Toyota Prius: Charge Inlet (for Phev Model)

• On-vehicle Inspection
• Removal
• Inspection
• Installation

On-vehicle Inspection

ON-VEHICLE INSPECTION

PROCEDURE

1. INSPECT CABLE EV CHARGER LOCK ASSEMBLY

(a) Charging connector lock operation inspection

(1) Push in the push lifter, perform the door lock operation, and check that the lock pin of the EV charge lock assembly operates. CAUTION: Do not place your hand or fingers under the lock pin while performing this inspection as they may be pinched when the lock pin operates. HINT: Confirm that the auxiliary battery is normal before performing this inspection. Click here

*a Locked *b Unlocked *c Push Lifter *d Charging Connector Lock *e Lock Pin

2. INSPECT INLET AC CHARGER CABLE

(a) Check that the terminals of the inlet charger cable (charging inlet side) are not bent or deformed. OK: The terminals are not bent or deformed. HINT: If the result is not as specified, replace the inlet charger cable.

*1 Inlet AC Charger Cable (Charging Inlet Side)

Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during inlet AC charger cable removal/installation are shown below.

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal.

Click here

HINT:

When the cable is disconnected / reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

Items for which learning is completed by driving the Toyota Prius vehicle

Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
Front Camera System	Drive the Toyota Prius vehicle straight ahead at 35 km/h (22 mph) or more for 5 seconds or more.

Items for which learning is completed by operating the vehicle normally

Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
*1: w/o Power Back Door System *2: w/ Power Back Door System
Power Door Lock Control System*1 Back door opener	Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch.
Power Back Door System*2	Reset back door close position
Air Conditioning System	After the ignition switch is turned to ON, the servo motor and expansion valve standard position is recognized.	-

CAUTION / NOTICE / HINT

COMPONENTS (REMOVAL)

Procedure		Part Name Code
1	PRECAUTION	-		-	-
2	SERVICE PLUG GRIP	G3834	-	-	-

Procedure		Part Name Code
3	FRONT WIPER ARM HEAD CAP	85292B		-	-
4	SHIELD CAP	85247		-	-
5	FRONT WIPER ARM AND BLADE ASSEMBLY LH	-	-	-	-
6	FRONT WIPER ARM AND BLADE ASSEMBLY RH	-	-	-	-
7	WINDSHIELD LOWER OUTSIDE MOULDING LH	75536D		-	-
8	WINDSHIELD LOWER OUTSIDE MOULDING RH	75535F	-	-	-
9	COWL WATER EXTRACT SHIELD LH	55754F	-	-	-
10	COWL WATER EXTRACT SHIELD RH	55753D	-	-	-
11	COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY	55708	-	-	-
12	CHECK TERMINAL VOLTAGE	-		-	-
13	COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY	55708		-	-
14	COWL WATER EXTRACT SHIELD RH	55753D	-	-	-
15	COWL WATER EXTRACT SHIELD LH	55754F	-	-	-
16	WINDSHIELD LOWER OUTSIDE MOULDING LH	75536D	-	-	-
17	WINDSHIELD LOWER OUTSIDE MOULDING RH	77535F	-	-	-
18	FRONT WIPER ARM AND BLADE ASSEMBLY LH	-		-	-
19	FRONT WIPER ARM AND BLADE ASSEMBLY RH	-		-	-
20	SHIELD CAP	85247	-	-	-
21	FRONT WIPER ARM HEAD CAP	85292B	-	-	-

*1	Connector Cover Assembly	-	-
	Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)		N*m (kgf*cm, ft.*lbf): Specified torque

Procedure		Part Name Code
22	DECK BOARD ASSEMBLY	58410B	-	-	-
23	REAR SEATBACK ASSEMBLY RH	-		-	-

Procedure		Part Name Code
24	DECK FLOOR BOX RH	64995	-	-	-
25	DECK FLOOR BOX LH	64997	-	-	-
26	LUGGAGE HOLD BELT STRIKER ASSEMBLY	58460D	-	-	-
27	REAR DECK TRIM COVER	64716D	-	-	-

*A

for Rear Side

-

-

Procedure		Part Name Code
28	REAR DOOR SCUFF PLATE INSIDE RH	67917F	-	-	-
29	REAR DOOR OPENING TRIM WEATHERSTRIP RH	62331A	-	-	-
30	REAR SEAT BACK HINGE SUB-ASSEMBLY RH	71303C	-	-	-
31	REAR SEAT SIDE GARNISH RH	62551F		-	-
32	LUGGAGE HOLD BELT STRIKER ASSEMBLY	58460D	-	-	-
33	NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY	81330		-	-
34	DECK TRIM SIDE PANEL ASSEMBLY RH	64730B		-	-

*A

for RH Side

-

-

Procedure		Part Name Code
35	DISCONNECT NO. 1 EV CHARGE CONNECTOR DRAIN HOSE	G93B1	-	-	-
36	INLET AC CHARGER CABLE	G9081C		-	-
37	REMOVE NO. 1 EV CHARGE CONNECTOR DRAIN HOSE	G93B1	-	-	-
38	CABLE EV CHARGER LOCK ASSEMBLY	G90F0A	-	-	-

*1

CONNECTOR PIN

-

-

PROCEDURE

1. PRECAUTION

Click here

2. REMOVE SERVICE PLUG GRIP

Click here

3. REMOVE FRONT WIPER ARM HEAD CAP

Click here

4. REMOVE SHIELD CAP

Click here

5. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH

Click here

6. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH

Click here

7. REMOVE WINDSHIELD LOWER OUTSIDE MOULDING LH

Click here

8. REMOVE WINDSHIELD LOWER OUTSIDE MOULDING RH

(a) Use the same procedure as for the LH side.

9. REMOVE COWL WATER EXTRACT SHIELD LH

Click here

10. REMOVE COWL WATER EXTRACT SHIELD RH

(a) Use the same procedure as for the LH side.

11. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

Click here

12. CHECK TERMINAL VOLTAGE

Click here

13. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

Click here

14. INSTALL COWL WATER EXTRACT SHIELD RH

15. INSTALL COWL WATER EXTRACT SHIELD LH

16. INSTALL WINDSHIELD LOWER OUTSIDE MOULDING LH

Click here

17. INSTALL WINDSHIELD LOWER OUTSIDE MOULDING RH

(a) Use the same procedure as for the LH side.

18. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH

Click here

19. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH

Click here

20. INSTALL SHIELD CAP

21. INSTALL FRONT WIPER ARM HEAD CAP

22. REMOVE DECK BOARD ASSEMBLY

Click here

23. REMOVE REAR SEATBACK ASSEMBLY RH

Click here

24. REMOVE DECK FLOOR BOX RH

Click here

25. REMOVE DECK FLOOR BOX LH

Click here

26. REMOVE LUGGAGE HOLD BELT STRIKER ASSEMBLY (for Rear Side)

Click here

27. REMOVE REAR DECK TRIM COVER

Click here

28. REMOVE REAR DOOR SCUFF PLATE INSIDE RH

(a) Use the same procedure as for the LH side.

Click here

29. DISCONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH

Click here

30. REMOVE REAR SEAT BACK HINGE SUB-ASSEMBLY RH

(a) Use the same procedure as for the LH side.

Click here

31. REMOVE REAR SEAT SIDE GARNISH RH

Use the same procedure as for the LH side. Click here

32. REMOVE LUGGAGE HOLD BELT STRIKER ASSEMBLY (for RH Side)

(a) Use the same procedure as for the LH side.

Click here

33. REMOVE NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY

Click here

34. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH

Use the same procedure as for the LH side. Click here

35. DISCONNECT NO. 1 EV CHARGE CONNECTOR DRAIN HOSE

36. REMOVE INLET AC CHARGER CABLE

CAUTION: Be sure to wear insulated gloves.

*a	Green-colored Lock	*b	Earth Terminal
	Slide	-	-

(1) Using a screwdriver, slide the green-colored lock of the connector as shown in the illustration to release it and disconnect the inlet AC charger cable connector.

(2) Disengage the 2 clamps.

(3) Disconnect the 2 inlet AC charger cable connectors.

(4) Remove the bolt and disconnect the earth terminal.

(5) Remove the 4 nuts and inlet AC charger cable.

37. REMOVE NO. 1 EV CHARGE CONNECTOR DRAIN HOSE

38. REMOVE CABLE EV CHARGER LOCK ASSEMBLY

Inspection

INSPECTION

PROCEDURE

1. INSPECT INLET AC CHARGER CABLE

(a) Visual inspection

NOTICE:

Visual inspection is done with confirming comparisons with a AC charger inlet cable that is known to operate normally.

(1) There are not the damage of the Charge bin location of the AC charger inlet cable, cable damage (disconnection), lock part damage, the damage of the connector or confirms it.

*1	Charger opening	*2	Lock part
*3	Connector (kM1)	*4	Connector (Mk1)
*5	Earth terminal	-	-

HINT:

If there is damage in the charger opening that obstructs the charger connector fitting as well as cable damage (disconnection), the lock damaged, or connector damage, replace the AC charger inlet cable.

(2) Confirm there is no foreign objects within the charge opening for the AC charger inlet cable.

*a	Inspect the terminal (ACIH, ACIC, GND, CPLT, PISW)	-	-
	Confirm the region within the terminal		Confirm the region within charger opening

HINT:

If a foreign object that entered within the downward pointing terminals of the AC charging inlet as well as within the charger opening is able to be removed, remove the foreign object and use. If a foreign object in the terminals is not able to be removed, replace the AC charge inlet cable.

(b) Electricity check

(1) Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Click Location & Routing(s1,ss1,Rs1) Click Connector(s1) Click Connector(ss1) Click Connector(Rs1)

Tester Connection	Specified Condition
s1-1 (ACIH) - ss1-1 (ACIH)	Below 1 Ω
s1-2 (ACIC) - ss1-2 (ACIC)
s1-3 (PISW) - Rs1-1 (PISW)
s1-4 (CPLT) - Rs1-6 (CPLT)
s1-5 (GND) - Earth terminal
s1-3 (PISW) - s1-5 (GND)	2.3 to 3.0 kΩ

HINT:

If the result is not as specified, replace the inlet AC charger cable.

2. INSPECT CABLE EV CHARGER LOCK ASSEMBLY

(a) Visual inspection

(1) Check that there is no foreign matter on the lock pin of the cable EV charger lock assembly. HINT: If there is foreign matter on the lock pin, remove it. If the foreign matter cannot be removed, replace the cable EV charger lock assembly.

*a Lock Pin

(2) Check that the lock pin of the cable EV charger lock assembly is not bent, damaged or deformed.

HINT:

If the lock pin of the cable EV charger lock assembly is bent, damaged or deformed, replace the cable EV charger lock assembly.

(b) Check the operation of the lock pin.

(1) Apply auxiliary battery voltage to the terminals of the connector and check that the lock pin operates.

*a	Component without harness connected (Cable EV Charger Lock Assembly)	*b	Unlocked
*c	Locked	*d	Lock Pin

OK:

Measurement Condition	Specified Condition
Auxiliary Battery positive ( ) → R76-10 (CBMP) and R76-7 ( B) Auxiliary Battery negative (-) → R76-1 (GND)	Locks
Auxiliary Battery positive ( ) → R76-4 (CBMN) and R76-7 ( B) Auxiliary Battery negative (-) → R76-1 (GND)	Unlocks

HINT:

If the result is not as specified, replace the cable EV charger lock assembly.

(c) Inspect the lock pin position detection circuit.

(1) Measure the resistance according to the value(s) in the table below.

*a	Component without harness connected (Cable EV Charger Lock Assembly)	*b	Unlocked
*c	Locked	*d	Lock Pin
*e	Lock Release Lever	-	-

Standard Resistance:

Click Location & Routing(R76) Click Connector(R76)

Tester Connection	Condition	Specified Condition
R76-9 (CBSW) - R76-1 (GND)	Locks	Below 1 Ω
	Unlocks	10 kΩ or higher

NOTICE:

The lock release lever moves when the lock pin changes from locked to unlocked or from unlocked to locked.

HINT:

If the result is not as specified, replace the cable EV charger lock assembly.

(d) Inspect the power supply circuit of the fuel lid lock with motor assembly

(1) Measure the resistance according to the value(s) in the table below. Standard Resistance: Click Location & Routing(R76) Click Connector(R76) Tester Connection Condition Specified Condition R76-12(E) - R76-1(GND) (Auxiliary battery voltage not applied between terminals R76-10 (CBMP) - R76-1 (GND)) Below 1 Ω R76-6(B) - R76-1(GND) (Auxiliary battery voltage applied between terminals R76-4 (CBMN) - R76-1 (GND)) HINT: If the result is not as specified, replace the cable EV charger lock assembly.

*a Component without harness connected (Cable EV Charger Lock Assembly)

Installation

INSTALLATION

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure		Part Name Code
1	CABLE EV CHARGER LOCK ASSEMBLY	G90F0A	-	-	-
2	INSTALL NO. 1 EV CHARGE CONNECTOR DRAIN HOSE	G93B1		-	-
3	INLET AC CHARGER CABLE	G9081C		-	-
4	CONNECT NO. 1 EV CHARGE CONNECTOR DRAIN HOSE	G93B1	-	-	-

*1	CONNECTOR PIN	-	-
	Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)		N*m (kgf*cm, ft.*lbf): Specified torque

Procedure		Part Name Code
5	DECK TRIM SIDE PANEL ASSEMBLY RH	64730B	-	-	-
6	NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY	81330	-	-	-
7	LUGGAGE HOLD BELT STRIKER ASSEMBLY	58460D	-	-	-
8	REAR SEAT SIDE GARNISH RH	62551F		-	-
9	REAR SEAT BACK HINGE SUB-ASSEMBLY RH	71303C	-	-	-
10	REAR DOOR OPENING TRIM WEATHERSTRIP RH	62331A	-	-	-
11	REAR DOOR SCUFF PLATE INSIDE RH	67917F	-	-	-

*A	for RH Side	-	-
	Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)	-	-

Procedure		Part Name Code
12	REAR DECK TRIM COVER	64716D	-	-	-
13	LUGGAGE HOLD BELT STRIKER ASSEMBLY	58460D	-	-	-
14	DECK FLOOR BOX LH	64997	-	-	-
15	DECK FLOOR BOX RH	64995	-	-	-

*A

for Rear Side

-

-

Procedure		Part Name Code
16	REAR SEATBACK ASSEMBLY RH	-		-	-
17	DECK BOARD ASSEMBLY	58410B	-	-	-

Procedure		Part Name Code
18	SERVICE PLUG GRIP	G3834	-	-	-

PROCEDURE

1. INSTALL CABLE EV CHARGER LOCK ASSEMBLY

2. INSTALL NO. 1 EV CHARGE CONNECTOR DRAIN HOSE

*a	Front of Toyota Prius Vehicle	*b	RH Side
*c	Alignment Mark	-	-

(1) Install the No. 1 EV charge connector drain hose to the inlet AC charger cable and slide the clip to secure it.

NOTICE:

Make sure that the clip is positioned as shown in the illustration.

3. INSTALL INLET AC CHARGER CABLE

CAUTION: Be sure to wear insulated gloves.

*a	Green-colored Lock	*b	Earth Terminal
	Slide	-	-

(1) Install the inlet AC charger cable with the 4 nuts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(2) Connect the earth terminal with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(3) Connect the 2 inlet AC charger cable connectors.

(4) Engage the 2 clamps.

(5) Connect the inlet AC charger cable connector and slide the green-colored lock as shown in the illustration to lock it securely.

4. CONNECT NO. 1 EV CHARGE CONNECTOR DRAIN HOSE

5. INSTALL DECK TRIM SIDE PANEL ASSEMBLY RH

6. INSTALL NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY

7. INSTALL LUGGAGE HOLD BELT STRIKER ASSEMBLY (for RH Side)

8. INSTALL REAR SEAT SIDE GARNISH RH

Use the same procedure as for the LH side. Click here

9. INSTALL REAR SEAT BACK HINGE SUB-ASSEMBLY RH

(a) Use the same procedure as for the LH side.

Click here

10. CONNECT REAR DOOR OPENING TRIM WEATHERSTRIP RH

11. INSTALL REAR DOOR SCUFF PLATE INSIDE RH

12. INSTALL REAR DECK TRIM COVER

13. INSTALL LUGGAGE HOLD BELT STRIKER ASSEMBLY (for Rear Side)

14. INSTALL DECK FLOOR BOX LH

15. INSTALL DECK FLOOR BOX RH

16. INSTALL REAR SEATBACK ASSEMBLY RH

Click here

17. INSTALL DECK BOARD ASSEMBLY

18. INSTALL SERVICE PLUG GRIP

Click here