HV BATTERY CHARGING

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced when charging the HV battery are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure Necessary Procedures Effect/Inoperative Function when Necessary Procedure not Performed Link
Disconnect cable from negative auxiliary battery terminal Memorize steering angle neutral point LKA/LDA system

Click here

Pre-collision system
Parking assist monitor system

Click here

Steering sensor zero point calibration Variable gear ratio steering system

Click here

Front seat assembly RH (Only for removal and installation) Initialize position control ECU Front Power Seat Control System

Click here

CAUTION:


  • B004A7G

    Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.

    Click here

  • B004BJX

    To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    Click here

  2. INSPECT AUXILIARY BATTERY VOLTAGE


    1. Measure the auxiliary battery voltage.

      Standard Voltage
      Approximately 11 V or more

      Tech Tips


      • 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.

  3. PREPARATION FOR HV BATTERY CHARGING

    CAUTION:


    • 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.

      Click here

    • Wear insulated gloves.

    Tech Tips


    • Removing the service plug grip interrupts the high voltage circuit.

    • High voltage wiring connectors are orange.


    1. Check the SOC (State of Charge) of the HV battery.


      1. If the hybrid system fails to start and "Traction Battery needs to be Protected. Shift into [P] to Restart" or "Traction Battery Needs to be Protected Refrain from the Use of [N] Position" 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 position in P until the engine stops (self charge has completed).

        If the engine cannot start, follow the procedure to charge the HV battery.

        Tech Tips


        • Before performing external charging, always use the GTS 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.)

    2. Remove the service plug grip.

      Click here

    3. Check the terminal voltage.


      1. Remove the connector cover assembly.

        Click here

      2. Check the terminal voltage.

        Click here

      3. Install the connector cover assembly.

        Click here

    4. Remove the front seat assembly RH.

      Tech Tips

      Use the same procedure described for the front seat assembly LH.

      Click here

    5. Remove the rear seat assembly.

      Click here

    6. Remove the rear seat speaker.

      Click here

    7. Remove the front door scuff plate RH.

      Tech Tips

      Use the same procedure described for the front door scuff plate LH.

      Click here

    8. Remove the outer lap belt anchor cover.

      Click here

    9. Disconnect the front outer seat belt assembly RH.

      Tech Tips

      Use the same procedure described for the front outer seat belt assembly LH.

      Click here

    10. Remove the quarter inside trim board RH.

      Tech Tips

      Use the same procedure described for the quarter inside trim board LH.

      Click here

    11. Remove the rear inner seat belt assembly RH.

      Tech Tips

      Use the same procedure described for the rear No. 1 seat inner belt assembly LH.

      Click here

    12. Remove the quarter trim panel assembly RH.

      Tech Tips

      Use the same procedure described for the quarter trim panel assembly LH.

      Click here

    13. Remove the No. 1 hybrid battery intake duct.

      Click here

    14. Remove the No. 2 hybrid battery intake duct.

      Click here

    15. Remove the No. 10 HV battery shield panel.

      Click here

    16. Disconnect the HV floor under wire.


      1. B004AYE

        Remove the nut and disconnect the 2 HV battery junction block assembly connectors.

        Note

        Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

    17. Inspect the electrical insulation of the HV battery.


      1. B004BPVC01
        *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
      2. B004AJSC01
        *a

        Component without harness connected

        (HV Battery Junction Block Assembly)

        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
        f2-1 (CBI) - Body ground Power switch off 10 MΩ or higher
        f3-1 (CEI) - Body ground Power switch off 10 MΩ or higher

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

      B0049VHC01
      *1 HV Battery *2 HV Floor Under Wire
      *3 Inverter with Converter Assembly - -
      *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.

    19. B004CHEC01
      *a High Voltage Cable
      *b EV Bonding Cable (Green Cable)

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

      SST
      09882-10090

    20. Connect SST (high voltage cable) terminal to the position shown in the illustration with the nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

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

      SST
      09882-10070
      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    22. B004CGRC01
      *a EV Bonding Cable (Green Cable)
      *b THS Charger

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

      SST
      09880-10021   ( 09881-10041 )
    23. B004CFYC01
      *a Low Voltage Cable

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

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    24. B004CGMC05
      *a Low Voltage Cable
      *b High Voltage Cable
      *c THS Charger
      *d Power Input Plug

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

    25. Install the service plug grip.

      Click here

    26. Connect the cable to the negative (-) auxiliary battery terminal.

      Click here

    27. Connect SST (power input plug) of SST (THS charger) to a grounded AC 100 to 240 V receptacle.

      SST
      09881-10081

      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.

  4. HV BATTERY CHARGING


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

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


      Powertrain > Hybrid Control > Active Test
      Tester Display
      Hybrid Battery Charge

      Tech Tips


      • 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 GTS 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

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

    5. Make sure that the BREAKER is in the ON position.

    6. B004BDJ

      Turn the THS charger MAIN switch on.

      Tech Tips

      The MAIN indicator will illuminate (green).

    7. Press the START switch.

      B004AXO

      Tech Tips


      • 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.

    8. Repeat the charge cycle 3 times. When the last cycle has finished, turn the THS charger MAIN switch off.

      Tech Tips


      • 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%.

    9. Turn the power switch off.

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

      Note

      Make sure to disconnect the EV bonding cable last.


      1. Disconnect SST (power inlet plug) of SST (THS charger) from the grounded AC 100 to 240 V receptacle.

      2. Disconnect the cable from the negative (-) auxiliary battery terminal.

        Click here

      3. Remove the service plug grip.

        Click here

      4. B004B7EC08
        *a Low Voltage Cable
        *b High Voltage Cable
        *c THS Charger

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

      5. B004CFYC01
        *a Low Voltage Cable

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

      6. B004CGRC01
        *a EV Bonding Cable (Green Cable)
        *b THS Charger

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

      7. B004CHEC03
        *a EV Bonding Cable (Green Cable)
        *b High Voltage Cable

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

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

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

      10. Connect the HV floor under wire.

        Click here

      11. Install the No. 10 HV battery shield panel.

        Click here

      12. Install the service plug grip.

        Click here

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

      Tech Tips

      If the engine does not start, perform the HV battery charging operation again.

    12. Install the No. 2 hybrid battery intake duct.

      Click here

    13. Install the No. 1 hybrid battery intake duct.

      Click here

    14. Install the quarter trim panel assembly RH.

      Tech Tips

      Use the same procedure described for the quarter trim panel assembly LH.

      Click here

    15. Install the rear inner seat belt assembly RH.

      Tech Tips

      Use the same procedure described for the rear No. 1 seat inner belt assembly LH.

      Click here

    16. Install the quarter inside trim board RH.

      Tech Tips

      Use the same procedure described for the quarter inside trim board LH.

      Click here

    17. Connect the front outer seat belt assembly RH.

      Tech Tips

      Use the same procedure described for the front outer seat belt assembly LH.

      Click here

    18. Install the outer lap belt anchor cover.

      Click here

    19. Install the front door scuff plate RH.

      Tech Tips

      Use the same procedure described for the front door scuff plate LH.

      Click here

    20. Install the rear seat speaker.

      Click here

    21. Install the rear seat assembly.

      Click here

    22. Install the front seat assembly RH.

      Tech Tips

      Use the same procedure described for the front seat assembly LH.

      Click here

  5. CHECK HV BATTERY AFTER HV BATTERY CHARGE


    1. Check for DTCs.

      Click here

    2. Perform the self-charging operation.


      1. Start the engine and leave it idling with the shift position in P until the engine stops.

        Tech Tips

        When the engine stops idling, this indicates that self-charging is complete. Perform any initialization procedures required after the cable is disconnected and reconnected to the negative (-) auxiliary battery terminal.