HV RELAY ASSEMBLY > REMOVAL

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1. PRECAUTION
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2. READ OUTPUT DTC

  1. Check the DTC.

    NOTICE:
    Check the DTC, and confirm that P0AA6 (High voltage insulation is unusual) is not output before doing removal or installation work inside the battery. If the DTC is output, perform troubleshooting procedures first.



3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL


4. REMOVE SERVICE PLUG GRIP

CAUTION:
  1. Remove the service plug to interrupt a high voltage circuit at the time of the check.
  2. Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle.
  3. All the high voltage wiring connectors are colored in orange.



    A115547

  1. Remove the 2 clips, then open the battery service hole cover.

  1. Wear insulation glove, and remove the service plug grip, after sliding up the lever of the service plug grip.

    CAUTION:
    1. Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle.
    2. After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes.

    NOTICE:
    After removing the service plug grip, do not operate the ignition switch as it may damage the hybrid vehicle control ECU.



5. REMOVE REAR SEAT TRACK BRACKET COVER


    B115707

  1. Move the rear seat assembly LH to the rearmost position by operating the rear seat track adjusting handle.

  1. Using a screwdriver, disengage the 4 claws.

    HINT:
    Tape the screwdriver tip before use.

  1. Pull the 2 rear seat track bracket covers toward the rear of the vehicle and remove them.



6. REMOVE REAR SEAT ASSEMBLY LH

  1. Using a clip remover, remove the 3 clips.

  1. Remove the bolt and disconnect the floor anchor side of the fold seat stopper band assembly No.2.

  1. Move the rear seat assembly LH to the rearmost position by operating the rear seat track adjusting handle.

  1. Remove the 2 bolts on the front side.

  1. Move the rear seat assembly LH fully forward by operating the rear seat track adjusting handle.

  1. Remove the 3 bolts on the rear side.

  1. Move the rear seat assembly LH to the center position and adjust the seatback to the vertical position.

  1. Remove the rear seat assembly LH.



7. REMOVE REAR SEAT TRACK BRACKET COVER


    B115707

  1. Move the rear seat assembly RH to the rearmost position by operating the rear seat track adjusting handle.

  1. Using a screwdriver, disengage the 4 claws.

    HINT:
    Tape the screwdriver tip before use.

  1. Pull the 2 rear seat track bracket covers toward the rear of the vehicle and remove them.



8. REMOVE REAR SEAT ASSEMBLY RH

  1. Using a clip remover, remove the 5 clips.

  1. Remove the bolt and disconnect the floor anchor side of the fold seat stopper band assembly No.1.

  1. Move the rear seat assembly RH to the rearmost position by operating the rear seat track adjusting handle.

  1. Remove the 2 bolts on the front side.

  1. Move the rear seat assembly RH fully forward by operating the rear seat track adjusting handle.

  1. Remove the 3 bolts on the rear side.

  1. Move the rear seat assembly RH to the center position and adjust the seatback to the vertical position.

  1. Remove the rear seat assembly RH.



9. REMOVE AIR INTAKE COVER


  1. Remove the air intake cover LH.



      A108244E01

    1. Release the claw by using the screwdriver with the tip taped, and remove the 2 hole covers.



      2. A108247E01

    2. Remove the 2 screws, then release the 2 claws and remove air intake cover LH.



  1. Remove the air intake cover RH.



      A108245E01

    1. Release the claw by using the screwdriver with the tip taped, and remove the 2 hole covers.



      2. A108248E01

    2. Remove the 2 screws, then release the 2 claws and remove air intake cover RH.



10. REMOVE AIR INTAKE COVER CENTER


    A108246E01

  1. Release the claw by using the screwdriver with the tip taped, and remove the 2 hole covers.



    A108249E01

  1. Remove the 2 screws, then release the 2 claws and remove air intake cover center.



11. SEPARATE FLOOR CARPET ASSEMBLY FRONT

  1. Turn back the front floor carpet assembly.



12. REMOVE REAR CENTER SEAT INNER BELT


    B109591

  1. Remove the bolt and rear center seat inner belt assembly.



13. REMOVE BATTERY CARRIER BRACKET


    A108250

  1. Remove the 2 bolts and battery carrier bracket.



14. REMOVE BATTERY CARRIER DUCT


    A109681

  1. Remove the 2 bolts and battery carrier duct (LH).



    A109795

  1. Remove the 2 bolts and battery carrier duct (CTR).



    A109796

  1. Remove the 2 bolts and battery carrier duct (RH).



15. REMOVE HV BATTERY SERVICE HOLE COVER


    A108251E01

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

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

  1. Remove the 2 bolts and battery service hole cover.



16. REMOVE BATTERY COVER SUB-ASSEMBLY

CAUTION:
Wear insulating gloves.



    A108252

  1. Remove the bolt, then disconnect the No.3 wire frame.



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


    A108253E01

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

  1. Remove the 28 bolts, 6 nuts and battery cover.



17. REMOVE HYBRID VEHICLE RELAY ASSEMBLY

NOTICE:
  1. Wear insulating gloves and protective glasses.
  2. Insulate the removed terminals with insulating tape.



    A108324

  1. Disconnect the No.3 wire frame connector from the HV relay assembly.

  1. Remove the 2 nuts, then disconnect the No.3 wire frame from the HV relay assembly.



    A108325

  1. Disconnect the 2 main battery cable connectors from the HV relay assembly.



    A108326

  1. Disconnect the 2 connectors from the HV relay assembly.



    A108327

  1. Remove the 3 nuts and HV relay assembly.