System Main Relay No.1
SYSTEM MAIN RELAY NO.1REPLACEMENT
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.
19. REMOVE SYSTEM MAIN RELAY NO.2
NOTICE: Wear insulating gloves.
20. REMOVE SYSTEM MAIN RELAY NO.3
NOTICE: Wear insulating gloves.
21. REMOVE SYSTEM MAIN RELAY NO.1
NOTICE: 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 system main relay No. 1.
22. INSTALL SYSTEM MAIN RELAY NO.1
NOTICE: Wear insulating gloves.
a. Install the system main relay No. 1 with the 2 bolts.
Torque: 3.4 Nm (35 kgf-cm, 30 inch lbs.)
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 Nm (57 kgf-cm, 50 inch lbs.)
e. Install the connector.
23. INSTALL SYSTEM MAIN RELAY NO.3
NOTICE: Wear insulating gloves.
24. INSTALL SYSTEM MAIN RELAY NO.2
NOTICE: Wear insulating gloves.
25. INSPECT CONTACT CONDITION
NOTICE: Wear insulating gloves.
a. Check that all the wiring wire harnesses are correctly and securely connected on the under battery carrier.
NOTICE: Make sure that the connectors and clamps are connected exactly the same as the illustration above. If any of them is different, correct it immediately.
26. INSTALL FRAME WIRE
NOTICE: Wear insulating gloves.
27. INSTALL JUNCTION TERMINAL
NOTICE: Wear insulating gloves.
28. INSTALL BATTERY CARRIER PANEL NO.6
29. INSTALL BATTERY CARRIER BRACKET
30. INSTALL DECK TRIM SIDE PANEL ASSY LH
31. INSTALL DECK FLOOR BOX LH
32. INSTALL REAR FLOOR BOARD NO.4
33. INSTALL REAR SIDE SEAT BACK FRAME LH
34. INSTALL REAR FLOOR BOARD NO.1
35. INSTALL REAR SEAT CUSHION ASSY
36. INSTALL TONNEAU COVER ASSY
37. INSTALL DECK TRIM COVER REAR
38. INSTALL SERVICE PLUG GRIP
NOTICE: Wear insulating gloves.
39. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 6.0 Nm (61 kgf-cm, 53 inch lbs.)
40. INSTALL REAR FLOOR BOARD NO.3
41. INSTALL DECK FLOOR BOX REAR
42. INSTALL REAR FLOOR BOARD NO.2
43. POWER WINDOW CONTROL SYSTEM INITIALIZE