A25A-FXS (BATTERY / CHARGING): CHARGING SYSTEM: ON-VEHICLE INSPECTION; 2023 MY RAV4 HV [10/2022

Last Modified: 01-30-2024	6.11:8.1.0	Doc ID: RM1000000026RL8
Model Year Start: 2023	Model: RAV4 HV	Prod Date Range: [10/2022 - 10/2023]
Title: A25A-FXS (BATTERY / CHARGING): CHARGING SYSTEM: ON-VEHICLE INSPECTION; 2023 MY RAV4 HV [10/2022 - 10/2023]

ON-VEHICLE INSPECTION

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced when inspecting auxiliary battery are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced

Replacement Part or Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed
*: When performing learning using the Techstream. Click here
Auxiliary battery terminal is disconnected/reconnected	Perform steering sensor zero point calibration	Lane control system
		Parking support brake system (for HV model)*
		Pre-collision system
	Reset back door close position	Power back door system (for HV model)
	Back door lock initialization	Power door lock control system

NOTICE:

After the ignition switch is turned off, the audio and visual system records various types of memory and settings. As a result, after turning the ignition switch off, make sure to wait at least 2 minutes before disconnecting the cable from the negative (-) auxiliary battery terminal.
When the cable is disconnected from the negative (-) auxiliary battery terminal and the security lock setting has been enabled, multi-display operations will be disabled upon next startup unless the password is entered. Be sure to check the security lock setting before disconnecting the cable from the negative (-) auxiliary battery terminal.

PROCEDURE

1. CHECK AUXILIARY BATTERY

(a) Check that the auxiliary battery cables are connected to the correct terminals.

If they are not, connect them properly.

(b) 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

(a) Turn the ignition switch off and turn on the high beam headlights for 30 seconds. This will remove the surface charge from the auxiliary battery.

(b) Measure the auxiliary battery voltage according to the value(s) in the table below.

Tester Connection	Condition	Specified Condition	Result
Positive (+) auxiliary battery terminal - Negative (-) auxiliary battery terminal	20°C (68°F), Ignition switch off	12.0 V or higher	Auxiliary battery is OK
	20°C (68°F), Ignition switch off	12.0 V or less	Recharge auxiliary battery

3. RECHARGE AUXILIARY BATTERY

(a) 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 shown in the table below.

Charge Method	Charging Current
Normal	Below 5 A
Quick	Below 15 A

(b) Turn the ignition switch off and turn on the high beam headlights for 30 seconds. This will remove the surface charge from the auxiliary battery.

Tester Connection	Condition	Specified Condition	Result
Positive (+) auxiliary battery terminal - Negative (-) auxiliary battery terminal	20°C (68°F), Ignition switch off	12.0 V or higher	Auxiliary battery is OK
	20°C (68°F), Ignition switch off	12.0 V or less	Recharge auxiliary battery

4. CHECK AUXILIARY BATTERY TERMINAL, FUSIBLE LINK AND FUSE

(a) Check that the auxiliary battery terminals are not loose or corroded.

Torque:

Positive (+) Auxiliary Battery Terminal :

5.4 N·m {55 kgf·cm, 48 in·lbf}

Negative (-) Auxiliary Battery Terminal :

5.4 N·m {55 kgf·cm, 48 in·lbf}

If a terminal is loose or corroded, tighten or clean the terminal.

(b) Measure the resistance of each fusible link and fuse for the auxiliary battery charging system.

Standard resistance:

Below 1 Ω

If the result is not as specified, replace the fusible link or fuse as necessary.

5. CHECK AMD TERMINAL

CAUTION:

Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.
Click here
To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.

(a) Remove the service plug grip.

Click here

(b) Check that the AMD terminal is connected securely, and there is no contact problem.

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

Torque:

Inverter with Converter Assembly Side :

10 N·m {102 kgf·cm, 7 ft·lbf}

No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly Side :

8.0 N·m {82 kgf·cm, 71 in·lbf}

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

*a	Inverter with Converter Assembly Side
*b	No. 1 Engine Room Relay Block and No. 1 Junction Block Assembly Side

(d) Install the service plug grip.

Click here

6. CHECK DC/DC CONVERTER FUNCTION

(a) Connect the AC/DC 400 A probe to the positive (+) auxiliary battery cable.

*a	Probe Direction
*b	Current Flowing into Auxiliary Battery

(b) Turn the ignition switch to on (READY) and leave the vehicle as is until the electric current flowing to the auxiliary battery becomes 10 A or less.

(c) Turn on the high beam headlights, and turn the blower motor switch to the HI position and the rear window defogger on.

(d) Measure the current and voltage according to the value(s) in the table below.

Result:

Item

Tester Connection

Condition

Specified Condition

Current flowing from auxiliary battery

Positive (+) auxiliary battery cable

Ignition switch ON

(The high beam headlights are on, the blower motor switch is 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 (+) auxiliary battery terminal - Negative (-) auxiliary battery terminal

12.5 to 15 V

If the result is not as specified, replace the inverter with converter assembly.

*a	Probe Direction
*b	Current Flowing from Auxiliary Battery