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System Main Relay: Removal

CAUTION:
  • When working on the high voltage systems, always wear insulating gloves.
  • 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.
NOTE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU.
  1. PRECAUTION 
    CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (including installation/removal, inspection and replacement of parts), be sure to follow the procedures (see PRECAUTION  ).
  2. REMOVE REAR NO. 2 FLOOR BOARD (See  REMOVAL  ) 
  3. REMOVE REAR DECK FLOOR BOX (See  REMOVAL  ) 
  4. REMOVE REAR NO. 3 FLOOR BOARD (See  INSTALLATION  ) 
  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 (See  REMOVAL   ) 
  7. REMOVE REAR DECK TRIM COVER (See  REMOVAL   ) 
  8. REMOVE TONNEAU COVER (See  DISASSEMBLY   ) 
  9. REMOVE REAR SEAT CUSHION ASSEMBLY (See  DISASSEMBLY   ) 
  10. REMOVE REAR NO. 1 FLOOR BOARD (See  DISASSEMBLY   ) 
  11. REMOVE REAR SIDE SEAT BACK FRAME LH (See  DISASSEMBLY   ) 
  12. REMOVE REAR NO. 4 FLOOR BOARD (See  DISASSEMBLY   ) 
  13. REMOVE DECK FLOOR BOX LH (See  DISASSEMBLY   ) 
  14. REMOVE DECK TRIM SIDE PANEL LH (See  DISASSEMBLY   ) 
  15. REMOVE BATTERY CARRIER BRACKET (See  DISASSEMBLY   ) 
  16. REMOVE NO. 6 BATTERY CARRIER PANEL (See  DISASSEMBLY   ) 
  17. REMOVE JUNCTION TERMINAL (See  DISASSEMBLY   ) 
  18. SEPARATE FRAME WIRE (See  DISASSEMBLY   ) 
  19. REMOVE NO. 2 SYSTEM MAIN RELAY 
    CAUTION: Wear insulating gloves.
    1. Remove the 2 terminal covers.
      Fig 1: Removing Terminal Covers
      G04473965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut, then disconnect the system main battery relay terminal and main battery cable.
      Fig 2: Disconnecting System Main Battery Relay Terminal And Main Battery Cable
      G04473966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the connector.
    4. Remove the 2 nuts and No. 2 system main relay.
      Fig 3: Removing No 2 System Main Relay
      G04473967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE NO. 3 SYSTEM MAIN RELAY 
    NOTE: Wear insulating gloves.
    1. Remove the nut, then disconnect the main battery cable.
    2. Remove the 2 nuts, then disconnect the No. 3 system main relay.
    3. Disconnect the connector and remove the No. 3 system main relay.
      Fig 4: Removing No 3 System Main Relay
      G04473968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE NO. 1 SYSTEM MAIN RELAY 
    CAUTION: Wear insulating gloves.
    1. Disconnect the connector.
    2. Remove the nut, then disconnect the ground terminal.
    3. Disconnect the 2 clamps.
    4. Remove the system main relay connector.
    5. Remove the 2 bolts and No. 1 system main relay.
      Fig 5: Removing System Main Relay Connector
      G04473969Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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