Toyota Avalon (XX50): Hv Relay Assembly

Toyota Avalon (XX50) 2019-2022 Service & Repair Manual / Engine / Hybrid / Battery Control / Hv Relay Assembly

Components

COMPONENTS

ILLUSTRATION

BATTERY SERVICE HOLE COVER

SERVICE PLUG GRIP

ILLUSTRATION

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

ILLUSTRATION

*1	REAR UNDER COVER	*2	REAR UNDER SIDE COVER LH
*3	REAR UNDER SIDE COVER RH	*4	REAR SEAT CUSHION LEG SUB-ASSEMBLY
*5	REAR DOOR SCUFF PLATE RH	*6	REAR DOOR SCUFF PLATE LH
	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": Nm (kgfcm, ft.*lbf)	-	-

ILLUSTRATION

*1	BATTERY COVER LOCK STRIKER	*2	NO. 1 HYBRID BATTERY EXHAUST DUCT
*3	NO. 1 HV BATTERY COVER PANEL RH	*4	HV FLOOR UNDER WIRE
*5	FLOOR WIRE	-	-
	Nm (kgfcm, ft.*lbf): Specified torque	-	-

ILLUSTRATION

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

Inspection

INSPECTION

PROCEDURE

1. INSPECT HV BATTERY JUNCTION BLOCK ASSEMBLY

(a) Inspect SMRB:

(1) Measure the resistance according to the value(s) in the table below.

Component without harness connected

(HV Battery Junction Block Assembly)

Standard Resistance:

Tester Connection	Condition	Specified Condition
y5-1 (+) - S2-1 (CBI)	Auxiliary battery voltage not applied between terminals K18-1 (SMRB) and K18-3 (GND)	10 kΩ or higher
y5-1 (+) - S2-1 (CBI)	Auxiliary battery voltage applied between terminals K18-1 (SMRB) and K18-3 (GND)	Below 1 Ω

(2) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection	Condition	Specified Condition
K18-1 (SMRB) - K18-3 (GND)	-40 to 80°C (-40 to 176°F)	25.0 to 59.0 Ω

If the result is not as specified, replace the HV battery junction block assembly.

(b) Inspect SMRG:

(1) Measure the resistance according to the value(s) in the table below.

Component without harness connected

(HV Battery Junction Block Assembly)

Standard Resistance:

Tester Connection	Condition	Specified Condition
y3-1 (-) - S3-1 (CEI)	Auxiliary battery voltage not applied between terminals K18-4 (SMRG) and K18-3 (GND)	10 kΩ or higher
y3-1 (-) - S3-1 (CEI)	Auxiliary battery voltage applied between terminals K18-4 (SMRG) and K18-3 (GND)	Below 1 Ω

(2) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection	Condition	Specified Condition
K18-4 (SMRG) - K18-3 (GND)	-40 to 80°C (-40 to 176°F)	25.0 to 59.0 Ω

If the result is not as specified, replace the HV battery junction block assembly.

(1) Measure the resistance according to the value(s) in the table below.

Component without harness connected

(HV Battery Junction Block Assembly)

Standard Resistance:

Tester Connection	Condition	Specified Condition
y3-1 (-) - S3-1 (CEI)	Auxiliary battery voltage not applied between terminals K18-2 (SMRP) and K18-3 (GND)	10 kΩ or higher
y3-1 (-) - S3-1 (CEI)	Auxiliary battery voltage applied between terminals K18-2 (SMRP) and K18-3 (GND)	24.3 to 29.7 Ω

(2) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection	Condition	Specified Condition
K18-2 (SMRP) - K18-3 (GND)	-40 to 80°C (-40 to 176°F)	140 to 290 Ω

If the result is not as specified, replace the HV battery junction block assembly.

Installation

INSTALLATION

PROCEDURE

1. INSTALL HV BATTERY JUNCTION BLOCK ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

(a) Install the HV battery junction block assembly to the HV battery with the 4 nuts.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

NOTICE:

If the HV battery junction block assembly has been struck or dropped, replace it with a new one.

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

NOTICE:

Make sure that the connectors are connected securely.

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

NOTICE:

Make sure that the connectors are connected securely.

(e) Engage the 2 claws to close the wiring harness protector.

(f) Engage the clamp.

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

NOTICE:

Make sure that the connectors are connected securely.

(h) Connect the electric vehicle battery plug assembly with the bolt.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

2. INSTALL UPPER HV BATTERY COVER SUB-ASSEMBLY

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3. INSTALL NO. 1 HYBRID BATTERY EXHAUST DUCT

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4. CONNECT FLOOR WIRE

CAUTION:

Be sure to wear insulated gloves.

(a) Engage the 2 clamps to connect the floor wire.

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

(d) Engage the clamp.

5. CONNECT HV FLOOR UNDER WIRE

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6. INSTALL NO. 1 HV BATTERY COVER PANEL RH

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7. INSTALL REAR SEAT CUSHION LEG SUB-ASSEMBLY

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8. INSTALL REAR UNDER COVER

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9. INSTALL REAR UNDER SIDE COVER LH

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10. INSTALL REAR DOOR SCUFF PLATE LH

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11. INSTALL REAR UNDER SIDE COVER RH

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12. INSTALL REAR DOOR SCUFF PLATE RH

HINT:

Use the same procedure as for the LH side.

13. INSTALL NO. 1 INDOOR ELECTRICAL KEY ANTENNA ASSEMBLY

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14. INSTALL SERVICE PLUG GRIP

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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 junction block assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed
*: When performing learning using the Techstream. Click here
Auxiliary battery terminal is disconnected/reconnected	Perform steering sensor zero point calibration	Lane departure alert system (w/ Steering Control)
		Pre-collision system
		Intelligent clearance sonar system*
		Lighting System (for HV Model with Cornering Light)
	Memorize steering angle neutral point	Parking assist monitor system
	Memorize steering angle neutral point	Panoramic view monitor system

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. 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.

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

17. REMOVE NO. 1 HYBRID BATTERY EXHAUST DUCT

Click here

18. REMOVE UPPER HV BATTERY COVER SUB-ASSEMBLY

Click here

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.

(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.

Hv Battery

Hybrid Control System

See More:

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