Drive Motor Power Relay Resistor: Service and Repair

System Main Resistor:

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.

2. REMOVE REAR NO. 2 FLOOR BOARD
3. REMOVE REAR DECK FLOOR BOX
4. REMOVE REAR NO. 3 FLOOR BOARD
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 REAR DECK TRIM COVER
8. REMOVE TONNEAU COVER
9. REMOVE REAR SEAT CUSHION ASSEMBLY
10. REMOVE REAR NO. 1 FLOOR BOARD
11. REMOVE REAR SIDE SEAT BACK FRAME LH
12. REMOVE REAR NO. 4 FLOOR BOARD
13. REMOVE DECK FLOOR BOX LH
14. REMOVE DECK TRIM SIDE PANEL LH
15. REMOVE BATTERY CARRIER BRACKET
16. REMOVE NO. 6 BATTERY CARRIER PANEL
17. REMOVE JUNCTION TERMINAL

18. DISCONNECT FRAME WIRE

CAUTION:
- Wear insulating gloves.
- Insulate the removed terminals with insulating tape.

a. Remove the nut, then disconnect the frame wire from the No. 2 system main relay.

19. REMOVE SYSTEM MAIN RESISTOR

CAUTION: Wear insulating gloves.

a. Disconnect the connector from the No. 1 system main relay.
b. Remove the bolt and system main resistor.

INSTALLATION

1. INSTALL SYSTEM MAIN RESISTOR

CAUTION: Wear insulating gloves.

a. Install the system main resistor with the bolt.

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

b. Install the connector to the No. 1 system main relay.

2. INSPECT CONTACT CONDITION

3. INSTALL FRAME WIRE

CAUTION: Wear insulating gloves.

a. Temporarily install 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)

4. INSTALL JUNCTION TERMINAL
5. INSTALL NO. 6 BATTERY CARRIER PANEL
6. INSTALL BATTERY CARRIER BRACKET
7. INSTALL DECK TRIM SIDE PANEL LH
8. INSTALL DECK FLOOR BOX LH
9. INSTALL REAR NO. 4 FLOOR BOARD
10. INSTALL REAR SIDE SEAT BACK FRAME LH
11. INSTALL REAR NO. 1 FLOOR BOARD
12. INSTALL REAR SEAT CUSHION ASSEMBLY
13. INSTALL TONNEAU COVER
14. INSTALL REAR DECK TRIM COVER
15. INSTALL SERVICE PLUG GRIP
16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
17. INSTALL REAR NO. 3 FLOOR BOARD
18. INSTALL REAR DECK FLOOR BOX
19. INSTALL REAR NO. 2 FLOOR BOARD
20. PERFORM INITIALIZATION
a. Perform initialization.

NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.