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System Main Relay No. 3: 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 (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 System Main Relay No. 3
      G00950495Courtesy 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 System Main Relay No. 3
      G00950496Courtesy 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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