System Main Relay No.2
SYSTEM MAIN RELAY NO.2REPLACEMENT
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.
19. REMOVE SYSTEM MAIN RELAY NO.2
NOTICE: 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 No. 2.
c. Disconnect the connector.
d. Remove the 2 nuts and system main relay No. 2.
20. INSTALL SYSTEM MAIN RELAY NO.2
NOTICE: Wear insulating gloves.
a. Install the system main relay No. 2 with the 2 nuts.
Torque: 3.4 Nm (35 kgf-cm, 30 inch lbs.)
b. Connect the connector.
c. Temporarily fasten the system main relay terminal and main battery cable No. 2 terminal, in that order, and tighten a new nut.
Torque: 5.6 Nm (57 kgf-cm, 50 inch lbs.)
d. Install the 2 terminal covers.
21. INSPECT CONTACT CONDITION
NOTICE: Wear insulating gloves.
22. INSTALL FRAME WIRE
NOTICE: Wear insulating gloves.
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