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HV Relay Assembly: Removal

  1. PRECAUTION 

    (See PRECAUTION )

  2. READ OUTPUT DTC (See  REMOVAL  ) 
  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  4. REMOVE SERVICE PLUG GRIP (See  REMOVAL   )
  5. REMOVE RECLINING HINGE COVER LH (w/ Rear No. 2 Seat)  (See REMOVAL )
  6. REMOVE REAR SEAT TRACK BRACKET COVER OUTER (w/ Rear No. 2 Seat)  (See REMOVAL )
  7. REMOVE REAR SEAT TRACK COVER LH (w/ Rear No. 2 Seat)  (See REMOVAL )
  8. REMOVE REAR SEAT TRACK BRACKET COVER INNER LH (w/ Rear No. 2 Seat)  (See REMOVAL )
  9. REMOVE SEAT TRACK COVER INNER LH (w/ Rear No. 2 Seat)  (See REMOVAL )
  10. REMOVE REAR NO. 1 SEAT ASSEMBLY LH (w/ Rear No. 2 Seat)  (See REMOVAL )
  11. REMOVE REAR SEAT TRACK BRACKET COVER OUTER (w/ Rear No. 2 Seat)  (See REMOVAL )
  12. REMOVE REAR SEAT TRACK COVER RH (w/ Rear No. 2 Seat)  (See REMOVAL )
  13. REMOVE REAR SEAT TRACK BRACKET COVER INNER RH (w/ Rear No. 2 Seat)  (See REMOVAL )
  14. REMOVE SEAT TRACK INNER COVER RH (w/ Rear No. 2 Seat)  (See REMOVAL )
  15. REMOVE REAR NO. 1 SEAT ASSEMBLY RH (w/ Rear No. 2 Seat)  (See REMOVAL )
  16. REMOVE REAR SEAT TRACK BRACKET COVER OUTER (w/o Rear No. 2 Seat)  (See REMOVAL )
  17. REMOVE REAR SEAT TRACK BRACKET COVER OUTER (w/o Rear No. 2 Seat)  (See REMOVAL )
  18. REMOVE REAR NO. 1 SEAT ASSEMBLY RH (w/o Rear No. 2 Seat)  (See REMOVAL )
  19. REMOVE REAR SEAT TRACK BRACKET COVER OUTER (w/o Rear No. 2 Seat)  (See REMOVAL )
  20. REMOVE REAR SEAT TRACK BRACKET COVER OUTER (w/o Rear No. 2 Seat)  (See REMOVAL )
  21. REMOVE REAR NO. 1 SEAT ASSEMBLY LH (w/o Rear No. 2 Seat)  (See REMOVAL )
  22. REMOVE TONNEAU COVER ASSEMBLY 
  23. REMOVE DECK BOARD SUB-ASSEMBLY (w/ Rear No. 2 Seat)  (See REMOVAL )
  24. REMOVE DECK BOARD SUB-ASSEMBLY (w/o Rear No. 2 Seat)  (See REMOVAL )
  25. REMOVE DECK BOARD SUB-ASSEMBLY NO.3 
  26. REMOVE DECK BOARD SUB-ASSEMBLY NO.2 
  27. REMOVE DECK FLOOR BOX REAR  (See REMOVAL )
  28. REMOVE DECK FLOOR BOX FRONT (w/o Rear No. 2 Seat)  (See REMOVAL )
  29. REMOVE REAR FLOOR FINISH PLATE  (See REMOVAL )
  30. REMOVE BACK DOOR WEATHERSTRIP 
  31. REMOVE REAR SEAT RECLINING COVER NO.2 LH (w/ Rear No. 2 Seat)  (See REMOVAL )
  32. REMOVE REAR SEAT RECLINING COVER NO.2 RH (w/ Rear No. 2 Seat) 
  33. REMOVE JACK CARRIER ASSEMBLY  (See REMOVAL )
  34. REMOVE DECK SIDE TRIM BOX LH  (See REMOVAL )
  35. REMOVE DECK SIDE TRIM BOX RH 
  36. REMOVE REAR DOOR SCUFF PLATE LH (w/ Rear No. 2 Seat)  (See REMOVAL )
  37. REMOVE REAR DOOR SCUFF PLATE LH (w/o Rear No. 2 Seat)  (See REMOVAL )
  38. REMOVE REAR DOOR SCUFF PLATE RH 
  39. REMOVE DECK SIDE TRIM COVER LH (w/ Rear No. 2 Seat)  (See REMOVAL )
  40. REMOVE DECK SIDE TRIM COVER LH (w/o Rear No. 2 Seat)  (See REMOVAL )
  41. REMOVE DECK SIDE TRIM COVER RH 
  42. REMOVE REAR NO.1 SEAT BELT ASSEMBLY OUTER LH  (See REMOVAL )
  43. REMOVE REAR NO.1 SEAT BELT ASSEMBLY OUTER RH 
  44. REMOVE ROPE HOOK  (See REMOVAL )
  45. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH  (See REMOVAL )
  46. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH 
  47. REMOVE AIR INTAKE COVER (See  REMOVAL  ) 
  48. REMOVE AIR INTAKE COVER CENTER (See  REMOVAL  ) 
  49. SEPARATE FLOOR CARPET ASSEMBLY FRONT (See  REMOVAL  ) 
  50. REMOVE FLOOR BOARD NO.1 (See  REMOVAL  ) 
  51. REMOVE FLOOR BOARD NO.2 (See  REMOVAL  ) 
  52. REMOVE FLOOR BOARD NO.3 (See  REMOVAL  ) 
  53. REMOVE REAR CENTER SEAT INNER BELT  (See REMOVAL )
  54. REMOVE BATTERY CARRIER DUCT (See  REMOVAL  ) 
  55. REMOVE HV BATTERY SERVICE HOLE COVER (See  REMOVAL  ) 
  56. REMOVE BATTERY COVER SUB-ASSEMBLY (See  REMOVAL  ) 
  57. REMOVE HYBRID VEHICLE RELAY ASSEMBLY 
    NOTE:
    • Wear insulating gloves and protective glasses.
    • Insulate the removed terminals with insulating tape.
    1. Disconnect the No.3 wire frame connector from the HV relay assembly.
      2. Fig 1: Locating No 3 Wire Frame Connector
      G05202083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 nuts, then disconnect the No.3 wire frame from the HV relay assembly.
    3. Disconnect the 2 main battery cable connectors from the HV relay assembly.
      Fig 2: Locating Main Battery Cable Connectors
      G05202084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the 2 connectors from the HV relay assembly.
      Fig 3: Locating Connectors On HV Relay Assembly
      G05202085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 3 nuts and HV relay assembly.
      Fig 4: Locating HV Relay Assembly Nuts
      G05202086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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