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System Main Relay No.3: 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. 
  19. REMOVE SYSTEM MAIN RELAY NO.2 (See  SYSTEM MAIN RELAY NO.2   ) 
    NOTE: Wear insulating gloves. 
  20. REMOVE SYSTEM MAIN RELAY NO.3 
    NOTE: Wear insulating gloves. 
    1. Remove the nut, then disconnect the main battery cable.
    2. Remove the 2 nuts, then disconnect the system main relay No. 3.
    3. Remove the connector and system main relay No. 3.
      Fig 1: Removing Connector And System Main Relay
      G02617322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL SYSTEM MAIN RELAY NO.3 
    NOTE: Wear insulating gloves. 
    1. Connect the connector, then temporarily fasten the system main relay No. 3.
    2. Install the system main relay No. 3 with 2 new nuts.

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

    3. Install the main battery cable with the nut.

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

      Fig 2: Installing Main Battery Cable With Nut
      G02617323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL SYSTEM MAIN RELAY NO.2 (See  SYSTEM MAIN RELAY NO.2   ) 
    NOTE: Wear insulating gloves. 
  23. INSPECT CONTACT CONDITION (See  SYSTEM MAIN RELAY NO.1   ) 
    NOTE: Wear insulating gloves. 
  24. INSTALL FRAME WIRE (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
    NOTE: Wear insulating gloves. 
  25. INSTALL JUNCTION TERMINAL (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
    NOTE: Wear insulating gloves. 
  26. INSTALL BATTERY CARRIER PANEL NO.6 (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  27. INSTALL BATTERY CARRIER BRACKET (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  28. INSTALL DECK TRIM SIDE PANEL ASSY LH 
  29. INSTALL DECK FLOOR BOX LH 
  30. INSTALL REAR FLOOR BOARD NO.4 
  31. INSTALL REAR SIDE SEAT BACK FRAME LH 
  32. INSTALL REAR FLOOR BOARD NO.1 
  33. INSTALL REAR SEAT CUSHION ASSY 
  34. INSTALL TONNEAU COVER ASSY 
  35. INSTALL DECK TRIM COVER REAR 
  36. INSTALL SERVICE PLUG GRIP (See  SERVICE PLUG GRIP   ) 
    NOTE: Wear insulating gloves. 
  37. CONNECT BATTERY NEGATIVE TERMINAL 

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

  38. INSTALL REAR FLOOR BOARD NO.3 
  39. INSTALL DECK FLOOR BOX REAR 
  40. INSTALL REAR FLOOR BOARD NO.2 
  41. POWER WINDOW CONTROL SYSTEM INITIALIZE (SEE  INITIALIZATION  ) 
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