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On-Vehicle Inspection [10/2023 - ]: Procedure

  1. PRECAUTION 
    NOTE:

    After the power switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

    Refer to BEFORE DISCONNECTING BATTERY [10/2023 - ]

  2. CHECK AUXILIARY BATTERY 
    1. Check that the auxiliary battery cables are connected to the correct terminals.

      If they are not, connect them properly.

    2. Check the auxiliary battery for damage and deformation. If severe damage, deformation or leakage is found, replace the auxiliary battery.
    3. Check the electrolyte level in each cell.
      • If the electrolyte level is below the lower line, replace the auxiliary battery.
      • If the electrolyte level is below the lower line, add distilled water to each cell. Then, recharge the battery and check the electrolyte specific gravity.

        Standard Specific Gravity

        1.25 or higher at 20°C (68°F)

  3. CHECK AUXILIARY BATTERY VOLTAGE 
    1. Turn the power switch off and turn on the high beam headlights for 30 seconds. This will remove the surface charge from the auxiliary battery.
    2. Measure the auxiliary battery voltage according to the value(s) in the table below.

      Result

      Tester Connection Condition Specified Condition Result
      Positive (+) auxiliary battery terminal - Negative (-) auxiliary battery terminal 20°C (68°F), Power switch off 12.0 V or higher Auxiliary battery is OK
      12.0 V or less Recharge auxiliary battery
  4. RECHARGE AUXILIARY BATTERY 
    1. Recharge the auxiliary battery.

      HINT: 

      • Recharge the auxiliary battery according to the charger's instructions.
      • Apply the appropriate charging current according to the type of auxiliary battery shown in the table below.
      Charge Method Charging Current
      Normal Below 5 A
      Quick Below 15 A
    2. Turn the power switch off and turn on the high beam headlights for 30 seconds. This will remove the surface charge from the auxiliary battery.
    3. Measure the auxiliary battery voltage according to the value(s) in the table below.

      Result

      Tester Connection Condition Specified Condition Result
      Positive (+) auxiliary battery terminal - Negative (-) auxiliary battery terminal 20°C (68°F), Power switch off 12.0 V or higher Auxiliary battery is OK
      12.0 V or less Recharge auxiliary battery
  5. CHECK AUXILIARY BATTERY TERMINAL, FUSIBLE LINK AND FUSE 
    1. Check that the auxiliary battery terminals are not loose or corroded.

      Positive (+) Auxiliary Battery Terminal 

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      w/ Front LiDAR Sensor

      Negative (-) Auxiliary Battery Terminal 

      Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf) 

      w/o Front LiDAR Sensor

      Negative (-) Auxiliary Battery Terminal 

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      If a terminal is loose or corroded, tighten or clean the terminal.

    2. Measure the resistance of each fusible link and fuse for the auxiliary battery charging system.

      Standard Resistance

      Below 1 Ω

      If the result is not as specified, replace the fusible link or fuse as necessary.

  6. CHECK AMD TERMINAL 
    WARNING:
    • Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair information.
      GTY588409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [10/2023 - ]

    • To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.
      GTY588386Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the service plug grip.

      Refer to REMOVAL [10/2023 - ]

    2. Check that the AMD terminal is connected securely, and there is no contact problem.
      GTY965557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A w/ Advanced Drive
      *a AMD Terminal (Fusible Link Block Assembly Side)
      *b AMD Terminal (DC/DC Converter Assembly Side)

      If there are any arc marks, replace the affected parts.

    3. Check that the nut for the AMD terminal is tightened to the specified torque.

      Fusible Link Block Assembly Side 

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

      DC/DC Converter Assembly Side 

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

      Check that the nut for the AMD terminal is tightened to the specified torque.

      If there are no arc marks and the AMD terminal connection is faulty, connect the AMD terminal securely.

    4. Install the service plug grip.

      Refer to INSTALLATION [10/2020 - ]

  7. CHECK DC/DC CONVERTER FUNCTION 
    1. Connect the AC/DC 400 A probe to the positive (+) auxiliary battery cable.
      GTY596726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Probe Direction
      *b Current Flowing into Auxiliary Battery
    2. Turn the power switch on (READY) and leave the vehicle as is until the electric current flowing to the auxiliary battery becomes 10 A or less.
    3. Turn on the high beam headlights, and turn the blower motor switch to the HI position and the rear window defogger on.
    4. Measure the current and voltage according to the value(s) in the table below.
      GTY450666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Probe Direction
      *b Current Flowing from Auxiliary Battery

      Result

      Item Tester Connection Condition Specified Condition
      Current flowing from auxiliary battery Positive (+) auxiliary battery cable Power switch on (READY)
      (The high beam headlights are on, the blower motor switch is in the HI position, and the rear window defogger is turned on.)      		 0 A or less
      (No current from auxiliary battery)
      Auxiliary battery voltage Positive (+) auxiliary battery terminal - Negative (-) auxiliary battery terminal 12.5 to 15 V

      If the result is not as specified, replace the inverter with converter assembly.

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