Hybrid System - HV And Auxiliary Batteries Maintenance
T-SB-0235-08August 12, 2008
Maintenance for HV & Auxiliary Batteries
Service Category
General
Section
Pre-Delivery Service
Market
USA
Applicability
Introduction
The 2009 model year Prius hybrid vehicle is equipped with 2 types of special batteries the HV (Hybrid Vehicle) battery and the 12-volt auxiliary battery.
If the hybrid vehicle is put into storage the state of charge (SOC) of its HV battery and auxiliary battery will gradually decrease. To prevent the battery from becoming discharged during storage proper maintenance is necessary.
Perform the following maintenance service for the HV battery and 12-volt auxiliary battery.
Maintenance Items
Warranty Information
Required Tools & Equipment
NOTE
The GR8 Battery Diagnostic Station (P/N 00002-MCGR8) supersedes the Automatic Trickle Charger (P/N 00002-YA122-O1) and Fast Battery Chargers (Associated P/N ASE6003 and Christie P/N CAPPDQ). P/N 00002-YA122-01, ASE6003, and CAPPDQ are now obsolete.
Just After Unloading & Every 2 Months
NOTE
The 12-volt auxiliary battery is charged by the HV battery whenever the "READY" light is ON, regardless of the gasoline engine operation.
1. Park the vehicle in an open air area or connect an exhaust extraction hose to the exhaust pipe.
2. Apply the parking brake.
3. Make sure the key is fully inserted into the key slot.
4. With the brake pedal depressed press the "POWER" switch and check that the "READY" light in the meter illuminates when the hybrid system starts (the "READY" light is ON).
5. Turn OFF all lights and accessories.
6. Check that the shift selector is in the "P" position.
7. Keep the "READY" light ON for 30 minutes, charging the HV battery.
Check 12-Volt Auxiliary Battery Before Delivery
NOTE
^ Before you disconnect the auxiliary battery, confirm the shift position is in the "P" position and apply the parking brake completely.
^ While the auxiliary battery is disconnected, the back door latch will NOT operate using the handle on the outside of the door. To open the door; pull the security opener in the luggage storage box. For details, refer to the Owner's Manual.
1. Remove the auxiliary battery.
A. Turn OFF all lights and accessories.
B. Open the back door.
C. Remove the rear deck cover.
D. Remove the deck under tray and auxiliary battery cover.
E. Remove the positive (+) terminal cover.
F. Disconnect the two connectors from the positive (+) terminal block and the connector to the brake system's power source backup unit.
G. Remove the HV battery vent duct.
H. Disconnect the negative (-) terminal and then the positive (+) terminal.
I. Disconnect the vent hose.
NOTE
The plastic elbow pulls straight out of the battery case - do NOT twist.
J. Remove the hold-down clamp and auxiliary battery.
2. Charge the 12-volt auxiliary battery.
CAUTION
^ Do NOT charge with the battery mounted in the vehicle.
^ Charge in a well-ventilated area.
^ Do NOT allow sparks or fire near the battery.
A. Obtain the GR8 Battery Diagnostics Station (SST P/N 00002-MCGR8).
CAUTION
To prevent battery damage, do NOT use a standard battery charger.
B. Connect the red charger clamp to the positive (+) battery terminal and the black charger clamp to the negative (-) battery terminal.
C. Plug the charger into a grounded 11OV nominal outlet and flip the power switch to the "ON" position.
D. Once the charger is properly turned ON, perform a diagnostic charge by MODEL (Prius).
The GR8 Battery Diagnostics Station will indicate result when complete.
3. If the GR8 Battery Diagnostics Station is NOT available you may charge the 12-volt battery by turning the vehicle on to "READY"
^ Run time will vary depending on the state of charge.
^ If this method is used, you must confirm that the battery is charged to 12.8 volts using a DVOM.
The Prius auxiliary battery is NOT part of the TrueStart(TM) Replacement Program.
CAUTION
The Prius auxiliary battery is a special Valve Regulated Absorbed Glass Mat (AGM) design and should NEVER be replaced with a conventional battery design.
4. Install the auxiliary battery.
A. Place the auxiliary battery in the correct position and install the hold-down clamp.
B. Connect the vent hose.
C. Connect the positive (+) terminal first, and then the negative (-) terminal.
Torque: 6.0 N*m (61 kgf*cm, 4.4 ft*lbf)
D. Install the HV battery vent duct.
E. Reconnect the harness to the positive (+) terminal block and power source backup unit.
F. Install the positive (+) terminal cover.
G. Install the auxiliary battery cover and the deck under tray.
H. Install the deck cover.
I. Close the back door.
To Store for 10 Days or More
Disconnect the wire harness from the exclusive jump starting terminal.
1. Turn OFF all lights and accessories.
2. Open the hood and remove the relay block cover.
3. Open the cover (red) for the exclusive jump starting terminal.
4. Use a 10 mm long socket to remove the nut.
NOTE
When removing or installing the nut and wire harness, do NOT touch the inverter or other parts, as it may cause electrical system damage.
5. Use needle-nose pliers to pull up the wire harness from the exclusive jump starting terminal (positive [+] terminal).
6. Temporarily install the nut on the exclusive jump starting terminal.
7. Close the cover for the exclusive jump starting terminal and place the wire harness on the cover.
8. After closing the relay block cover close the hood.
HINT
If the negative (-) terminal of the battery is reconnected, even if the "POWER" switch is pressed once while depressing the brake pedal, the hybrid system may NOT start. At this time, the "READY" light is OFF. In this case, press the "POWER" switch again to start the hybrid system (the "READY" light is ON). If the hybrid system still does NOT start (the "READY" light is OFF), refer to the Repair Manual.
After Storage Period is Over
Connect the wire harness.
After reconnecting the auxiliary battery, the power window must be initialized. For details, refer to TSB No. T-SB-0221-08, "Initialization of Power Window."
1. Open the hood and remove the relay block cover.
2. Open the cover for the exclusive jump starting terminal.
3. Remove the temporarily installed nut and after installing the wire harness on the exclusive jump starting terminal securely tighten the nut.
Torque: 6.8 - 9.8 N*m (69 - 100 kg*cm, 5.0 - 7.2 ft*lbf)
4. Close the cover for the exclusive jump starting terminal.
5. After closing the relay block cover close the hood.