System Main Relay, Hybrid Drive: Service and Repair
REMOVAL1. OBSERVE PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE
2. READ OUTPUT DTC
3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
4. REMOVE SERVICE PLUG GRIP
5. REMOVE REAR SEAT TRACK BRACKET COVER
6. REMOVE REAR SEAT ASSEMBLY LH
7. REMOVE REAR SEAT TRACK BRACKET COVER
8. REMOVE REAR SEAT ASSEMBLY RH
9. REMOVE AIR INTAKE COVER
10. REMOVE AIR INTAKE COVER CENTER
11. SEPARATE FLOOR CARPET ASSEMBLY FRONT
12. REMOVE REAR CENTER SEAT INNER BELT
13. REMOVE BATTERY CARRIER BRACKET
14. REMOVE BATTERY CARRIER DUCT
15. REMOVE HV BATTERY SERVICE HOLE COVER
16. REMOVE BATTERY COVER SUB-ASSEMBLY
17. REMOVE HYBRID VEHICLE RELAY ASSEMBLY
NOTE:
- Wear insulating gloves and protective glasses.
- Insulate the removed terminals with insulating tape.
a. Disconnect the No.3 wire frame connector from the HV relay assembly.
b. Remove the 2 nuts, then disconnect the No.3 wire frame from the HV relay assembly.
c. Disconnect the 2 main battery cable connectors from the HV relay assembly.
d. Disconnect the 2 connectors from the HV relay assembly.
e. Remove the 3 nuts and HV relay assembly.
INSTALLATION
1. INSTALL HYBRID VEHICLE RELAY ASSEMBLY
NOTE: Wear insulating gloves and protective glasses.
a. Install the HV relay assembly with the 3 nuts.
Torque: 4.5 N.m (46 kgf.cm, 40 in.lbf)
b. Connect the 2 connectors on the HV relay assembly.
c. Connect the 2 main battery cable connectors on the HV relay assembly.
d. Install the No.3 wire frame on the HV relay with the 2 nuts.
NOTE:
- Make sure that the No. 3 wire frame do not cross each other.
- Be sure to connect the No. 3 wire frame to each correct terminal as shown in the illustration.
Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
e. Install the No.3 wire frame connector on the HV relay assembly.
2. CHECK HIGH VOLTAGE CABLE CONNECTION
3. INSTALL BATTERY COVER SUB-ASSEMBLY
4. INSTALL HV BATTERY SERVICE HOLE COVER
5. INSTALL BATTERY CARRIER DUCT
6. INSTALL BATTERY CARRIER BRACKET
7. INSTALL REAR CENTER SEAT INNER BELT
8. INSTALL FLOOR CARPET ASSEMBLY FRONT
9. INSTALL AIR INTAKE COVER CENTER
10. INSTALL AIR INTAKE COVER
11. INSTALL REAR SEAT ASSEMBLY LH
12. INSTALL REAR SEAT TRACK BRACKET COVER
13. INSTALL REAR SEAT ASSEMBLY RH
14. INSTALL REAR SEAT TRACK BRACKET COVER
15. INSPECT SLIDE ADJUSTER LOCK SIMULTANEOUSLY
16. INSTALL SERVICE PLUG GRIP
17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
18. PERFORM INITIALIZATION
Some systems need initialization when disconnecting the cable from the negative battery terminal.