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System Main Resistor: 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 
    NOTE:
    • Wear insulating gloves. 
    • Insulate the removed terminals with insulating tape. 
    1. Remove the nut, then disconnect the frame wire from the system main relay No. 2.
      Fig 1: Identifying System Main Relay
      G02617324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE SYSTEM MAIN RESISTOR 
    NOTE: Wear insulating gloves. 
    1. Disconnect the connector from the system main relay No. 1.
    2. Remove the bolt and system main resistor.
      Fig 2: Disconnecting Connector From System Main Relay No. 1
      G02617325Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL SYSTEM MAIN RESISTOR 
    NOTE: Wear insulating gloves. 
    1. Install the system main resistor with the bolt.

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

    2. Install the connector to the system main relay No. 1.
      Fig 3: Installing Connector To System Main Relay
      G02617326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSPECT CONTACT CONDITION (See  SYSTEM MAIN RELAY NO.1   ) 
    NOTE: Wear insulating gloves. 
  22. INSTALL FRAME WIRE 
    NOTE: Wear insulating gloves. 
    1. Temporarily fasten the system main resistor terminal and frame wire, in that order, and tighten a new nut.

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

      Fig 4: Temporarily Fastening System Main Resistor Terminal
      G02617327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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  ) 
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