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
Auxiliary battery terminal is disconnected/reconnected Memorize steering angle neutral point Lane departure alert system (w/ Steering Control)

Click here

Intelligent clearance sonar system*1
Simple intelligent parking assist system*1
Pre-crash safety system
Parking assist monitor system

Click here

Initialize back door lock Power door lock control system

Click here

*1: When performing learning using the GTS.
Click here Click here

CAUTION:


  • B004PF2

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

    Click here

  • B004Q03

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

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 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.

        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 windshield wiper motor and link assembly.

        Click here

      2. Remove the No. 1 heater air duct splash shield seal. (for LHD)

        Click here

      3. Remove the No. 2 heater air duct splash shield seal. (for RHD)

        Click here

      4. Remove the water guard plate LH.

        Click here

      5. Remove the cowl body mounting reinforcement LH.

        Click here

      6. Remove the outer cowl top panel sub-assembly.

        Click here

      7. Remove the No. 1 engine cover sub-assembly.

        Click here

      8. Disconnect the engine wire.

        Click here

      9. Remove the connector cover assembly.

        Click here

      10. Check the terminal voltage.

        Click here

      11. Install the connector cover assembly.

        Click here

      12. Connect the engine wire.

        Click here

      13. Install the No. 1 engine cover sub-assembly.

        Click here

      14. Install the outer cowl top panel sub-assembly.

        Click here

      15. Install the cowl body mounting reinforcement LH.

        Click here

      16. Install the water guard plate LH.

        Click here

      17. Install the No. 1 heater air duct splash shield seal. (for LHD)

        Click here

      18. Install the No. 2 heater air duct splash shield seal. (for RHD)

        Click here

      19. Install the windshield wiper motor and link assembly.

        Click here

    4. Remove the rear seat cushion assembly.

      Click here

    5. Remove the rear seat cushion lock hook.

      Click here

    6. Remove the rear door scuff plate LH.

      Click here

    7. Remove the rear under side cover LH.

      Click here

    8. Remove the rear door scuff plate RH.

      Click here

    9. Remove the rear under side cover RH.

      Click here

    10. Remove the rear under cover.

      Click here

    11. Remove the rear seat cushion leg sub-assembly.

      Click here

    12. Remove the No. 1 HV battery cover panel RH.

      Click here

    13. Disconnect the HV floor under wire.

      Click here

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

      B004PDDC01
      *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.

    15. B004QHLN01

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

      SST
      09882-10090
    16. B004PNUN01

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

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

      Note

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

    17. 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 }
    18. B004PE7N01

      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 }
    19. B004OYUE03

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

      SST
      09880-10021   ( 09881-10041 )
    20. B004PO3N01

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

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    21. B004QDWC01
      *a Low Voltage Cable
      *b High Voltage Cable

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

    22. Install the service plug grip.

      Click here

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

      Click here

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

      SST
      09881-10050

      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. B004P4U

      Turn the THS charger MAIN switch on.

      Tech Tips

      The MAIN indicator will illuminate (green).

    7. Press the START switch.

      B004QWB

      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. B004QK5C04
        *a Low Voltage Cable
        *b High Voltage Cable

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

      5. B004PO3N01

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

      6. B004OYUE03

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

      7. B004PE7N01

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

      8. B004PNUN01

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

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

      10. B004QHLN01

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

      11. Connect the HV floor under wire.

        Click here

      12. Install the No. 1 HV battery cover panel RH.

        Click here

      13. 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 rear seat cushion leg sub-assembly.

      Click here

    13. Install the rear under cover.

      Click here

    14. Install the rear under side cover LH.

      Click here

    15. Install the rear door scuff plate LH.

      Click here

    16. Install the rear under side cover RH.

      Click here

    17. Install the rear door scuff plate RH.

      Click here

    18. Install the rear seat cushion lock hook.

      Click here

    19. Install the rear seat cushion assembly.

      Click here

    20. Install the battery service hole cover.

      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 lever 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 negative (-) terminal of the auxiliary battery is disconnected and reconnected.