System Main Relay, Hybrid Drive: Service and Repair
REMOVAL1. PRECAUTION
2. READ OUTPUT DTC
3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
4. REMOVE SERVICE PLUG GRIP
5. REMOVE RECLINING HINGE COVER LH (w/ Rear No. 2 Seat)
6. REMOVE REAR SEAT TRACK BRACKET COVER OUTER (w/ Rear No. 2 Seat)
7. REMOVE REAR SEAT TRACK COVER LH (w/ Rear No. 2 Seat)
8. REMOVE REAR SEAT TRACK BRACKET COVER INNER LH (w/ Rear No. 2 Seat)
9. REMOVE SEAT TRACK COVER INNER LH (w/ Rear No. 2 Seat)
10. REMOVE REAR NO. 1 SEAT ASSEMBLY LH (w/ Rear No. 2 Seat)
11. REMOVE REAR SEAT TRACK BRACKET COVER OUTER (w/ Rear No. 2 Seat)
12. REMOVE REAR SEAT TRACK COVER RH (w/ Rear No. 2 Seat)
13. REMOVE REAR SEAT TRACK BRACKET COVER INNER RH (w/ Rear No. 2 Seat)
14. REMOVE SEAT TRACK INNER COVER RH (w/ Rear No. 2 Seat)
15. REMOVE REAR NO. 1 SEAT ASSEMBLY RH (w/ Rear No. 2 Seat)
16. REMOVE REAR SEAT TRACK BRACKET COVER OUTER (w/o Rear No. 2 Seat)
17. REMOVE REAR SEAT TRACK BRACKET COVER OUTER (w/o Rear No. 2 Seat)
18. REMOVE REAR NO. 1 SEAT ASSEMBLY RH (w/o Rear No. 2 Seat)
19. REMOVE REAR SEAT TRACK BRACKET COVER OUTER (w/o Rear No. 2 Seat)
20. REMOVE REAR SEAT TRACK BRACKET COVER OUTER (w/o Rear No. 2 Seat)
21. REMOVE REAR NO. 1 SEAT ASSEMBLY LH (w/o Rear No. 2 Seat)
22. REMOVE TONNEAU COVER ASSEMBLY
23. REMOVE DECK BOARD SUB-ASSEMBLY (w/ Rear No. 2 Seat)
24. REMOVE DECK BOARD SUB-ASSEMBLY (w/o Rear No. 2 Seat)
25. REMOVE DECK BOARD SUB-ASSEMBLY NO.3
26. REMOVE DECK BOARD SUB-ASSEMBLY NO.2
27. REMOVE DECK FLOOR BOX REAR
28. REMOVE DECK FLOOR BOX FRONT (w/o Rear No. 2 Seat)
29. REMOVE REAR FLOOR FINISH PLATE
30. REMOVE BACK DOOR WEATHERSTRIP
31. REMOVE REAR SEAT RECLINING COVER NO.2 LH (w/ Rear No. 2 Seat)
32. REMOVE REAR SEAT RECLINING COVER NO.2 RH (w/ Rear No. 2 Seat)
33. REMOVE JACK CARRIER ASSEMBLY
34. REMOVE DECK SIDE TRIM BOX LH
35. REMOVE DECK SIDE TRIM BOX RH
36. REMOVE REAR DOOR SCUFF PLATE LH (w/ Rear No. 2 Seat)
37. REMOVE REAR DOOR SCUFF PLATE LH (w/o Rear No. 2 Seat)
38. REMOVE REAR DOOR SCUFF PLATE RH
39. REMOVE DECK SIDE TRIM COVER LH (w/ Rear No. 2 Seat)
40. REMOVE DECK SIDE TRIM COVER LH (w/o Rear No. 2 Seat)
41. REMOVE DECK SIDE TRIM COVER RH
42. REMOVE REAR NO.1 SEAT BELT ASSEMBLY OUTER LH
43. REMOVE REAR NO.1 SEAT BELT ASSEMBLY OUTER RH
44. REMOVE ROPE HOOK
45. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH
46. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH
47. REMOVE AIR INTAKE COVER
48. REMOVE AIR INTAKE COVER CENTER
49. SEPARATE FLOOR CARPET ASSEMBLY FRONT
50. REMOVE FLOOR BOARD NO.1
51. REMOVE FLOOR BOARD NO.2
52. REMOVE FLOOR BOARD NO.3
53. REMOVE REAR CENTER SEAT INNER BELT
54. REMOVE BATTERY CARRIER DUCT
55. REMOVE HV BATTERY SERVICE HOLE COVER
56. REMOVE BATTERY COVER SUB-ASSEMBLY
57. 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 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 REAR CENTER SEAT INNER BELT
7. INSTALL FLOOR BOARD NO.3
8. INSTALL FLOOR BOARD NO.2
9. INSTALL FLOOR BOARD NO.1
10. INSTALL FLOOR CARPET ASSEMBLY FRONT
11. INSTALL AIR INTAKE COVER CENTER
12. INSTALL AIR INTAKE COVER
13. INSTALL DECK TRIM SIDE PANEL ASSEMBLY LH
14. INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH
15. INSTALL ROPE HOOK
16. INSTALL REAR NO.1 SEAT BELT ASSEMBLY OUTER LH
17. INSTALL REAR NO.1 SEAT BELT ASSEMBLY OUTER RH
18. INSTALL DECK SIDE TRIM COVER LH (w/ Rear No. 2 Seat)
19. INSTALL DECK SIDE TRIM COVER LH (w/o Rear No. 2 Seat)
20. INSTALL DECK SIDE TRIM COVER RH
21. INSTALL REAR DOOR SCUFF PLATE LH (w/ Rear No. 2 Seat)
22. INSTALL REAR DOOR SCUFF PLATE LH (w/o Rear No. 2 Seat)
23. INSTALL REAR DOOR SCUFF PLATE RH
24. INSTALL DECK SIDE TRIM BOX LH
25. INSTALL DECK SIDE TRIM BOX RH
26. INSTALL JACK CARRIER ASSEMBLY
27. INSTALL REAR SEAT RECLINING COVER NO.2 LH (w/ Rear No. 2 Seat)
28. INSTALL REAR SEAT RECLINING COVER NO.2 RH (w/ Rear No. 2 Seat)
29. INSTALL BACK DOOR WEATHERSTRIP
30. INSTALL REAR FLOOR FINISH PLATE
31. INSTALL DECK FLOOR BOX FRONT (w/o Rear No. 2 Seat)
32. INSTALL DECK FLOOR BOX REAR
33. INSTALL DECK BOARD SUB-ASSEMBLY NO.3
34. INSTALL DECK BOARD SUB-ASSEMBLY NO.2
35. INSTALL DECK BOARD SUB-ASSEMBLY (w/ Rear No. 2 Seat)
36. INSTALL DECK BOARD SUB-ASSEMBLY (w/o Rear No. 2 Seat)
37. INSTALL TONNEAU COVER ASSEMBLY
38. INSTALL REAR NO. 1 SEAT ASSEMBLY LH (w/ Rear No. 2 Seat)
39. INSTALL SEAT TRACK COVER INNER LH (w/ Rear No. 2 Seat)
40. INSTALL REAR SEAT TRACK BRACKET COVER INNER LH (w/ Rear No. 2 Seat)
41. INSTALL REAR SEAT TRACK COVER LH (w/ Rear No. 2 Seat)
42. INSTALL REAR SEAT TRACK BRACKET COVER OUTER (w/ Rear No. 2 Seat)
43. INSTALL RECLINING HINGE COVER LH (w/ Rear No. 2 Seat)
44. INSTALL REAR NO. 1 SEAT ASSEMBLY RH (w/ Rear No. 2 Seat)
45. INSTALL SEAT TRACK INNER COVER RH (w/ Rear No. 2 Seat)
46. INSTALL REAR SEAT TRACK BRACKET COVER INNER RH (w/ Rear No. 2 Seat)
47. INSTALL REAR SEAT TRACK COVER RH (w/ Rear No. 2 Seat)
48. INSTALL REAR SEAT TRACK BRACKET COVER OUTER (w/ Rear No. 2 Seat)
49. INSTALL REAR NO. 1 SEAT ASSEMBLY RH (w/o Rear No. 2 Seat)
50. INSTALL REAR SEAT TRACK BRACKET COVER OUTER (w/o Rear No. 2 Seat)
51. INSTALL REAR SEAT TRACK BRACKET COVER OUTER (w/o Rear No. 2 Seat)
52. INSTALL REAR NO. 1 SEAT ASSEMBLY LH (w/o Rear No. 2 Seat)
53. INSPECT SLIDE ADJUSTER LOCK SIMULTANEOUSLY
54. INSTALL SERVICE PLUG GRIP
55. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
56. PERFORM INITIALIZATION
Some systems need initialization when disconnecting the cable from the negative battery terminal.