HV BATTERY CHARGING


  1. INSPECT AUXILIARY BATTERY VOLTAGE


    1. Measure the voltage between the terminals of the auxiliary battery.

      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.

    2. Check the charge level of the HV battery.


      1. A01I5XG

        Check whether the HV battery warning message is shown in the multi-information display.

      2. Confirm if the engine starts. If the engine starts, leave it idling with park (P) selected until the engine stops (self charge has completed).

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

        Tech Tips


        • 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 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.)

  2. PREPARATION FOR HV BATTERY CHARGING

    CAUTION:


    • Wear insulated gloves when working on the high voltage system.

    • After removing the service plug grip, do not turn the power switch on (READY) as this may cause a malfunction.

    • After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high voltage system.

    • After removing the service plug grip, wait 10 minutes before touching any of the high voltage connectors or terminals.

    Tech Tips


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

    • High voltage wiring connectors are orange.


    1. Remove the service plug grip Click here.

    2. Remove the cool air intake duct seal Click here.

    3. Remove the inlet air cleaner assembly Click here.

    4. Remove the air cleaner cap sub-assembly Click here.

    5. Remove the air cleaner filter element sub-assembly.

    6. Remove the air cleaner case sub-assembly Click here.

    7. A01I2Z5

      Remove the 2 bolts and connector cover assembly.

      Note

      Make sure to pull the connector cover assembly straight up, as a connector is connected to the bottom of the cover.

    8. Check terminal voltage Click here.

    9. A01I563

      Remove the bolt.

    10. A01I2U5

      Disconnect the wire harness clamp and connector.

    11. A01I52W

      Measure the resistance according to the value(s) in the table below.

      Tech Tips

      If the shield line of the No. 4 floor wire is not securely connected to body ground, the THS charger will not operate. The "FAULT" and "CABLE CONNECTION" warning lights will illuminate on the THS charger.

      Standard Resistance
      Tester Connection Condition Specified Condition
      No. 4 floor wire connector housing - Body ground Always Below 1 Ω
    12. A01I4L0

      If the result is not as specified, inspect the connection shown in the illustration for proper installation Click here.

    13. A01I2Z5

      Temporarily install the connector cover assembly with the 2 bolts to prevent any foreign objects or water from entering the inverter with converter assembly.

    14. Connect the THS charger in the order shown by the circled numbers in the illustration.

      A01I2NAE01
      Text in Illustration
      *1 EV Bonding Cable (Green Cable) *2 Low Voltage Cable
      *3 High Voltage Cable *4 HV Battery
      *5 No. 4 floor wire *6 Inverter with Converter Assembly
      *7 EV Bonding Cable *8 Grounded AC 100 to 240 V Receptacle
      *9 THS Charger *10 Bolt (91553-80665)
      SST
      09880-10021   ( 09881-10041 )
      09881-10081
      09881-10050
      09882-10040
      09882-10070

      Note


      • Make sure to connect the EV bonding cable first to prevent electrical shock.

      • Connect all THS charger cables in the order shown in the illustration to prevent electrical shock.

    15. A01I5U5

      Connect the EV bonding cable to the illustration bolt of the No. 5 inverter bracket.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }
    16. A01I3TA

      Connect the EV bonding cable to the THS charger.

    17. A01I4X5

      Connect the low voltage cable to the positions shown in the illustration, and then tighten the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    18. A01I5EZ

      Connect the No. 4 floor wire to the high voltage cable with the bolt (91553-80665).

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

      Note


      • The installation bolt that comes with the vehicle is too short to securely connect the No. 4 floor wire to the high voltage cable of the charger.

      • Do not use the bolt (91553-80665) used for connecting the high voltage cable when reconnecting the No. 4 floor wire to the vehicle.

      Tech Tips

      When connecting the high voltage cable, use a bolt with a nominal diameter of 6 mm, a shaft length of 69 mm and a pitch of 1.0 mm.

    19. A01I5OVE01
      Text in Illustration
      *1 Low Voltage Cable
      *2 High Voltage Cable

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

    20. Install the service plug grip Click here.

    21. Connect the negative auxiliary battery terminal.

    22. Connect the power input plug of the charger to a grounded AC 100 to 240 V receptacle.

      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.

  3. HV BATTERY CHARGING


    1. Turn the power switch of the vehicle on (IG).

    2. Connect the Techstream to the DLC3.

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

      Tech Tips


      • During the "Battery Charge" Active Test, check "System Main Relay Status - SMRB" and "System Main Relay Status - SMRG" in the Data List.

      • If the Data List values are not as specified in the table below, turn the Techstream and the power switch off and then perform the Charge Battery procedure again.

      "SMRB" and "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. A01I4RM

      Turn the THS charger MAIN switch on.

      Tech Tips

      The MAIN indicator will illuminate green.

    7. Press the START switch.

      A01I3IM

      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 install the No. 4 floor wire.

      Note

      Make sure to disconnect the EV bonding cable last.


      1. Disconnect the power inlet plug of the charger from the receptacle.

      2. Disconnect the negative terminal of the auxiliary battery.

      3. Remove the service plug grip Click here.

      4. A01I3R9E01
        Text in Illustration
        *1 Low Voltage Cable
        *2 High Voltage Cable

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

      5. A01I5EZ

        Remove the bolt (91553-80665) and disconnect the high voltage cable from the No. 4 floor wire.

        Note

        Do not use the bolt (91553-80665) used for connecting the high voltage cable when reconnecting the No. 4 floor wire to the vehicle.

      6. A01I4X5

        Remove the 2 bolts and disconnect the low voltage cable.

      7. A01I3TA

        Disconnect the EV bonding cable from the THS charger.

      8. A01I5U5

        Disconnect the EV bonding cable from the installation bolt of the No. 5 inverter bracket.

      9. Tighten the bolt.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      10. Remove the connector cover assembly.

      11. A01I2U5

        Connect the wire harness clamp and connector.

      12. A01I563

        Connect the No. 4 floor wire with the bolt.

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

        Note

        Do not use the bolt (91553-80665) used for connecting the high voltage cable of the charger.

      13. Install the connector cover assembly with the 2 bolts.

        Note

        Make sure that the interlock is fully engaged.

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

      14. Install the air cleaner case sub-assembly Click here.

      15. Install the air cleaner filter element sub-assembly.

      16. Install the air cleaner cap sub-assembly Click here.

      17. Install the inlet air cleaner assembly Click here.

      18. Install the cool air intake duct seal Click here.

      19. Install the service plug grip Click here.

    11. Check if the engine starts.

      Tech Tips

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

  4. CHECK HV BATTERY AFTER HV BATTERY CHARGE


    1. Check for DTCs.

    2. Perform the self-charging operation.


      1. Start the engine and leave park (P) selected until the engine stops idling.

        Tech Tips

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