Charging [07/2022 - ]: Procedure

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INSPECT AUXILIARY BATTERY VOLTAGE
1. Measure the auxiliary battery voltage.
  Standard Voltage
  
  Approximately 11 V or more
  
  HINT:
  - The horn should sound clearly.
  - If the voltage is 10 V or less, either charge the auxiliary battery (charging usually takes about 1 hour), or replace it with an auxiliary battery that is already charged.

PREPARATION FOR HV BATTERY CHARGING

WARNING:

The hybrid system has high-voltage circuits. Accidents, such as electric shock, or electric leaks may result if the hybrid system is not operated in a correct manner. Make sure to follow the correct procedure.
Refer to PRECAUTION [07/2022 - ]
Wear insulated gloves.

HINT:

Removing the service plug grip interrupts the high voltage circuit.
High voltage wiring connectors are orange.

Check the charge level of the HV battery.
1. If the hybrid system fails to start and "Hybrid Battery Low. Shift Out of [N] to Recharge." or "Hybrid Battery Low. Hybrid System Stopped. Shift to [P] and Restart." is displayed on the multi-information display, the HV battery may be discharged.
2. Confirm if the engine starts. If the engine starts, leave it idling with the shift lever in P until the engine stops (self charge has completed).
  If the engine cannot start, charge the HV battery.
  
  HINT:
  - Before performing external charging, always use the Techstream to perform troubleshooting.
  - Charging time using the THS charger is 10 minutes per charge cycle. The charging time when using a THS charger is a short charging time (when the HV battery temperature is 25°C (77°F), 10 minutes may be sufficient, if the HV battery temperature is 0°C (32°F), then three 10 minute charge cycles may be required) for putting the engine in a condition where it can be started (the system can enter the READY-on state). (The THS charger will automatically stop 10 minutes after charging starts.)
Remove the service plug grip.
Refer to REMOVAL [07/2022 - ]
Check the terminal voltage.
1. Disconnect the engine wire.
  See step 3
2. Remove the connector cover assembly.
  Refer to PROCEDURE - Step 12
3. Check the terminal voltage.
  Refer to PROCEDURE - Step 13
4. Install the connector cover assembly.
  See step 6
5. Connect the engine wire.
  See step 29
Remove the bench type rear seat cushion assembly.
Refer to PROCEDURE - Step 5
Remove the rear seat cushion lock hook.
Refer to PROCEDURE - Step 8
Remove the rear door scuff plate LH.
Refer to PROCEDURE - Step 18
Remove the rear under side cover LH.
Refer to PROCEDURE - Step 28
Remove the rear door scuff plate RH.
Refer to PROCEDURE - Step 27
Remove the rear under side cover RH.
Refer to PROCEDURE - Step 29
Remove the rear under cover.
See step 14
Remove the rear seat cushion leg sub-assembly.
See step 15
Remove the No. 1 HV battery cover panel RH.
See step 17
Disconnect the HV floor under wire.
See step 19

Inspect the electrical insulation of the HV battery.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Service Plug Grip Removed (Service Plug Grip Connecting Terminals)

Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

NOTE:

Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

Standard Resistance

Tester Connection	Condition	Specified Condition
1 - Body ground	Power switch off	10 MΩ or higher
2 - Body ground	Power switch off	10 MΩ or higher

Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

NOTE:

Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*A	for 2WD
*B	for AWD
*a	Component without harness connected (HV Battery Junction Block Assembly)

Standard Resistance (for 2WD)

Tester Connection	Condition	Specified Condition
W4-1 (CBI) - Body ground	Power switch off	10 MΩ or higher
W3-1 (CEI) - Body ground	Power switch off	10 MΩ or higher

Standard Resistance (for AWD)

Tester Connection	Condition	Specified Condition
Y8-1 (CBI) - Body ground	Power switch off	10 MΩ or higher
Y7-1 (CEI) - Body ground	Power switch off	10 MΩ or higher

Connect the THS charger in the order shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	HV Battery	*2	HV Floor Under Wire
*3	Inverter with Converter Assembly	*4	No. 1 HV Battery Cover Panel RH
*a	EV Bonding Cable (Green Cable)	*b	Low Voltage Cable
*c	High Voltage Cable	*d	Power Input Plug
*e	Grounded AC 100 to 240 V Receptacle	*f	THS Charger

NOTE:

Make sure to connect the EV bonding cable first to prevent electrical shock.
Connect all of the THS charger cables in the order shown in the illustration to prevent electrical shock.

Connect the 2 SST (high voltage cable) connectors to the HV battery junction block assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09882-10090

Temporarily install the No. 1 HV battery cover panel RH with the 2 bolts.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

NOTE:

Be careful not to pinch SST (high voltage cable).

Connect the SST (high voltage cable) terminal to the position shown in the illustration with the nut.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

Connect SST (EV bonding cable (green cable)) to the position shown in the illustration with the nut.

SST: 09882-10070

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

Connect SST (EV bonding cable (green cable)) to SST (THS charger).

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST: 09880-10021
1. 09881-10041

Connect SST (low voltage cable) to the position shown in the illustration with the bolt.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

Connect SST (low voltage cable) and SST (high voltage cable) to SST (THS charger) in the order shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Low Voltage Cable
*b	High Voltage Cable

Install the service plug grip.
See step 1
Connect the cable to the negative (-) auxiliary battery terminal.
Refer to PROCEDURE - Step 2
Connect SST (power input plug) of SST (THS charger) to a grounded AC 100 to 240 V receptacle.
- SST: 09881-1005009881-1011009881-1008109881-1009009881-1010009881-10130
NOTE:
Always use an AC 100 to 240 V receptacle with a properly functioning ground. The ground is designed to reduce the chance of electric shock if a malfunction occurs. Do not use the charger if any of the pins on its plug have been damaged or removed.

HV BATTERY CHARGING

Connect the Techstream to the DLC3.
Turn the power switch on (IG).

Enter the following menus: Powertrain / Hybrid Control / Active Test / Hybrid Battery Charge

Powertrain > Hybrid Control > Active Test

Tester Display
Hybrid/EV Battery Charge

HINT:

While performing the "Battery Charge" Active Test, check the Data List items "System Main Relay Status - SMRB" and "System Main Relay Status - SMRG".
If the values of the Data List items are not as specified in the table below, turn the Techstream and the power switch off and then perform the HV battery charging procedure again.

"System Main Relay Status - SMRB" and "System Main Relay Status - SMRG" in Data List during "Battery Charge" Active Test

Step	Active Test "Battery Charge"	THS charger START Switch	Data List "System Main Relay Status - SMRB"	Data List "System Main Relay Status - SMRG"
1	OFF	OFF	OFF	OFF
2	OFF → ON	OFF	OFF → ON	OFF → ON
3	ON	OFF → ON	ON	ON

Make sure that the EMERGENCY STOP switch is in the reset condition (the switch is turned clockwise and released).
Make sure that the BREAKER is in the ON position.

Turn the THS charger MAIN switch on.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

The MAIN indicator will illuminate (green).

Press the START switch.

HINT:

When the START switch is turned on, the INITIAL CHECK indicator illuminates and an initial check starts. When the initial check completes successfully, the INITIAL CHECK indicator turns off, the CHARGING indicator illuminates and charging will start at the same time.
While the INITIAL CHECK indicator is illuminated, the insulation, 400 V output, emergency stop switch, connector connections and ground connection are inspected.

Repeat the charge cycle 3 times. When the last cycle has finished, turn the THS charger MAIN switch off.
HINT:
- Charging time using the THS charger is 10 minutes per charge cycle. The charging time when using a THS charger is a short charging time (when the battery temperature is 25°C (77°F), 10 minutes may be sufficient, if the battery temperature is 0°C (32°F), then three 10 minute charge cycles may be required) for putting the engine in a condition where it can be started (the system can enter the READY-on state). (The THS charger will automatically stop 10 minutes after charging starts.)
- There is very little chance of overcharging the HV battery during the second or third charging cycle. The SOC will not likely increase beyond the upper limit because it was low enough to prevent the engine from starting. Even if the SOC was to increase enough to exceed the limit, the hybrid vehicle control ECU will stop the Active Test to prevent overcharging.
- Cranking the engine once causes the SOC to drop approximately 1%.
- Charging the HV battery once (10 minutes) using the THS charger restores the SOC approximately 2%.
Turn the power switch off.

Remove the THS charger and connect the HV floor under wire (for HV Battery).

NOTE:

Make sure to disconnect the EV bonding cable last.

Disconnect SST (power inlet plug) of SST (THS charger) from the grounded AC 100 to 240 V receptacle.
Disconnect the cable from the negative (-) auxiliary battery terminal.
Refer to PROCEDURE - Step 5
Remove the service plug grip.
Refer to PRECAUTION [07/2022 - ]

Disconnect SST (high voltage cable) and SST (low voltage cable) from SST (THS charger) in the order shown in the illustration.

*a	Low Voltage Cable
*b	High Voltage Cable

Remove the bolt and disconnect SST (low voltage cable).

Disconnect SST (EV bonding cable (green cable)) from SST (THS charger).

Remove the nut and disconnect SST (EV bonding cable (green cable)).

Remove the nut and disconnect the SST (high voltage cable) terminal.

Remove the 2 bolts and No. 1 HV battery cover panel RH.

Disconnect the 2 SST (high voltage cable) connectors from the HV battery junction block assembly.

Connect the HV floor under wire.
Refer to REMOVAL [07/2022 - ]
Install the No. 1 HV battery cover panel RH.
Refer to PROCEDURE - Step 11
Install the service plug grip.
Refer to INSTALLATION [10/2018 - ]

Turn the power switch on (READY) and check if the engine starts.
HINT:

If the engine does not start, perform the HV battery charging operation again.
Install the rear seat cushion leg sub-assembly.
See step 16
Install the rear under cover.
See step 17
Install the rear under side cover LH.
Refer to PROCEDURE - Step 8
Install the rear door scuff plate LH.
Refer to PROCEDURE - Step 42
Install the rear under side cover RH.
Refer to PROCEDURE - Step 41
Install the rear door scuff plate RH.
Refer to PROCEDURE - Step 43
Install the rear seat cushion lock hook.
Refer to PROCEDURE - Step 1
Install the bench type rear seat cushion assembly.
Refer to PROCEDURE - Step 4
Install the battery service hole cover.
See step 2

CHECK HV BATTERY AFTER HV BATTERY CHARGE
1. Check for DTCs.
  Refer to DTC CHECK / CLEAR [10/2018 - ]
2. Perform the self-charging operation.
  1. Start the engine and leave it idling with the shift lever in P until the engine stops.
    HINT:
    
    When the engine stops idling, this indicates that self-charging is complete. Perform any initialization procedures required after the negative (-) terminal of the auxiliary battery is disconnected and reconnected.