Canada - Hybrid System - HV And Auxiliary Batteries Maintenance
Bulletin
2894
Issue Date
September 18, 2007
Market
Canada
Title:
MAINTENANCE FOR HV BATTERY AND AUXILIARY BATTERY
Component
GENERAL INFORMATION
Models
'08 - '09 Prius
INTRODUCTION:
The 2008-2009 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 deteriorating during storage, proper maintenance is necessary.
Perform the following maintenance service for the HV battery and 12-volt auxiliary battery.
MAINTENANCE ITEMS AT PORT OF ENTRY AND DEALERSHIP:
APPLICABLE VEHICLES:
- 2008-2009 model year Prius vehicles.
WARRANTY INFORMATION:
REQUIRED SSTs:
JUST AFTER UNLOADING AND THEN EVERY TWO 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 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.
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 Automatic Battery Trickle Charger (SST P/N CXC-2815*).
* Note: P/N 00002-YA122-01 or P/N 00002-YA121-01(with switch in 10 AMP position) may still be used.
NOTE IF USING P/N 00002-YA121-01:
Ensure that the charge current switch is set on the 10 AMP position.
When operated in the 10 AMP position, the Automatic Battery Trickle Charger (SST P/N 00002-YA121- 01) is designed to automatically regulate charging current and voltage. Using this mode, the charger will minimize charge time, while preventing overheating and possible battery damage. Charging in the 2 AMP position is not recommended for the Prius 12-volt battery, due to prolonged charge time.
CAUTION:
Use of standard battery chargers is NOT recommended on the Prius 12-volt auxiliary battery, in order to prevent battery damage.
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 110V nominal outlet and verify the RED "POWER" light is on.
NOTE:
The Automatic Battery Trickle Charger (SST P/N CXC-2815) control tests for correct polarity before applying current to the battery (a built-in safety feature). When connected properly, the YELLOW light comes on. If no lights come on, check for proper connection and/or a dead battery.
D. Once the charger is properly connected, the YELLOW light indicates the battery in combination with the RED light, is being charged. The battery is fully charged once the GREEN light comes on.
NOTE:
The GREEN charged light and YELLOW charging light will switch back and forth once the battery is at 80% state of charge. At this point the battery is charged and may be returned to the vehicle. If you continue charging, the switching between YELLOW (charging) and GREEN (charged) will slow until the GREEN (charged) light stays on continuously at 100% state of charge.
3. If the Automatic Battery Trickle Charger 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.
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 HV battery vent duct.
E. Reconnect harness to positive (+) terminal block and power source back-up 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.
IN ORDER TO STORE FOR 10 DAYS OR MORE:
1. Disconnect the wire harness from the exclusive jump starting terminal.
A. Turn off all lights and accessories.
B. Open the hood and remove the relay block cover.
C. Open the cover (red) for the exclusive jump starting terminal.
D. 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.
E. Use needle-nose pliers to pull up the wire harness from the exclusive jump starting terminal (positive (+) terminal).
F. Temporarily install the nut on the exclusive jump starting terminal.
G. Close the cover for the exclusive jump starting terminal, and place the wire harness on the cover.
H. 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.
2. Connect the wire harness.
HINT:
After reconnecting the auxiliary battery, the power window must be initialized.
For details, refer to applicable Technical Service Bulletin:
- TSB No. 2619 for 2008 model year vehicles
A. Open the hood and remove the relay block cover.
B. Open the cover for the exclusive jump starting terminal.
C. 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 kgf-cm, 5.0-7.2 ft-lbf)
D. Close the cover for the exclusive jump starting terminal.
E. After closing the relay block cover, close the hood.
NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.