System Main Relay, Hybrid Drive: Service and Repair

System Main Relay:

REMOVAL

CAUTION:
- When working on the high voltage systems, always wear insulating gloves.
- Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle.
- After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes.

NOTE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU.

1. PRECAUTION

CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/ removal, inspection and replacement of parts), be sure to follow the procedures

2. REMOVE REAR NO. 2 FLOOR BOARD
3. REMOVE REAR DECK FLOOR BOX
4. REMOVE REAR NO. 3 FLOOR BOARD
5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

6. REMOVE SERVICE PLUG GRIP
7. REMOVE REAR DECK TRIM COVER
8. REMOVE TONNEAU COVER
9. REMOVE REAR SEAT CUSHION ASSEMBLY
10. REMOVE REAR NO. 1 FLOOR BOARD
11. REMOVE REAR SIDE SEAT BACK FRAME LH
12. REMOVE REAR NO. 4 FLOOR BOARD
13. REMOVE DECK FLOOR BOX LH
14. REMOVE DECK TRIM SIDE PANEL LH
15. REMOVE BATTERY CARRIER BRACKET
16. REMOVE NO. 6 BATTERY CARRIER PANEL
17. REMOVE JUNCTION TERMINAL
18. SEPARATE FRAME WIRE
19. REMOVE NO. 2 SYSTEM MAIN RELAY

CAUTION: Wear insulating gloves.

a. Remove the 2 terminal covers.

b. Remove the nut, then disconnect the system main battery relay terminal and main battery cable.

c. Disconnect the connector.
d. Remove the 2 nuts and No. 2 system main relay.

20. REMOVE NO. 3 SYSTEM MAIN RELAY

NOTE: Wear insulating gloves.

a. Remove the nut, then disconnect the main battery cable.
b. Remove the 2 nuts, then disconnect the No. 3 system main relay.
c. Disconnect the connector and remove the No. 3 system main relay.

21. REMOVE NO. 1 SYSTEM MAIN RELAY

CAUTION: Wear insulating gloves.

a. Disconnect the connector.
b. Remove the nut, then disconnect the ground terminal.
c. Disconnect the 2 clamps.
d. Remove the system main relay connector.

e. Remove the 2 bolts and No. 1 system main relay.

INSTALLATION
1. INSTALL NO. 1 SYSTEM MAIN RELAY

CAUTION: Wear insulating gloves.

a. Install the No. 1 system main relay with the 2 bolts.

Torque: 3.4 N.m (35 kgf.cm, 30 in.lbf)

b. Connect the system main relay connector.
c. Connect the 2 clamps, then install the system main relay sub wiring harness to the upper battery carrier.
d. Install the ground terminal with the nut.

Torque: 5.6 N.m (57 kgf.cm, 50 in.lbf)

e. Install the connector.

2. INSTALL NO. 3 SYSTEM MAIN RELAY

CAUTION: Wear insulating gloves.

a. Connect the connector, then temporarily install the No. 3 system main relay.
b. Install the No. 3 system main relay with 2 new nuts.

Torque: 3.4 N.m (35 kgf.cm 30 in.lbf)

c. Install the main battery cable with the nut.

Torque: 5.6 N.m (57 kgf.cm, 50 in.lbf)

3. INSTALL NO. 2 SYSTEM MAIN RELAY

CAUTION: Wear insulating gloves.

a. Install the No. 2 system main relay with the 2 nuts.

Torque: 3.4 N.m (35 kgf.cm, 30 in.lbf)

b. Connect the connector.

c. Temporarily install the system main relay terminal and No. 2 main battery cable terminal, in that order, and tighten a new nut.

Torque: 5.6 N.m (57 kgf.cm, 50 in.lbf)

d. Install the 2 terminal covers.

4. INSPECT CONTACT CONDITION

CAUTION: Wear insulating gloves.

a. Check that all the wire harnesses are correctly and securely connected on the upper battery carrier.

NOTE: Make sure that the connectors and clamps are connected exactly the same as the illustration. If any of them is different, correct it immediately.

5. INSTALL FRAME WIRE
6. INSTALL JUNCTION TERMINAL
7. INSTALL NO. 6 BATTERY CARRIER PANEL
8. INSTALL BATTERY CARRIER BRACKET
9. INSTALL DECK TRIM SIDE PANEL LH
10. INSTALL DECK FLOOR BOX LH
11. INSTALL REAR NO. 4 FLOOR BOARD
12. INSTALL REAR SIDE SEAT BACK FRAME LH
13. INSTALL REAR NO. 1 FLOOR BOARD
14. INSTALL REAR SEAT CUSHION ASSEMBLY
15. INSTALL TONNEAU COVER
16. INSTALL REAR DECK TRIM COVER
17. INSTALL SERVICE PLUG GRIP
18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
19. INSTALL REAR NO. 3 FLOOR BOARD
20. INSTALL REAR DECK FLOOR BOX
21. INSTALL REAR NO. 2 FLOOR BOARD
22. PERFORM INITIALIZATION
a. Perform initialization

NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.