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Home >> Toyota >> 2012 >> Prius Five >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Hybrid Battery Control System (Plug-In) (Service Information)) >> HV Relay Assembly >> Removal >> Removal
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HV Relay Assembly: Removal: Removal

WARNING: This page is about a different variant/trim than selected.
  1. PRECAUTION 

    Refer to PRECAUTION

  2. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL 

  3. REMOVE INVERTER COVER  See step  9
  4. CHECK TERMINAL VOLTAGE  See step  10
  5. INSTALL INVERTER COVER  See step  13
  6. REMOVE REAR NO. 2 FLOOR BOARD  . Refer to REMOVAL - Step 1
  7. REMOVE REAR NO. 4 FLOOR BOARD SUB-ASSEMBLY  . Refer to REMOVAL - Step 30
  8. REMOVE DECK FLOOR BOX LH 

    HINT: 

    Use the same procedure described for the RH side. Refer to REMOVAL - Step 3 .

  9. REMOVE TONNEAU COVER ASSEMBLY (w/ Tonneau Cover)  . Refer to REMOVAL - Step 29
  10. REMOVE REAR NO. 2 FLOOR BOARD SUB-ASSEMBLY  . Refer to REMOVAL - Step 32
  11. REMOVE REAR NO. 1 FLOOR BOARD SUB-ASSEMBLY  . Refer to REMOVAL - Step 33
  12. REMOVE REAR NO. 1 FLOOR BOARD  . Refer to REMOVAL - Step 34
  13. REMOVE DECK TRIM SERVICE HOLE COVER  . Refer to REMOVAL - Step 35
  14. REMOVE REAR DECK TRIM COVER  . Refer to REMOVAL - Step 36
  15. REMOVE REAR DOOR SCUFF PLATE RH 

    HINT: 

    Use the same procedure described for the LH side. Refer to REMOVAL - Step 9 .

  16. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 

    HINT: 

    Use the same procedure described for the LH side. Refer to INSTALLATION - Step 37 .

  17. REMOVE REAR SEAT CUSHION ASSEMBLY  . Refer to REMOVAL - Step 4
  18. REMOVE REAR SIDE SEAT BACK ASSEMBLY RH  . Refer to REMOVAL - Step 7
  19. REMOVE LUGGAGE HOLD BELT STRIKER ASSEMBLY (for RH Side) 

    HINT: 

    Use the same procedure described for the LH side. Refer to REMOVAL - Step 37 .

  20. REMOVE TONNEAU COVER HOLDER CAP (for RH Side) 

    HINT: 

    Use the same procedure described for the LH side. Refer to REMOVAL - Step 38 .

  21. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH  . Refer to REMOVAL - Step 43
  22. REMOVE BATTERY COOLING BLOWER ASSEMBLY (for RH Side)  See step  8
  23. REMOVE BATTERY COOLING BLOWER ASSEMBLY (for LH Side)  See step  9
  24. REMOVE HYBRID BATTERY HOSE ASSEMBLY 
    1. Disconnect the clip.
      Fig 1: Identifying Hose, Clip & Claw
      GTY326899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the claw.
    3. Disconnect the grommet and remove the hybrid battery hose assembly.
  25. REMOVE NO. 3 HYBRID BATTERY EXHAUST DUCT 
    1. Remove the 2 clips and No. 3 hybrid battery exhaust duct (for RH side).
      Fig 2: Identifying Exhaust Duct & Clips
      GTY330454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 clips and No. 3 hybrid battery exhaust duct (for LH side).
      Fig 3: Identifying Exhaust Duct & Clips
      GTY330452Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE NO. 4 HYBRID VEHICLE BATTERY CARRIER BRACKET 
    1. Remove the bolt and No. 4 hybrid vehicle battery carrier bracket.
      Fig 4: Identifying Bracket & Bolt
      GTY330448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE REAR NO. 1 HYBRID BATTERY SHIELD 
    WARNING:

    Wear insulated gloves.

    1. Disconnect the connector and 2 clamps.
      Fig 5: Identifying Connector & Clamps
      GTY336001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the clamp.
      Fig 6: Identifying Clamp
      GTY335502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using the service plug grip, remove the battery cover lock striker.
      Fig 7: Removing Battery Cover Lock Striker Using Service Plug Grip
      GTY332219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Battery Cover Lock Striker
      *2 Button
      *a Projection
      *b Turn

      HINT: 

      Insert the projection part of the service plug grip, and turn the button of the battery cover lock striker counterclockwise, and release the lock.

    4. Remove the 9 bolts and rear No. 1 hybrid battery shield.
      Fig 8: Identifying Hybrid Battery Shield & Bolts
      GTY329976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE NO. 2 HYBRID VEHICLE BATTERY SHIELD PANEL 
    WARNING:

    Wear insulated gloves.

    1. Using the service plug grip, remove the battery cover lock striker.
      Fig 9: Removing Battery Cover Lock Striker Using Service Plug Grip
      GTY334503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Battery Cover Lock Striker
      *2 Button
      *a Projection
      *b Turn

      HINT: 

      Insert the projection part of the service plug grip, and turn the button of the battery cover lock striker counterclockwise, and release the lock.

    2. Remove the 3 nuts and No. 2 hybrid vehicle battery shield panel.
      Fig 10: Identifying Hybrid Vehicle Battery Shield Panel & Nuts
      GTY329890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE NO. 1 HYBRID VEHICLE BATTERY SHIELD PANEL 
    WARNING:

    Wear insulated gloves.

    1. Disengage the 2 claws and remove the 3 clamps and electrical key oscillator.
      Fig 11: Identifying Claws & Clamps
      GTY329934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connector and clamp.
      Fig 12: Identifying Battery Shield Panel, Clamp & Nuts
      GTY330451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 7 nuts and No. 1 hybrid vehicle battery shield panel.
  30. REMOVE NO. 1 HYBRID VEHICLE BATTERY COVER PANEL RH 
    WARNING:

    Wear insulated gloves.

    1. Disconnect the 4 clamps.
      Fig 13: Identifying Clamps
      GTY332518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 6 bolts and No. 1 hybrid vehicle battery cover panel RH.
      Fig 14: Identifying Battery Cover Panel & Bolts
      GTY330462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE NO. 1 HYBRID VEHICLE BATTERY COVER PANEL LH 
    WARNING:

    Wear insulated gloves.

    1. Remove the 6 bolts and No. 1 hybrid vehicle battery cover panel LH.
      Fig 15: Identifying Battery Cover Panel & Bolts
      GTY330463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE UPPER HYBRID BATTERY COVER SUB-ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. Remove the 2 bolts, 4 nuts and upper hybrid battery cover sub-assembly.
      Fig 16: Identifying Upper Hybrid Battery Cover Sub-Assembly, Bolts & Nuts
      GTY330464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. DISCONNECT ELECTRIC VEHICLE CHARGER WIRE 
    WARNING:

    Wear insulated gloves.

    1. Disconnect the connector.
      Fig 17: Identifying Electric Vehicle Charger Wire, Connector & Nut
      GTY326616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Insulate the disconnected connector with insulating tape.

    2. Remove the nut and disconnect the electric vehicle charger wire.
  34. DISCONNECT FRAME WIRE 
    WARNING:

    Wear insulated gloves.

    1. Using an insulated tool, remove the 2 nuts.
      Fig 18: Identifying Shielded Wire Ground, Frame Wire & Nuts
      GTY331963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the shielded wire ground and frame wire.
      NOTE:

      Insulate the disconnected terminal with insulating tape.

  35. REMOVE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    1. Disconnect the 10 clamps.
      Fig 19: Identifying Clamps
      GTY330457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 3 connectors from the hybrid battery junction block assembly.
      Fig 20: Identifying Connectors
      GTY330458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the 2 connectors from the hybrid battery junction block assembly.
      Fig 21: Identifying Connectors
      GTY330473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Insulate the disconnected connectors with insulating tape.

    4. Remove the 3 nuts and hybrid battery junction block assembly.
      Fig 22: Identifying Hybrid Battery Junction Block Assembly & Nuts
      GTY330475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE NO. 4 HYBRID VEHICLE BATTERY PACK WIRE 

    HINT: 

    Perform this procedure only when replacement of the No. 4 hybrid battery pack wire is necessary.

    1. Disconnect the 2 connectors and 3 clamps and remove the No. 4 hybrid vehicle battery pack wire.
      Fig 23: Identifying Connectors & Clamps
      GTY330471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE ELECTRIC VEHICLE FUSE 

    HINT: 

    Perform this procedure only when replacement of the electric vehicle fuse is necessary.

    1. Disconnect the clamp from the hybrid battery junction block assembly.
      Fig 24: Identifying Clamp
      GTY329977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and electric vehicle fuse.
      Fig 25: Identifying Electric Vehicle Fuse Bolts
      GTY330472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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