LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Toyota >> 2006 >> Prius >> Repair and Diagnosis >> Hybrid/Electric Powertrain >> Battery Management Systems >> P112 Hybrid Battery Control System >> System Main Relay >> Installation
April 5, 2026: LEMON Manuals is launched! Read the announcement.

System Main Relay: Installation

  1. INSTALL NO. 1 SYSTEM MAIN RELAY 
    CAUTION: Wear insulating gloves.
    1. Install the No. 1 system main relay with the 2 bolts.

      Torque: 3.4 N*m (35 kgf*cm, 30 in.*lbf) 

    2. Connect the system main relay connector.
      Fig 1: Connecting System Main Relay Connector
      G04473973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the 2 clamps, then install the system main relay sub wiring harness to the upper battery carrier.
    4. Install the ground terminal with the nut.

      Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) 

    5. Install the connector.
  2. INSTALL NO. 3 SYSTEM MAIN RELAY 
    CAUTION: Wear insulating gloves.
    1. Connect the connector, then temporarily install the No. 3 system main relay.
    2. Install the No. 3 system main relay with 2 new nuts.

      Torque: 3.4 N*m (35 kgf*cm, 30 in.*lbf) 

    3. Install the main battery cable with the nut.

      Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) 

      Fig 2: Installing No 3 System Main Relay
      G04473974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 2 SYSTEM MAIN RELAY 
    CAUTION: Wear insulating gloves.
    1. Install the No. 2 system main relay with the 2 nuts.

      Torque: 3.4 N*m (35 kgf*cm, 30 in.*lbf) 

    2. Connect the connector.
      Fig 3: Installing No 2 System Main Relay
      G04473975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Temporarily install the system main relay terminal and No. 2 main battery cable terminal, in that order, and tighten a new nut.

      Torque: 5.6 N*m (57 kgf*cm, 50 in.*lbf) 

    4. Install the 2 terminal covers.
  4. INSPECT CONTACT CONDITION 
    CAUTION: Wear insulating gloves.
    1. Check that all the wire harnesses are correctly and securely connected on the upper battery carrier.
      Fig 4: Installing System Main Relay Terminal And Main Battery Cable
      G04473976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 5: Identifying Proper Installation Of Wire Harnesses On Upper Battery Carrier
      G04473977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Make sure that the connectors and clamps are connected exactly the same as the illustration above. If any of them is different, correct it immediately.
  5. INSTALL FRAME WIRE (See  INSTALLATION   ) 
  6. INSTALL JUNCTION TERMINAL (See  INSTALLATION   ) 
  7. INSTALL NO. 6 BATTERY CARRIER PANEL (See  INSTALLATION   ) 
  8. INSTALL BATTERY CARRIER BRACKET (See  INSTALLATION   ) 
  9. INSTALL DECK TRIM SIDE PANEL LH (See  INSTALLATION   ) 
  10. INSTALL DECK FLOOR BOX LH (See  INSTALLATION   ) 
  11. INSTALL REAR NO. 4 FLOOR BOARD (See  INSTALLATION   ) 
  12. INSTALL REAR SIDE SEAT BACK FRAME LH (See  INSTALLATION   ) 
  13. INSTALL REAR NO. 1 FLOOR BOARD (See  INSTALLATION   ) 
  14. INSTALL REAR SEAT CUSHION ASSEMBLY (See  INSTALLATION   ) 
  15. INSTALL TONNEAU COVER (See  INSTALLATION   ) 
  16. INSTALL REAR DECK TRIM COVER (See  INSTALLATION   ) 
  17. INSTALL SERVICE PLUG GRIP (See  REMOVAL   ) 
  18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (See  INSTALLATION  ) 
  19. INSTALL REAR NO. 3 FLOOR BOARD (See  INSTALLATION  ) 
  20. INSTALL REAR DECK FLOOR BOX (See  INSTALLATION  ) 
  21. INSTALL REAR NO. 2 FLOOR BOARD (See  INSTALLATION  ) 
  22. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
scientia non olet · About LEMON Manuals