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HV Relay Assembly: Installation

  1. INSTALL HYBRID VEHICLE RELAY ASSEMBLY 
    NOTE: Wear insulating gloves and protective glasses.
    1. Install the HV relay assembly with the 3 nuts.

      Torque: 4.5 N*m (46 kgf*cm, 40 in.*lbf) 

      Fig 1: Locating HV Relay Assembly Nuts
      G05202086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the 2 connectors on the HV relay assembly.
      Fig 2: Locating Connectors On HV Relay Assembly
      G05202085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the 2 main battery cable connectors on the HV relay assembly.
      Fig 3: Locating Main Battery Cable Connectors On HV Relay Assembly
      G05202084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the No.3 wire frame on the HV relay with the 2 nuts.
      Fig 4: Locating No.3 Wire Frame Connector On HV Relay Assembly
      G05201847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure that the No. 3 wire frame do not cross each other.
      • Be sure to connect the No. 3 wire frame to each correct terminal as shown in the illustration.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

    5. Install the No.3 wire frame connector on the HV relay assembly.
  2. CHECK HIGH VOLTAGE CABLE CONNECTION (See  INSTALLATION  ) 
  3. INSTALL BATTERY COVER SUB-ASSEMBLY (See  INSTALLATION  ) 
  4. INSTALL HV BATTERY SERVICE HOLE COVER (See  INSTALLATION  ) 
  5. INSTALL BATTERY CARRIER DUCT (See  INSTALLATION  ) 
  6. INSTALL REAR CENTER SEAT INNER BELT  (See REMOVAL )
  7. INSTALL FLOOR BOARD NO.3 (See  INSTALLATION  ) 
  8. INSTALL FLOOR BOARD NO.2 (See  INSTALLATION  ) 
  9. INSTALL FLOOR BOARD NO.1 (See  INSTALLATION  ) 
  10. INSTALL FLOOR CARPET ASSEMBLY FRONT (See  INSTALLATION  ) 
  11. INSTALL AIR INTAKE COVER CENTER (See  INSTALLATION  ) 
  12. INSTALL AIR INTAKE COVER (See  INSTALLATION  ) 
  13. INSTALL DECK TRIM SIDE PANEL ASSEMBLY LH  (See INSTALLATION )
  14. INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH 
  15. INSTALL ROPE HOOK  (See INSTALLATION )
  16. INSTALL REAR NO.1 SEAT BELT ASSEMBLY OUTER LH  (See INSTALLATION )
  17. INSTALL REAR NO.1 SEAT BELT ASSEMBLY OUTER RH 
  18. INSTALL DECK SIDE TRIM COVER LH (w/ Rear No. 2 Seat)  (See INSTALLATION )
  19. INSTALL DECK SIDE TRIM COVER LH (w/o Rear No. 2 Seat)  (See INSTALLATION )
  20. INSTALL DECK SIDE TRIM COVER RH 
  21. INSTALL REAR DOOR SCUFF PLATE LH (w/ Rear No. 2 Seat)  (See INSTALLATION )
  22. INSTALL REAR DOOR SCUFF PLATE LH (w/o Rear No. 2 Seat)  (See INSTALLATION )
  23. INSTALL REAR DOOR SCUFF PLATE RH 
  24. INSTALL DECK SIDE TRIM BOX LH  (See INSTALLATION )
  25. INSTALL DECK SIDE TRIM BOX RH 
  26. INSTALL JACK CARRIER ASSEMBLY 
  27. INSTALL REAR SEAT RECLINING COVER NO.2 LH (w/ Rear No. 2 Seat)  (See INSTALLATION )
  28. INSTALL REAR SEAT RECLINING COVER NO.2 RH (w/ Rear No. 2 Seat) 
  29. INSTALL BACK DOOR WEATHERSTRIP 
  30. INSTALL REAR FLOOR FINISH PLATE  (See INSTALLATION )
  31. INSTALL DECK FLOOR BOX FRONT (w/o Rear No. 2 Seat)  (See INSTALLATION )
  32. INSTALL DECK FLOOR BOX REAR  (See INSTALLATION )
  33. INSTALL DECK BOARD SUB-ASSEMBLY NO.3 
  34. INSTALL DECK BOARD SUB-ASSEMBLY NO.2 
  35. INSTALL DECK BOARD SUB-ASSEMBLY (w/ Rear No. 2 Seat)  (See INSTALLATION )
  36. INSTALL DECK BOARD SUB-ASSEMBLY (w/o Rear No. 2 Seat)  (See INSTALLATION )
  37. INSTALL TONNEAU COVER ASSEMBLY 
  38. INSTALL REAR NO. 1 SEAT ASSEMBLY LH (w/ Rear No. 2 Seat)  (See INSTALLATION )
  39. INSTALL SEAT TRACK COVER INNER LH (w/ Rear No. 2 Seat) 
  40. INSTALL REAR SEAT TRACK BRACKET COVER INNER LH (w/ Rear No. 2 Seat) 
  41. INSTALL REAR SEAT TRACK COVER LH (w/ Rear No. 2 Seat) 
  42. INSTALL REAR SEAT TRACK BRACKET COVER OUTER (w/ Rear No. 2 Seat) 
  43. INSTALL RECLINING HINGE COVER LH (w/ Rear No. 2 Seat) 
  44. INSTALL REAR NO. 1 SEAT ASSEMBLY RH (w/ Rear No. 2 Seat)  (See INSTALLATION )
  45. INSTALL SEAT TRACK INNER COVER RH (w/ Rear No. 2 Seat) 
  46. INSTALL REAR SEAT TRACK BRACKET COVER INNER RH (w/ Rear No. 2 Seat) 
  47. INSTALL REAR SEAT TRACK COVER RH (w/ Rear No. 2 Seat) 
  48. INSTALL REAR SEAT TRACK BRACKET COVER OUTER (w/ Rear No. 2 Seat) 
  49. INSTALL REAR NO. 1 SEAT ASSEMBLY RH (w/o Rear No. 2 Seat)  (See INSTALLATION )
  50. INSTALL REAR SEAT TRACK BRACKET COVER OUTER (w/o Rear No. 2 Seat) 
  51. INSTALL REAR SEAT TRACK BRACKET COVER OUTER (w/o Rear No. 2 Seat) 
  52. INSTALL REAR NO. 1 SEAT ASSEMBLY LH (w/o Rear No. 2 Seat)  (See INSTALLATION )
  53. INSPECT SLIDE ADJUSTER LOCK SIMULTANEOUSLY  (See INSTALLATION )
  54. INSTALL SERVICE PLUG GRIP (See  INSTALLATION  ) 
  55. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  56. PERFORM INITIALIZATION 

    Some systems need initialization when disconnecting the cable from the negative battery terminal. (See INITIALIZATION )

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