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Home >> Toyota >> 2012 >> Prius Two >> Repair and Diagnosis >> Electrical >> Charging Systems >> Charging System (Except Plug-In) (Inspection) >> Charging System >> On-Vehicle Inspection >> On-Vehicle Inspection

On-Vehicle Inspection

  1. CHECK AUXILIARY BATTERY 
    1. Check that the auxiliary battery cables are connected to the correct terminals.

      HINT: 

      If they are not, connect them properly.

    2. Check the auxiliary battery for damage and deformation. If severe damage, deformation or leakage is found, replace the auxiliary battery.
  2. CHECK AUXILIARY BATTERY VOLTAGE 
    1. Turn the power switch off and turn on the high beam headlights for 30 seconds. This will remove the surface charge from the auxiliary battery.
    2. Measure the auxiliary battery voltage according to the value(s) in the table below.

      Result

      Tester Connection Condition Specified Condition Result
      Positive (+) terminal - Negative (-) terminal 20°C (68°F), Power switch off 12.5 V or higher Auxiliary battery is OK
      11.0 to 12.5 V Recharge auxiliary battery
      Below 11.0 V Replace auxiliary battery
  3. RECHARGE AUXILIARY BATTERY 
    1. Recharge the auxiliary battery.

      HINT: 

      • Recharge the auxiliary battery according to the charger's instructions.
      • Apply the appropriate charging current according to the type of auxiliary battery as shown in the table below.
      Auxiliary Battery Type Charging Current
      S46B24R 4 to 5 A
    2. Turn the power switch off and turn on the high beam headlights for 30 seconds. This will remove the surface charge from the auxiliary battery.
    3. Measure the auxiliary battery voltage according to the value(s) in the table below.

      Result

      Tester Connection Condition Specified Condition Result
      Positive (+) terminal - Negative (-) terminal 20°C (68°F), Power switch off 12.5 V or higher Auxiliary battery is OK
      11.0 to 12.5 V Recharge auxiliary battery
      Below 11.5 V Replace auxiliary battery
  4. CHECK AUXILIARY BATTERY TERMINAL, FUSIBLE LINK AND FUSE 
    1. Check that the auxiliary battery terminals are not loose or corroded.

      HINT: 

      If the terminals are corroded, clean them.

    2. Measure the resistance of each fusible link and fuse for the auxiliary battery charging system.

      Standard resistance

      Below 1 Ω

      HINT: 

      If any of the results is not as specified, replace the fusible link or fuse as necessary.

  5. CHECK AMD TERMINAL 
    WARNING:

    Be sure to wear insulated gloves.

    1. Check that the service plug grip is not installed.
      NOTE:

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.

    2. Check that the AMD terminal is connected securely, and there is no contact problem.

      HINT: 

      If there are any arc marks, replace the affected parts.

    3. Check that the nuts for the AMD terminal is tightened to the specified torque.

      HINT: 

      If there are no arc marks and the AMD terminal connection is faulty, connect the AMD terminal securely.

    4. Install the service plug grip.
  6. CHECK DC/DC CONVERTER FUNCTION 
    1. Connect the AC/DC 400 A probe to the positive auxiliary battery cable.
      Fig 1: Identifying Inverter With Converter Assembly (Operation Of DC/DC Converter)
      GTY288327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Turn the power switch on (READY) and leave the vehicle as it is until the electric current flowing into the auxiliary battery becomes 10 A or less.
    3. Turn the power switch on (READY) and the headlight position switch and blower motor switch in the HI position, and the rear window defogger turned on.
    4. Measure the current and voltage according to the value(s) in the table below.
      Fig 2: Inspecting Inverter With Converter Assembly (Operation Of DC/DC Converter)
      GTY285281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result

      Item Tester Connection Condition Specified Condition
      Current flowing from auxiliary battery Auxiliary battery positive cable Power switch on (READY)
      (The headlight position switch and blower motor switch are in the HI position, and the rear window defogger is turned on.)      		 0 A or less
      (no current from auxiliary battery)
      Auxiliary battery voltage Positive (+) terminal - Negative (-) terminal 13 to 15 V

      HINT: 

      If the values are not as specified, replace the inverter with converter assembly.

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