System Main Relay, Hybrid Drive: Service and Repair
REMOVAL1. OBSERVE PRECAUTIONS FOR HIGH-VOLTAGE CIRCUIT INSPECTION AND SERVICE
2. CHECK DTC OUTPUT
3. REMOVE LUGGAGE COMPARTMENT FLOOR MAT
4. REMOVE BATTERY SERVICE HOLE COVER LH
5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
6. REMOVE SERVICE PLUG GRIP
7. REMOVE NO. 2 ENGINE ROOM SIDE RH COVER
8. REMOVE CONNECTOR COVER ASSEMBLY
9. CHECK TERMINAL VOLTAGE
10. INSTALL CONNECTOR COVER ASSEMBLY
11. INSTALL NO. 2 ENGINE ROOM SIDE RH COVER
12. REMOVE LUGGAGE COMPARTMENT TRIM SIDE COVER RH
13. REMOVE TOOL BOX
14. REMOVE ROPE HOOK ASSEMBLY
15. REMOVE LUGGAGE COMPARTMENT FRONT TRIM COVER
16. INSTALL TOOL BOX
17. REMOVE NO. 3 HV BATTERY EXHAUST DUCT
18. DISCONNECT FRAME WIRE
19. REMOVE BATTERY BRACKET SUB-ASSEMBLY
a. Remove the 3 bolts and battery bracket subassembly.
CAUTION: Wear insulating gloves.
20. REMOVE BATTERY CARRIER SUB-ASSEMBLY
a. Disconnect the 3 connectors and 2 clamps.
CAUTION: Wear insulating gloves.
NOTE: Insulate the removed terminals with insulating tape.
b. Remove the 2 bolts and 2 nuts, and pull out the battery carrier.
CAUTION: Wear insulated gloves.
NOTE:
- Cover the tool box in the luggage compartment with cardboard or other similar objects before pulling out the battery carrier to prevent the tool box from being damaged.
- Do not forcibly pull out the battery carrier because it is connected to high voltage wire harnesses.
21. REMOVE NO. 6 BATTERY CARRIER PANEL
a. Remove the 7 bolts and No. 6 battery carrier panel from the battery carrier.
CAUTION: Wear insulated gloves.
NOTE: Do not drop the bolts in the cooling air inlet.
22. REMOVE HV RELAY ASSEMBLY
a. Disconnect the 7 connectors and clamp from the HV relay assembly.
CAUTION: Wear insulated gloves.
NOTE: Insulate the removed terminals with insulating tape.
b. Remove the 3 nuts and HV relay assembly from the battery carrier.
CAUTION: Wear insulated gloves.
23. REMOVE HIGH VOLTAGE FUSE
a. Remove the 2 bolts and high voltage fuse.
INSTALLATION
1. INSTALL HIGH VOLTAGE FUSE
a. Install the high voltage fuse with the 2 bolts.
Torque: 4.5 N.m (46 kgf.cm, 40 in.lbf)
NOTE: Be sure to use a torque wrench to tighten the bolts.
2. INSTALL HV RELAY ASSEMBLY
a. Install the HV relay assembly with the 3 nuts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
CAUTION: Wear insulated gloves.
b. Connect the 7 connectors and clamp to the HV relay assembly.
CAUTION: Wear insulated gloves.
NOTE:
- Connect the wire wrapped with red tape to the terminal indicated by the "+" mark of the HV relay and the wire not wrapped with red tape to the terminal indicated by the "-" mark of the HV battery.
- Make sure that the connectors are engaged securely.
3. INSTALL NO. 6 BATTERY CARRIER PANEL
a. Install the No. 6 battery carrier panel with the 7 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
CAUTION: Wear insulated gloves.
NOTE: Do not drop the bolts in the cooling air inlet.
4. INSTALL BATTERY CARRIER SUB-ASSEMBLY
a. Install the battery carrier sub-assembly with the 2 bolts and 2 nuts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
CAUTION: Wear insulated gloves.
b. Connect the 3 connectors and 2 clamps.
CAUTION: Wear insulated gloves.
5. INSTALL BATTERY BRACKET SUB-ASSEMBLY
a. Pass the stud bolts on the battery carrier through holes A in the battery bracket. Install the battery bracket with the 3 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
CAUTION: Wear insulated gloves.
NOTE: Be sure to push the bracket onto the carrier when tightening the 3 bolts.
6. CONNECT FRAME WIRE
7. INSTALL NO. 3 HV BATTERY EXHAUST DUCT
8. REMOVE TOOL BOX
9. INSTALL LUGGAGE COMPARTMENT FRONT TRIM COVER
10. INSTALL ROPE HOOK ASSEMBLY
11. INSTALL TOOL BOX
12. INSTALL LUGGAGE COMPARTMENT TRIM SIDE COVER RH
13. INSTALL SERVICE PLUG GRIP
14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
15. INSTALL BATTERY SERVICE HOLE COVER LH
16. INSTALL LUGGAGE COMPARTMENT FLOOR MAT
17. PERFORM INITIALIZATION
a. Perform initialization procedure.
NOTE: Some vehicle systems require initialization after reconnecting the cable to the negative battery terminal.