Repair/replacement of HV relay and power contactors

Hybrid vehicles use high voltage battery contactors (often called battery relays) inside the hybrid battery pack. These components act as heavy duty electrical switches that connect and disconnect the high voltage battery from the rest of the vehicle's electrical system. When the vehicle starts and enters READY mode, the contactors close and allow high voltage power to flow to the inverter and electric motor. Over time the internal contacts can wear out, burn, or operate inconsistently. When this happens the vehicle may display hybrid system warnings, fail to enter READY mode, or intermittently disconnect the high voltage system. During diagnostics the condition of the contactors and related electrical connections is inspected. If necessary the contactors are replaced or the internal connections within the battery pack are repaired.