Drive Motor Power Relay Resistor: Service and Repair

SYSTEM MAIN RESISTOR
REPLACEMENT

NOTICE:
^ When working on the high voltage systems, always wear insulating gloves.
^ After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU.
^ 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.

1. PRECAUTION
2. REMOVE REAR FLOOR BOARD NO.2
3. REMOVE DECK FLOOR BOX REAR
4. REMOVE REAR FLOOR BOARD NO.3
5. DISCONNECT BATTERY NEGATIVE TERMINAL
6. REMOVE SERVICE PLUG GRIP
7. REMOVE DECK TRIM COVER REAR
8. REMOVE TONNEAU COVER ASSY
9. REMOVE REAR SEAT CUSHION ASSY
10. REMOVE REAR FLOOR BOARD NO.1
11. REMOVE REAR SIDE SEAT BACK FRAME LH
12. REMOVE REAR FLOOR BOARD NO.4
13. REMOVE DECK FLOOR BOX LH
14. REMOVE DECK TRIM SIDE PANEL ASSY LH
15. REMOVE BATTERY CARRIER BRACKET
16. REMOVE BATTERY CARRIER PANEL NO.6
17. REMOVE JUNCTION TERMINAL

NOTICE: Wear insulating gloves.





18. SEPARATE FRAME WIRE

NOTICE:
^ Wear insulating gloves.
^ Insulate the removed terminals with insulating tape.

a. Remove the nut, then disconnect the frame wire from the system main relay No. 2.





19. REMOVE SYSTEM MAIN RESISTOR

NOTICE: Wear insulating gloves.

a. Disconnect the connector from the system main relay No. 1.
b. Remove the bolt and system main resistor.





20. INSTALL SYSTEM MAIN RESISTOR

NOTICE: Wear insulating gloves.

a. Install the system main resistor with the bolt.
Torque: 3.4 Nm (35 kgf-cm, 30 inch lbs.)
b. Install the connector to the system main relay No. 1.
21. INSPECT CONTACT CONDITION

NOTICE: Wear insulating gloves.





22. INSTALL FRAME WIRE

NOTICE: Wear insulating gloves.

a. Temporarily fasten the system main resistor terminal and frame wire, in that order, and tighten a new nut.
Torque: 5.6 Nm (57 kgf-cm, 50 inch lbs.)
23. INSTALL JUNCTION TERMINAL

NOTICE: Wear insulating gloves.

24. INSTALL BATTERY CARRIER PANEL NO.6
25. INSTALL BATTERY CARRIER BRACKET
26. INSTALL DECK TRIM SIDE PANEL ASSY LH
27. INSTALL DECK FLOOR BOX LH
28. INSTALL REAR FLOOR BOARD NO.4
29. INSTALL REAR SIDE SEAT BACK FRAME LH
30. INSTALL REAR FLOOR BOARD NO.1
31. INSTALL REAR SEAT CUSHION ASSY
32. INSTALL TONNEAU COVER ASSY
33. INSTALL DECK TRIM COVER REAR
34. INSTALL SERVICE PLUG GRIP

NOTICE: Wear insulating gloves.

35. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 6.0 Nm (61 kgf-cm, 53 inch lbs.)
36. INSTALL REAR FLOOR BOARD NO.3
37. INSTALL DECK FLOOR BOX REAR
38. INSTALL REAR FLOOR BOARD NO.2
39. POWER WINDOW CONTROL SYSTEM INITIALIZE