HV RELAY ASSEMBLY REMOVAL


  1. PRECAUTION

    Click here

  2. REMOVE SERVICE PLUG GRIP

    Click here

  3. REMOVE INVERTER COVER

    CAUTION:

    Wear insulated gloves.


    1. A00446H

      Remove the 9 bolts and inverter cover.

      Note

      Make sure to pull the inverter cover straight up, as a connector is connected to the bottom of the cover.

  4. CHECK TERMINAL VOLTAGE

    CAUTION:

    Wear insulated gloves.

    Note

    Do not allow any foreign matter or water to enter the inverter with converter assembly.


    1. A0041DD

      Using a voltmeter, measure the voltage between the terminals of the 2 phase connectors.

      Standard voltage
      0 V

      Tech Tips

      Use measuring range of DC 750 V or more on the voltmeter.

  5. INSTALL INVERTER COVER

    CAUTION:

    Wear insulated gloves.


    1. A0042LKE01
      Text in Illustration
      *1 Interlock

      Install the inverter cover with the 9 bolts to the inverter with converter assembly.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

      Note


      • Make sure that the interlock is fully engaged.

      • Do not allow any foreign matter or water to enter the inverter with converter assembly.

  6. REMOVE REAR NO. 2 FLOOR BOARD


    1. A00449U

      Using a clip remover, remove the 2 clips.

    2. Disengage the 3 fasteners and remove the rear No. 2 floor board.

  7. REMOVE REAR NO. 4 FLOOR BOARD SUB-ASSEMBLY


    1. Remove the rear No.4 floor board sub-assembly.

  8. REMOVE DECK FLOOR BOX LH

    Tech Tips

    Use the same procedure described for the RH side Click here.

  9. REMOVE TONNEAU COVER ASSEMBLY


    1. Remove the tonneau cover assembly.

  10. REMOVE REAR NO. 2 FLOOR BOARD SUB-ASSEMBLY


    1. A0043P1

      Disengage the claw and 2 clips, and remove the rear No. 2 floor board sub-assembly.

  11. REMOVE REAR NO. 1 FLOOR BOARD SUB-ASSEMBLY


    1. A004109

      Disengage the claw and 3 clips, and remove the rear No. 1 floor board sub-assembly.

  12. REMOVE REAR NO. 1 FLOOR BOARD


    1. Fold the rear seatback assembly LH forward.

    2. A0042PSE01
      Text in Illustration
      *1 Fastener

      Disengage the fastener.

    3. Fold the rear seatback assembly LH forward.

    4. A0040XLE01
      Text in Illustration
      *1 Fastener

      Disengage the fastener.

    5. A0043PV

      Using a clip remover, remove the clip.

    6. Disengage the 3 fasteners and remove the rear No. 1 floor board.

  13. REMOVE DECK TRIM SERVICE HOLE COVER


    1. A0040WX

      Disengage the 4 claws.

    2. Disengage the 4 guides and remove the deck trim service hole cover.

  14. REMOVE REAR DECK TRIM COVER


    1. A0043JF

      Disengage the 4 claws and remove the rear deck trim cover.

  15. REMOVE REAR DOOR SCUFF PLATE RH

    Tech Tips

    Use the same procedure described for the LH side Click here.

  16. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH

    Tech Tips

    Use the same procedure described for the LH side Click here.

  17. REMOVE REAR SEAT CUSHION ASSEMBLY


    1. A0041DUE01
      Text in Illustration
      *1 Front Hook
      *2 Rear Hook

      Disengage the front hook of the rear seat cushion assembly from the vehicle body as shown in the illustration.

      Standard Measurement
      Dimension Measurement
      a 100 mm (3.94 in.) or less

      Note

      Follow the instructions below carefully as the cushion frame can be deformed easily.


      1. Choose a front hook to disengage first. Place your hands near the front hook as shown in the illustration. Then lift the seat cushion to disengage the front hook.

      2. Repeat the above procedure for the other hook.

    2. Disengage the 2 rear hooks of the rear seat cushion assembly from the rear seatback assembly.

    3. Remove the rear seat cushion assembly.

      Note

      Be careful not to damage the vehicle body.

  18. REMOVE REAR SIDE SEAT BACK ASSEMBLY RH


    1. A0041NL

      Remove the bolt.

    2. A0041DQE01
      Text in Illustration
      *1 Fastener

      Disengage the fastener.

    3. A0041ZJ

      Disengage the 2 guides and remove the rear side seatback assembly RH as shown in the illustration.

  19. REMOVE LUGGAGE HOLD BELT STRIKER ASSEMBLY (for RH Side)

    Tech Tips

    Use the same procedure described for the LH side Click here.

  20. REMOVE TONNEAU COVER HOLDER CAP (for RH Side)

    Tech Tips

    Use the same procedure described for the LH side Click here.

  21. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH


    1. Remove the screw.

      A0040C2

    2. Disengage the 7 claws and 2 clips, and remove the deck trim side panel assembly RH.

  22. REMOVE BATTERY COOLING BLOWER ASSEMBLY (for RH Side)

    Note


    • Be sure not to touch the fan part of the battery cooling blower assembly.

    • Do not lift the battery cooling blower assembly using the wire harness.


    1. A0044AD

      Disconnect the connector and clamp from the battery cooling blower assembly.

    2. Remove the 3 nuts and battery cooling blower assembly (for RH side).

  23. REMOVE BATTERY COOLING BLOWER ASSEMBLY (for LH Side)

    Note


    • Be sure not to touch the fan part of the battery cooling blower assembly.

    • Do not lift the battery cooling blower assembly using the wire harness.


    1. A0042D1

      Disconnect the connector and clamp from the battery cooling blower assembly.

    2. Remove the 3 nuts and battery cooling blower assembly (for LH side).

  24. REMOVE HYBRID BATTERY HOSE ASSEMBLY


    1. A0042GS

      Disconnect the clip.

    2. Disengage the claw.

    3. Disconnect the grommet and remove the hybrid battery hose assembly.

  25. REMOVE NO. 3 HYBRID BATTERY EXHAUST DUCT


    1. A0041VU

      Remove the 2 clips and No. 3 hybrid battery exhaust duct (for RH side).

    2. A0041N0

      Remove the 2 clips and No. 3 hybrid battery exhaust duct (for LH side).

  26. REMOVE NO. 4 HYBRID VEHICLE BATTERY CARRIER BRACKET


    1. A0041TP

      Remove the bolt and No. 4 hybrid vehicle battery carrier bracket.

  27. REMOVE REAR NO. 1 HYBRID BATTERY SHIELD

    CAUTION:

    Wear insulated gloves.


    1. A004483

      Disconnect the connector and 2 clamps.

    2. A00414J

      Disconnect the clamp.

    3. A0044ALE01
      Text in Illustration
      *1 Battery Cover Lock Striker
      *2 Button
      *a Projection
      *b Turn

      Using the service plug grip, remove the battery cover lock striker.

      Tech Tips

      Insert the projection part of the service plug grip, and turn the button of the battery cover lock striker counterclockwise, and release the lock.

    4. A004297

      Remove the 9 bolts and rear No. 1 hybrid battery shield.

  28. REMOVE NO. 2 HYBRID VEHICLE BATTERY SHIELD PANEL

    CAUTION:

    Wear insulated gloves.


    1. A00445NE01
      Text in Illustration
      *1 Battery Cover Lock Striker
      *2 Button
      *a Projection
      *b Turn

      Using the service plug grip, remove the battery cover lock striker.

      Tech Tips

      Insert the projection part of the service plug grip, and turn the button of the battery cover lock striker counterclockwise, and release the lock.

    2. A0042Z5

      Remove the 3 nuts and No. 2 hybrid vehicle battery shield panel.

  29. REMOVE NO. 1 HYBRID VEHICLE BATTERY SHIELD PANEL

    CAUTION:

    Wear insulated gloves.


    1. A00415T

      Disengage the 2 claws and remove the 3 clamps and electrical key oscillator.

    2. A0040AS

      Disconnect the connector and clamp.

    3. Remove the 7 nuts and No. 1 hybrid vehicle battery shield panel.

  30. REMOVE NO. 1 HYBRID VEHICLE BATTERY COVER PANEL RH

    CAUTION:

    Wear insulated gloves.


    1. A0041AY

      Disconnect the 4 clamps.

    2. A00445K

      Remove the 6 bolts and No. 1 hybrid vehicle battery cover panel RH.

  31. REMOVE NO. 1 HYBRID VEHICLE BATTERY COVER PANEL LH

    CAUTION:

    Wear insulated gloves.


    1. A0040FV

      Remove the 6 bolts and No. 1 hybrid vehicle battery cover panel LH.

  32. REMOVE UPPER HYBRID BATTERY COVER SUB-ASSEMBLY

    CAUTION:

    Wear insulated gloves.


    1. A0042XN

      Remove the 2 bolts, 4 nuts and upper hybrid battery cover sub-assembly.

  33. DISCONNECT EV CHARGER WIRE

    CAUTION:

    Wear insulated gloves.


    1. A004014

      Disconnect the connector.

      Note

      Insulate the disconnected connector with insulating tape.

    2. Remove the nut and disconnect the electric vehicle charger wire.

  34. DISCONNECT FRAME WIRE

    CAUTION:

    Wear insulated gloves.


    1. A0041UN

      Using an insulated tool, remove the 2 nuts.

    2. Disconnect the shield wire ground and frame wire.

      Note

      Insulate the disconnected terminal with insulating tape.

  35. REMOVE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. A0043NR

      Disconnect the 10 clamps.

    2. A0041L0

      Disconnect the 3 connectors from the hybrid battery junction block assembly.

    3. A0040OQ

      Disconnect the 2 connectors from the hybrid battery junction block assembly.

      Note

      Insulate the disconnected connectors with insulating tape.

    4. A0040GO

      Remove the 3 nuts and hybrid battery junction block assembly.

  36. REMOVE NO. 4 HYBRID VEHICLE BATTERY PACK WIRE

    Tech Tips

    Perform this procedure only when replacement of the No. 4 hybrid battery pack wire is necessary.


    1. A0043Q9

      Disconnect the 2 connectors and 3 clamps and remove the No. 4 hybrid vehicle battery pack wire.

  37. REMOVE ELECTRIC VEHICLE FUSE

    Tech Tips

    Perform this procedure only when replacement of the electric vehicle fuse is necessary.


    1. A0043XP

      Disconnect the clamp from the hybrid battery junction block assembly.

    2. A0041HF

      Remove the 2 bolts and electric vehicle fuse.