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System Main Resistor: Replacement

WARNING: This page is about a different car, the 2004 Toyota Prius. However, it is still accessible from the selected car via links, so may be relevant.
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: Disconnecting Frame Wire From System Main Relay No. 2
      G00950497Courtesy 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: Removing System Main Resistor
      G00950498Courtesy 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 System Main Resistor
      G00950499Courtesy 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: Installing Frame Wire
      G00950500Courtesy 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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