FixVault
Home › Toyota › 2005 › Prius › Repair and Diagnosis › Hybrid/Electric Powertrain › Testing and Diagnosis › Hybrid Control System › System Main Relay No.2 › Replacement

System Main Relay No.2: Replacement

NOTE:
  • 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 (SEE  PRECAUTION   ) 
  2. REMOVE REAR FLOOR BOARD NO.2 (See  SERVICE PLUG GRIP   ) 
  3. REMOVE DECK FLOOR BOX REAR (See  SERVICE PLUG GRIP   ) 
  4. REMOVE REAR FLOOR BOARD NO.3 (See  SERVICE PLUG GRIP   ) 
  5. DISCONNECT BATTERY NEGATIVE TERMINAL (See  SERVICE PLUG GRIP   ) 
  6. REMOVE SERVICE PLUG GRIP (See  SERVICE PLUG GRIP   ) 
  7. REMOVE DECK TRIM COVER REAR (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  8. REMOVE TONNEAU COVER ASSY (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  9. REMOVE REAR SEAT CUSHION ASSY (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  10. REMOVE REAR FLOOR BOARD NO.1 (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  11. REMOVE REAR SIDE SEAT BACK FRAME LH (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  12. REMOVE REAR FLOOR BOARD NO.4 (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  13. REMOVE DECK FLOOR BOX LH (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  14. REMOVE DECK TRIM SIDE PANEL ASSY LH (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  15. REMOVE BATTERY CARRIER BRACKET (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  16. REMOVE BATTERY CARRIER PANEL NO.6 (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  17. REMOVE JUNCTION TERMINAL (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
    NOTE: Wear insulating gloves. 
  18. SEPARATE FRAME WIRE (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
    NOTE:
    • Wear insulating gloves. 
    • Insulate the removed terminals with insulating tape. 
  19. REMOVE SYSTEM MAIN RELAY NO.2 
    NOTE: Wear insulating gloves. 
    1. Remove the 2 terminal covers.
      Fig 1: Removing Terminal Covers
      G02617316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut, then disconnect the system main battery relay terminal and main battery cable No. 2.
      Fig 2: Disconnecting System Main Battery Relay Terminal And Main Battery Cable
      G02617317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the connector.
    4. Remove the 2 nuts and system main relay No. 2.
      Fig 3: Disconnecting Connector
      G02617318Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL SYSTEM MAIN RELAY NO.2 
    NOTE: Wear insulating gloves. 
    1. Install the system main relay No. 2 with the 2 nuts.

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

    2. Connect the connector.
      Fig 4: Locating Connector
      G02617319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. 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 N.m (57 kgf.cm, 50 in.lbf) 

      Fig 5: Identifying Main Battery Cable
      G02617320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the 2 terminal covers.
      Fig 6: Installing Terminal Covers
      G02617321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSPECT CONTACT CONDITION (See  SYSTEM MAIN RELAY NO.1   ) 
    NOTE: Wear insulating gloves. 
  22. INSTALL FRAME WIRE (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
    NOTE: Wear insulating gloves. 
  23. INSTALL JUNCTION TERMINAL (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
    NOTE: Wear insulating gloves. 
  24. INSTALL BATTERY CARRIER PANEL NO.6 (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  25. INSTALL BATTERY CARRIER BRACKET (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  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 (See  SERVICE PLUG GRIP   ) 
    NOTE: Wear insulating gloves. 
  35. CONNECT BATTERY NEGATIVE TERMINAL 

    Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf) 

  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 (SEE  INITIALIZATION  ) 
About FixVault