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HV Relay Assembly: Installation: Installation

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL ELECTRIC VEHICLE FUSE 

    HINT: 

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

    1. Install the electric vehicle fuse with the 2 bolts.

      Torque: 2.1 N*m (21 kgf*cm, 19 in.*lbf) 

    2. Connect the clamp to the hybrid battery junction block assembly.
  2. INSTALL 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. Install the No. 4 hybrid vehicle battery pack wire with the 3 clamps and 2 connectors to the hybrid battery junction block assembly.
  3. INSTALL HYBRID BATTERY JUNCTION BLOCK ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    1. Install the hybrid battery junction block assembly with the 3 nuts.

      Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 

    2. Connect the 2 connectors to the hybrid battery junction block.
      NOTE:

      Make sure that the connectors are connected securely.

    3. Connect the 3 connectors to the hybrid battery junction block.
      NOTE:

      Make sure that the connectors are connected securely.

    4. Connect the 10 clamps.
  4. CONNECT FRAME WIRE 
    WARNING:

    Wear insulated gloves.

    1. Connect the shielded wire ground.
    2. Using an insulated tool, connect the frame wire with the 2 nuts.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

  5. CONNECT ELECTRIC VEHICLE CHARGER WIRE 
    WARNING:

    Wear insulated gloves.

    1. Connect the shielded wire ground with the nut.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

    2. Connect the connector.
      NOTE:

      Make sure that the connector is connected securely.

  6. INSTALL UPPER HYBRID BATTERY COVER SUB-ASSEMBLY 
    WARNING:

    Be sure to wear insulated gloves and protective goggles.

    1. Install the upper hybrid battery cover sub-assembly with the 2 bolts and 4 nuts.

      Bolt 

      Torque: 22 N*m (227 kgf*cm, 16 ft.*lbf) 

      Nut 

      Torque: 22 N*m (221 kgf*cm, 16 ft.*lbf) 

  7. INSTALL NO. 1 HYBRID VEHICLE BATTERY COVER PANEL LH 
    WARNING:

    Wear insulated gloves.

    1. Install the No. 1 hybrid vehicle battery cover panel LH with the 6 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  8. INSTALL NO. 1 HYBRID VEHICLE BATTERY COVER PANEL RH 
    WARNING:

    Wear insulated gloves.

    1. Install the No. 1 hybrid vehicle battery cover panel RH with the 6 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    2. Connect the 4 clamps.
  9. INSTALL NO. 1 HYBRID VEHICLE BATTERY SHIELD PANEL 
    WARNING:

    Wear insulated gloves.

    1. Install the No. 1 hybrid vehicle battery shield panel with the 7 nuts.

      Torque: 10 N*m (103 kgf*cm, 7 ft.*lbf) 

    2. Connect the connector and clamp.
    3. Install the electrical key oscillator with the 2 claws and 3 clamp.
  10. INSTALL NO. 2 HYBRID VEHICLE BATTERY SHIELD PANEL 
    WARNING:

    Wear insulated gloves.

    1. Install the No. 2 hybrid vehicle battery shield panel with the 3 nuts.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

    2. Install the battery cover lock striker, then push the button to lock it.
      Fig 1: Installing Battery Cover Lock Striker
      GTY330558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Battery Cover Lock Striker
      *2 Button
      *a Push
  11. INSTALL REAR NO. 1 HYBRID BATTERY SHIELD 
    WARNING:

    Wear insulated gloves.

    1. Install the rear No. 1 hybrid battery shield with the 9 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    2. Install the battery cover lock striker, then push the button to lock it.
      Fig 2: Installing Battery Cover Lock Striker
      GTY328353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Battery Cover Lock Striker
      *2 Button
      *a Push
    3. Connect the clamp.
    4. Connect the 2 clamps and connector.
  12. INSTALL NO. 4 HYBRID VEHICLE BATTERY CARRIER BRACKET 
    1. Install the No. 4 hybrid vehicle battery carrier bracket with the bolt.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

  13. INSTALL NO. 3 HYBRID BATTERY EXHAUST DUCT 
    1. Install the No. 3 hybrid battery exhaust duct (for RH side) with the 2 clips.
      Fig 3: Identifying Exhaust Duct Positioning Mark
      GTY337295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Positioning Mark

      HINT: 

      Install the No. 3 hybrid battery exhaust duct so that the positioning mark is on the right side of the vehicle.

    2. Install the No. 3 hybrid battery exhaust duct (for LH side) with the 2 clips.
      Fig 4: Identifying Exhaust Duct Positioning Mark
      GTY341359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Positioning Mark

      HINT: 

      Install the No. 3 hybrid battery exhaust duct so that the positioning mark is on the right side of the vehicle.

  14. INSTALL HYBRID BATTERY HOSE ASSEMBLY 
    1. Install the hybrid battery hose assembly with the claw and grommet.
      Fig 5: Identifying Correct Hose Assembly Installation
      GTY325411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Correct
      *b Incorrect
      NOTE:

      Make sure that there is no space or a gap between the grommet and the body.

    2. Connect the clip.
  15. INSTALL BATTERY COOLING BLOWER ASSEMBLY (for LH Side)  See step  2
  16. INSTALL BATTERY COOLING BLOWER ASSEMBLY (for RH Side)  See step  1
  17. INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH  . Refer to INSTALLATION - Step 18
  18. INSTALL TONNEAU COVER HOLDER CAP (for RH Side) 

    HINT: 

    Use the same procedure described for the LH side. Refer to INSTALLATION - Step 15 .

  19. INSTALL LUGGAGE HOLD BELT STRIKER ASSEMBLY (for RH Side) 

    HINT: 

    Use the same procedure described for the LH side. Refer to INSTALLATION - Step 16 .

  20. INSTALL REAR SIDE SEAT BACK ASSEMBLY RH  . Refer to INSTALLATION - Step 5
  21. INSTALL REAR SEAT CUSHION ASSEMBLY  . Refer to INSTALLATION - Step 7
  22. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH  . Refer to INSTALLATION - Step 47
  23. INSTALL REAR DOOR SCUFF PLATE RH 

    HINT: 

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

  24. INSTALL REAR DECK TRIM COVER  . Refer to INSTALLATION - Step 21
  25. INSTALL DECK TRIM SERVICE HOLE COVER  . Refer to INSTALLATION - Step 22
  26. INSTALL REAR NO. 1 FLOOR BOARD  . Refer to INSTALLATION - Step 23
  27. INSTALL REAR NO. 1 FLOOR BOARD SUB-ASSEMBLY  . Refer to INSTALLATION - Step 24
  28. INSTALL REAR NO. 2 FLOOR BOARD SUB-ASSEMBLY  . Refer to INSTALLATION - Step 25
  29. INSTALL TONNEAU COVER ASSEMBLY (w/ Tonneau Cover)  . Refer to INSTALLATION - Step 28
  30. INSTALL DECK FLOOR BOX LH 

    HINT: 

    Use the same procedure described for the RH side. Refer to INSTALLATION - Step 54 .

  31. INSTALL REAR NO. 4 FLOOR BOARD SUB-ASSEMBLY  . Refer to INSTALLATION - Step 27
  32. INSTALL REAR NO. 2 FLOOR BOARD  . Refer to INSTALLATION - Step 56
  33. INSTALL SERVICE PLUG GRIP 

    Refer to INSTALLATION 

  34. CURRENT SENSOR OFFSET LEARNING 

    HINT: 

    Perform this procedure when the hybrid battery junction block assembly or power management control ECU has been replaced.

    1. Connect the Techstream to the DLC3.
    2. Turn the power switch on (READY).
    3. Perform a road test.
      NOTE:

      Accelerate/decelerate gently. Avoid rapid acceleration/deceleration.

      1. Enter the following menus: Powertrain / Hybrid Control / Data List / Power Resource IB.
      2. Drive the vehicle with the value of Data List item "Power Resource IB" between -50 A and 50 A.

        HINT: 

        Distance and driving time are not specified.

    4. Turn the power switch off and leave the vehicle for 30 seconds or more.
    5. Turn the power switch on (IG).
    6. Enter the following menus: Powertrain / Hybrid Control / Data List / Power Resource IB.
    7. Check that the value of "Power Resource IB" is between - 0.5 A and 0.5 A with the power switch on (IG).
      NOTE:

      If the value is outside the specified range, perform the road test again.

      HINT: 

      • If the power switch is on (IG) and value of "Power Resource IB" is between - 0.5 A and 0.5 A, current sensor offset learning has been completed.
      • Even if the current sensor offset learning is not complete, the current sensor value will be corrected by repeating the road test a maximum of 7 times.
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