Camry 2008-2009

High Voltage Relay Assembly

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Removal & Installation




CAUTION
Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions, such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. Make sure to turn the power switch off before removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system. After disconnecting the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals.

  1. Check for any present DTCs and record them.
    NOTE
    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.

  2.  
  3. Release the 2 claws and remove the luggage trim service hole cover.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the service plug grip.
  8.  
  9. Remove the left engine room side cover as follows:
    1. Pull the A part upward to disengage the clip.
    2.  
    3. Pull the B parts upward by hand to disengage the 2 clips, and remove the No. 2 engine room side cover.

      Click image to see an enlarged view

      Fig. Remove the left engine room side cover

    4.  

  10.  
  11. Remove the 2 bolts and connector cover assembly.
    CAUTION
    Do not touch the high voltage connectors and terminals for 10 minutes after the service plug grip is removed. Wear insulating gloves.


    WARNING
    Do not start the engine with the service plug grip removed because it may cause a malfunction.

  12.  
  13. Using the voltmeter, measure the voltage between the terminals of the 2 phase connectors (N-P).
  14.  
  15. Use measuring range of DC 750 V or more on the voltmeter. Standard voltage: should read 0 volts.
  16.  
  17. Install the connector cover assembly.
  18.  
  19. Install the left engine room side cover.
  20.  
  21. Remove the 2 rear seat headrest assemblies.
  22.  
  23. Remove the rear center seat headrest assembly.
  24.  
  25. Detach the 2 front hooks of the seat cushion from the vehicle body.
  26.  
  27. Remove the seat cushion.
  28.  
  29. Remove the right and left rear side seat back assemblies.
  30.  
  31. Remove the front luggage compartment trim cover.
  32.  
  33. Remove the clip and No. 5 HV battery intake duct.
  34.  
  35. Using the service plug grip, release the interlock button.

    Click image to see an enlarged view

    Fig. Using the service plug grip, release the interlock button

  36.  
  37. Remove the bolt, nut, and wire harness clamp bracket.
  38.  
  39. Disconnect the 2 wire harness clamps.
  40.  
  41. Remove the 2 nuts and ground cable.
  42.  
  43. Remove the 3 nuts, bolt, and upper battery carrier sub-assembly.
  44.  
  45. Remove the battery shield contact.
  46.  
  47. Remove the 2 nuts and disconnect the frame wire (high voltage cable).
  48.  
  49. Remove the 3 bolts, clamp, and No. 1 battery cover lid.
  50.  
  51. Remove the 11 bolts and No.5 battery carrier panel
  52.  
  53. Remove the nut and filter noise capacitor.
  54.  
  55. Remove the nut and disconnect the ground cable
  56.  
  57. Disconnect the 7 connectors from the HV relay assembly.
  58.  
  59. Remove the wire harness clamp.
  60.  
  61. Remove the 2 bolts and HV relay assembly.
  62.  
  63. Remove the 2 bolts and high voltage fuse.

    Click image to see an enlarged view

    Fig. HV Relay and related components

  64.  

To install:

  1. Install the high voltage fuse with the 2 bolts. Tighten to 40 inch. lbs. (4.5 Nm).
  2.  
  3. Install the HV relay assembly with the 2 bolts. Tighten to 71 inch. lbs. (8.0 Nm).
  4.  
  5. Connect the 7 connectors and clamp to the HV relay assembly.
    NOTE
    Connect the wire wrapped with red tape to the terminal indicated by the "+" mark of the HV relay and the wire not wrapped with red tape to the terminal indicated by the "-" mark of the HV battery. Make sure that the connectors are engaged securely.

  6.  
  7. Connect the ground cable with the nut. Tighten to 71 inch. lbs. (8.0 Nm).
  8.  
  9. Install the filter noise capacitor with the nut. Tighten to 71 inch. lbs. (8.0 Nm).
  10.  
  11. Install the No. 5 battery carrier panel with the 11 bolts. Tighten to 71 inch. lbs. (8.0 Nm).
  12.  
  13. Install the No. 1 battery cover lid with the 3 bolts. Tighten to 71 inch. lbs. (8.0 Nm).
  14.  
  15. Connect the wire harness clamp to the No. 1 battery cover lid.
  16.  
  17. Connect the frame wire (high voltage cable) with the 2 nuts. Tighten to 71 inch. lbs. (8.0 Nm).
  18.  
  19. Install the battery shield contact.

    Click image to see an enlarged view

    Fig. Installation of battery contact shield

  20.  
  21. Install the upper battery carrier sub-assembly with the 3 nuts and bolt. Tighten the bolt and nuts to 71 inch. lbs. (8 Nm).
  22.  
  23. Install the wire harness clamp bracket as follows:
    1. Connect the 2 wire harness clamps
    2.  
    3. Install the wire harness clamp bracket with the interlock button.
    4.  
    5. Press the interlock button.
    6.  
    7. Secure the wire harness clamp bracket with the bolt and nut. Tighten the bolt and nut to 71 inch. lbs. (8 Nm).
    8.  

  24.  
  25. Install the No. 5 HV battery intake duct with the clamp
  26.  
  27. Install the front luggage compartment trim cover with the 3 clips.
  28.  
  29. Install the left and right rear side seat back assemblies.
  30.  
  31. Install the left and right separate type rear seat back assemblies.
  32.  
  33. Install the rear seat cushion by attaching the front hooks of the bench type rear seat cushion assembly to the vehicle body.
  34.  
  35. Confirm that the seat cushion is firmly installed.
  36.  
  37. Install the rear seat headrest assemblies.
  38.  
  39. Install the service plug grip.
  40.  
  41. Connect the negative battery cable.
  42.  
  43. Install the luggage trim hole cover.
  44.  
  45. Perform the initialization procedure.
    NOTE
    Some vehicle systems require initialization after reconnecting the cable to the negative battery terminal.

  46.  

 
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