check if the engine starts.

HINT:

If the engine does not start, perform the HV battery charging operation again.

(l) Install the rear seat cushion leg sub-assembly.

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(m) Install the rear under cover.

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(n) Install the rear under side cover LH.

Click here

(o) Install the rear door scuff plate LH.

Click here

(p) Install the rear under side cover RH.

Click here

(q) Install the rear door scuff plate RH.

HINT:

Use the same procedure as for the LH side.

(r) Install the rear seat cushion lock hook.

Click here

(s) Install the rear seat cushion assembly.

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(t) Connect the rear center seat outer belt assembly.

Click here

(u) Install the battery service hole cover.

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4. CHECK HV BATTERY AFTER HV BATTERY CHARGE

(a) Check for DTCs.

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(b) Perform the self-charging operation.

(1) Start the engine and leave it idling with the shift lever in P until the engine stops.

HINT:

When the engine stops idling, this indicates that self-charging is complete. Perform any initialization procedures required after the negative (-) terminal of the auxiliary battery is disconnected and reconnected.

Components

COMPONENTS

ILLUSTRATION

ILLUSTRATION

*1	CONNECTOR COVER ASSEMBLY	*2	ENGINE ROOM MAIN WIRE
	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)		N*m (kgf*cm, ft.*lbf): Specified torque

ILLUSTRATION

*1	HV BATTERY	*2	NO. 1 HYBRID BATTERY EXHAUST DUCT
*3	NO. 1 HV BATTERY COVER PANEL RH	*4	HV FLOOR UNDER WIRE
*5	FLOOR WIRE	*6	BATTERY COVER LOCK STRIKER
*7	NO. 1 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY	-	-
	N*m (kgf*cm, ft.*lbf): Specified torque	-	-

ILLUSTRATION

*1	UPPER HV BATTERY COVER SUB-ASSEMBLY	*2	HV BATTERY JUNCTION BLOCK ASSEMBLY
*3	ELECTRIC VEHICLE BATTERY PLUG ASSEMBLY	*4	BATTERY VOLTAGE SENSOR
*5	HYBRID BATTERY TERMINAL BLOCK	*6	NO. 2 HYBRID BATTERY SHIELD SUB-ASSEMBLY
*7	NO. 1 HV BATTERY INTAKE DUCT LH	*8	NO. 1 HV BATTERY SHIELD PANEL
*9	HV BATTERY	*10	NO. 4 HV BATTERY SHIELD SUB-ASSEMBLY
*11	NO. 3 HV BATTERY SHIELD SUB-ASSEMBLY	*12	NO. 4 HV BATTERY END PLATE SUB-ASSEMBLY
*13	NO. 5 HV BATTERY END PLATE SUB-ASSEMBLY	-	-
	N*m (kgf*cm, ft.*lbf): Specified torque	-	-

Installation

INSTALLATION

PROCEDURE

1. INSTALL NO. 1 HV BATTERY INTAKE DUCT LH

Click here

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

Click here

3. INSTALL HV BATTERY JUNCTION BLOCK ASSEMBLY

Click here

4. INSTALL HYBRID BATTERY TERMINAL BLOCK

Click here

5. INSTALL BATTERY VOLTAGE SENSOR

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6. INSTALL NO. 1 HV BATTERY SHIELD PANEL

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7. INSTALL UPPER HV BATTERY COVER SUB-ASSEMBLY

Click here

8. TEMPORARILY INSTALL NO. 4 HV BATTERY END PLATE SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Temporarily install the No. 4 HV battery end plate sub-assembly to the HV battery with the 2 bolts and 2 nuts.

(b) Fully tighten the 2 nuts.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

9. INSTALL NO. 5 HV BATTERY END PLATE SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Install the No. 5 HV battery end plate sub-assembly to the HV battery with the 12 nuts.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

10. INSTALL NO. 4 HV BATTERY SHIELD SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Install the No. 4 HV battery shield sub-assembly to the HV battery with the 4 nuts.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

11. INSTALL NO. 3 HV BATTERY SHIELD SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Install the No. 3 HV battery shield sub-assembly to the HV battery with the 4 nuts.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

12. INSTALL NO. 4 HV BATTERY END PLATE SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Fully tighten the 2 bolts.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

13. INSTALL HV BATTERY

CAUTION:

Be sure to wear insulated gloves.

(a) Install the HV battery to the vehicle body with the 3 bolts (A), bolt (B) and bolt (C). Torque: 19 N·m {194 kgf·cm, 14 ft·lbf} NOTICE: Do not allow foreign matter, such as grease or oil, to adhere to the bolts of the HV battery. To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent. Use cardboard or another similar material to protect the HV battery and vehicle body from damage. Since the HV battery is very heavy, 2 people are needed to install it. When installing the HV battery, be careful not to damage the parts around it. When removing/installing/moving the HV battery, make sure not to tilt it more than 80°. While lowering the HV battery into the vehicle, do not allow it to contact the vehicle. As bolts with 3 different lengths are used, make sure to install each bolt to the correct position. If the HV battery has been struck or dropped, replace it.

*a Bolt (A) (Bolt Length: 25 mm (0.984 in.)) *b Bolt (B) (Bolt Length: 24 mm (0.945 in.)) *c Bolt (C) (Bolt Length: 65 mm (2.559 in.))

14. CONNECT FLOOR WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Connect the battery voltage sensor connector.

(b) Engage the clamp.

15. INSTALL NO. 1 HYBRID BATTERY EXHAUST DUCT

CAUTION:

Be sure to wear insulated gloves.

(a) Engage the claw to install the No. 1 hybrid battery exhaust duct to the HV battery.

(b) Install the clip.

16. CONNECT FLOOR WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Engage the 2 clamps.

17. INSTALL NO. 1 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY

Click here

18. CONNECT FLOOR WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Connect the HV battery junction block assembly connector.

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

(c) Engage the clamp.

19. CONNECT HV FLOOR UNDER WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Connect the floor wire connector.

(b) Connect the shield ground to the HV battery.

*a Shield Ground

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

NOTICE:

Make sure that the connectors are connected securely.

20. INSTALL NO. 1 HV BATTERY COVER PANEL RH

CAUTION:

Be sure to wear insulated gloves.

(a) Install the No. 1 HV battery cover panel RH to the HV battery with the 3 bolts and 3 nuts. Torque: 7.5 N·m {76 kgf·cm, 66 in·lbf}

*1 Battery Cover Lock Striker *a Button *b Push

(b) Install the battery cover lock striker, then push the button to lock it.

21. INSTALL BATTERY COOLING BLOWER ASSEMBLY

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22. INSTALL SERVICE PLUG GRIP

Click here

23. PERFORM INITIALIZATION

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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 HV battery 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.

  Click here

• 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.

  Click here

• When the cable is disconnected from the negative (-) auxiliary battery terminal, some systems need to be initialized after the cable is reconnected.

  Click here

• If the HV battery has been struck or dropped, replace it.
• When connecting a connector to the HV battery, confirm that the connector is securely connected through the following:

  - Push the connector until a click sound is heard.

  - Visually check and confirm that the connector is securely connected by pulling on it.

• Make sure to insulate the high-voltage connectors and terminals of the HV battery with insulating tape after removing it.

  If the HV battery stored without insulating the connectors and terminals, electric shock or fire may result.

• When performing repairs around the HV battery, such as using a tap, do not allow metal shavings to enter the HV battery.
• Do not touch any high voltage wire harnesses, connectors or parts with bare hands.
• Hold the areas shown in the illustration and lift the HV battery.
• Do not allow foreign matter, such as grease or oil, to adhere to the bolts or nuts of the HV battery.
• Do not put your hands into the openings of the HV battery.

  *a

  Opening

• When removing/installing/moving the HV battery, make sure not to tilt it more than 80°.
• Do not climb on top of or stand on the HV battery.
• Do not allow any foreign matter or water to enter the HV battery.
• If any bolts, nuts or clips are dropped into the HV battery, make sure to remove them.

HINT:

When disposing of an HV battery, make sure to return it through an authorized collection agent who is capable of handling it safely. If the HV battery is returned via the manufacturer specified route, it will be returned properly and in a safe manner by an authorized collection agent.

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

CAUTION:

Be sure to wear insulated gloves.

(a) Using a T25 "TORX" socket wrench, install the connector cover assembly to the inverter with converter assembly with the bolt (A). Torque: 4.5 N·m {46 kgf·cm, 40 in·lbf} NOTICE: Do not touch the waterproof seal of the connector cover assembly.

*a Bolt (A) *b Bolt (B)

(b) Install the bolt (B).

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

6. CONNECT ENGINE ROOM MAIN WIRE

Click here

7. REMOVE BATTERY COOLING BLOWER ASSEMBLY

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8. REMOVE NO. 1 HV BATTERY COVER PANEL RH

CAUTION:

Be sure to wear insulated gloves.

(a) Using the service plug grip, remove the battery cover lock striker. HINT: Insert the projection of the service plug grip and turn the button of the battery cover lock striker counterclockwise to release the lock.

*1 Service Plug Grip *2 Battery Cover Lock Striker *a Projection *b Turn *c Button

(b) Remove the 3 bolts, 3 nuts and No. 1 HV battery cover panel RH from the HV battery.

9. 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.

(c) Disconnect the floor wire connector.

10. 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.

11. REMOVE NO. 1 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY

Click here

12. DISCONNECT FLOOR WIRE

CAUTION:

Be sure to wear insulated gloves.

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

13. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the clip.

(b) Disengage the claw to remove the No. 1 hybrid battery exhaust duct from the HV battery.

14. DISCONNECT FLOOR WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Disengage the clamp.

(b) Disconnect the battery voltage sensor connector.

15. REMOVE HV BATTERY

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the 5 bolts and HV battery from the vehicle body. NOTICE: Do not allow foreign matter, such as grease or oil, to adhere to the bolts of the HV battery. To prevent the wire harness from being caught, make sure to bundle the wire harness using insulating tape or equivalent. Use cardboard or another similar material to protect the HV battery and vehicle body from damage. Since the HV battery is very heavy, 2 people are needed to remove it. When removing the HV battery, be careful not to damage the parts around it. When removing the HV battery from the vehicle, do not allow it to contact the vehicle. When removing/installing/moving the HV battery, make sure not to tilt it more than 80°. Insulate the disconnected terminals or connectors with insulating tape. If the HV battery has been struck or dropped, replace it.

16. REMOVE NO. 4 HV BATTERY SHIELD SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the 4 nuts and No. 4 HV battery shield sub-assembly from the HV battery.

17. REMOVE NO. 3 HV BATTERY SHIELD SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the 4 nuts and No. 3 HV battery shield sub-assembly from the HV battery.

18. REMOVE NO. 4 HV BATTERY END PLATE SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the 2 bolts, 2 nuts and No. 4 HV battery end plate sub-assembly from the HV battery.

*a Bolt *b Nut

19. REMOVE NO. 5 HV BATTERY END PLATE SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves.

(a) Remove the 12 nuts and No. 5 HV battery end plate sub-assembly from the HV battery.

20. REMOVE UPPER HV BATTERY COVER SUB-ASSEMBLY

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21. REMOVE NO. 1 HV BATTERY SHIELD PANEL

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22. REMOVE BATTERY VOLTAGE SENSOR

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23. REMOVE HYBRID BATTERY TERMINAL BLOCK

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24. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY

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

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26. REMOVE NO. 1 HV BATTERY INTAKE DUCT LH

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