NHTSA ID Number: 11012753
Manufacturer Communication Number: T-SB-0110-20 Rev2
TSB/Document Date: 2025-01-09
Summary
This bulletin includes basic procedures for performing a rescue charge at battery on high voltage (HV) Ni-MH and Li-ion batteries. This bulletin should be used in conjunction with the applicable model and model year Repair Manual while performing the battery rescue charge. The GRX-5100 should be used wherever the Repair Manual references the Toyota
Hybrid System (THS) charger.
T-SB-0110-20
Rev2
November 2, 2020
High Voltage (HV) Battery Rescue Charge at Battery
(HEV Workstation/GRX-5100)
Service
Category
Engine/Hybrid System
Section
Hybrid/Battery Control System
Market USA and
Mexico
Applicability
YEAR(S)
MODEL(S)
2019 - 2022
Avalon HV
2018 - 2024
Camry HV
2023 - 2025
Corolla Cross HV, Crown
2020 - 2025
Corolla HV
2020 - 2025
Highlander HV
2021 - 2025
Mirai
2016 - 2022
Prius
2019 - 2025
RAV4 HV
2021 - 2025
Sienna HV
2022
Tundra HV
2021 - 2024
Venza HV
ADDITIONAL INFORMATION
© 2024 Toyota Motor Sales, USA
Page 1 of 20
T-SB-0110-20
Rev2
November 2, 2020
Page 2 of 20
High Voltage (HV) Battery Rescue Charge at Battery (HEV Workstation/GRX5100)
REVISION NOTICE
December 10, 2024 Rev2:
Applicability has been updated to include 2021 – 2025 model year Mirai; 2023 – 2024 model year
Camry Hybrid, and Venza Hybrid; 2023 – 2025 model year Corolla Hybrid, Corolla Cross Hybrid,
Crown, Highlander Hybrid, RAV4 Hybrid, and Sienna Hybrid vehicles.
The Required Tools & Equipment and Rescue Charge at Battery sections have been updated.
The market has been updated to include the Mexico market.
May 31, 2022 Rev1:
Applicability has been updated to include 2021 – 2022 model year Sienna Hybrid and Venza
Hybrid; and 2022 model year Avalon Hybrid, Camry Hybrid, Highlander Hybrid, RAV4 Hybrid,
Prius, and Tundra Hybrid vehicles.
The Required Tools & Equipment and Rescue Charge at Battery sections have been updated.
Any previous printed versions of this bulletin should be discarded.
Introduction
This bulletin includes basic procedures for performing a rescue charge at battery on high voltage
(HV) Ni-MH and Li-ion batteries. This bulletin should be used in conjunction with the applicable
model and model year Repair Manual while performing the battery rescue charge. The GRX-5100
should be used wherever the Repair Manual references the Toyota Hybrid System (THS) charger.
Warranty Information
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
N/A
Not Applicable to Warranty
–
–
–
–
© 2024 Toyota Motor Sales, USA
T-SB-0110-20
Rev2
November 2, 2020
Page 3 of 20
High Voltage (HV) Battery Rescue Charge at Battery (HEV Workstation/GRX5100)
Required Tools & Equipment
SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QTY
High Voltage Battery Service Unit*
01413-00002
1
High Voltage Cable* A619 A and B
01416-00119
1
Universal High Voltage Cable* (V)
01413-00007
1
Low Voltage Cable* (R)
01413-00004
1
Universal Fuse Box*
01413-00010
1
AC Power Cord* (S)
01413-00005
1
Banana Jack Extension Cable* (X)
01413-00031
1
AC Circuit Checker*
01413-00012
1
Battery Diagnostic Tool*
DCA-8000P T
1
High Voltage Cable* A940 A and B
A940
1
*Essential SST for TMNA, GST, SET (US) Market Dealers. For non-TMNA (TdPR, TdMEX, Servco) dealers, contact your
Distributor Representative for tool sourcing options or purchase the necessary SSTs.
NOTE
Additional SSTs may be ordered by calling 1-800-368-6787 (USA) or 01-800-504-5330 (Mexico) or by
visiting Home – Service Resources – Toyota Special Service Tools (SSTs).
© 2024 Toyota Motor Sales, USA
T-SB-0110-20
Rev2
November 2, 2020
Page 4 of 20
High Voltage (HV) Battery Rescue Charge at Battery (HEV Workstation/GRX5100)
Required Tools & Equipment (continued)
The table below is a cross-reference matrix showing the TMC THS charger part numbers and the
equivalent TMNA GRX-5100 charger part numbers. This matrix can be used as a guide to ensure
the correct cables are selected when following the applicable model and model year Repair
Manual and this Service Bulletin to complete a rescue charge.
Table 1. THS Charger to GRX-5100 Equivalent Part Number Matrix
TMC PART NUMBERS*
SUB-COMPONENTS
IMAGE
TMNA PART NUMBERS**
DESCRIPTION
MAIN
SUB-COMPONENTS
IMAGE
DESCRIPTION
09881-10041
THS Charger 01413-00002
GRX-5100T
GRX-5100 High
Voltage Battery
Service Unit
(HV/EV Charge/
Discharge Tool)
09881-10081
THS Charger
01413-00005
AC Cable
A573
AC Power
Cord (S)
09882-10070
Low Voltage
Cable
A533
Low Voltage
Cable (R)
01413-00004
* The TMC part numbers listed in the table are NOT available in North America.
**The TMNA part numbers listed in the table are available in North America and should be included in the HEV
Workstation (large orange toolbox).
© 2024 Toyota Motor Sales, USA
T-SB-0110-20
Rev2
November 2, 2020
Page 5 of 20
High Voltage (HV) Battery Rescue Charge at Battery (HEV Workstation/GRX5100)
Required Tools & Equipment (continued)
Table 1. (continued)
TMC PART NUMBERS*
SUB-COMPONENTS
09882-10090
09882-10100
IMAGE
TMNA PART NUMBERS**
DESCRIPTION
High
Voltage
Cable
High
Voltage
Cable
MAIN
SUB-COMPONENTS
IMAGE
DESCRIPTION
01416-00119
A619
High Voltage
Cable A619 A
and B
01413-00031
A564
Banana Jack
Extension
Cable (X)
01413-00010
A296
Universal
Fuse Box
01413-00007
A571
Universal High
Voltage
Cable (V)
–
A940
High Voltage
Cable A940 A
and B
(Pack High
Voltage
Harness #8)
01413-00031
A564
Banana Jack
Extension
Cable (X)
01413-00010
A296
Universal
Fuse Box
01413-00007
A571
Universal High
Voltage
Cable (V)
* The TMC part numbers listed in the table are NOT available in North America.
**The TMNA part numbers listed in the table are available in North America and should be included in the HEV
Workstation (large orange toolbox).
© 2024 Toyota Motor Sales, USA
T-SB-0110-20
Rev2
November 2, 2020
Page 6 of 20
High Voltage (HV) Battery Rescue Charge at Battery (HEV Workstation/GRX5100)
Required Tools & Equipment (continued)
REQUIRED EQUIPMENT
SUPPLIER
Techstream ADVi*
Techstream 2.0
Techstream Lite
PART NUMBER
QTY
TSADVUNIT
ADE
Techstream Lite (Green Cable)
TS2UNIT
TSLITEPDLR01
TSLP2DLR01
*Essential SST.
NOTE
Only ONE of the Techstream units listed above is required.
GTS+ software version 2024.03.004.02 or later is required.
Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE)
at 1-800-368-6787 (USA) or 01-55-50103041 (Mexico) or by visiting TIS – Diagnostics –
Tools & Equipment – Techstream Order Portal.
Rescue Charge at Battery
1. Inspect the vehicle.
A. Inspect the auxiliary battery voltage.
B. Test the auxiliary battery using the DCA-8000 Battery Diagnostic Tool to ensure the
battery is fully charged.
2. Inspect the HV battery.
A. Check the charge level of the HV battery.
B. Check whether the HV battery warning message is shown in the vehicle’s
multi-information display.
C. Confirm whether the engine starts.
Does the engine start?
YES — Go to step 7.
NO — Continue to step 3.
© 2024 Toyota Motor Sales, USA
1
T-SB-0110-20
Rev2
November 2, 2020
Page 7 of 20
High Voltage (HV) Battery Rescue Charge at Battery (HEV Workstation/GRX5100)
Rescue Charge at Battery (continued)
3. Prepare the vehicle for a rescue charge.
CAUTION
ALWAYS wear the appropriate Personal Protective Equipment (PPE) provided in the HEV
Workstation when working with high voltage. (Insulated gloves, insulated apron, and arc
protective helmet with face shield.)
ALWAYS use insulated tools when working with high voltage.
ALWAYS use the cones, barriers, and high voltage car toppers provided in the
HEV Workstation to create a perimeter around the vehicle and work area.
HINT
Removing the service plug grip interrupts the high voltage circuit.
High voltage wiring connectors are orange.
NOTE
Do NOT proceed with the Toyota THS charger connection instructions in the Repair Manual. Follow
the proceeding steps in this bulletin to correctly use the GRX-5100 instead.
Refer to TIS, applicable model and model year Repair Manual:
2019 – 2020 Avalon HV:
Engine / Hybrid System – Hybrid / Battery Control –
HV Battery (for Nickel Metal Hydride Battery) – Charging
2021 / 2022 Avalon HV:
Engine / Hybrid System – Hybrid / Battery Control –
HV Battery (for Lithium-Ion Battery) – Charging
2018 – 2020 / 2021 – 2024 Camry HV:
Engine / Hybrid System – Hybrid / Battery Control –
HV Battery (for Nickel Metal Hydride Battery) – Charging
2018 – 2020 / 2021 – 2024 Camry HV:
Engine / Hybrid System – Hybrid / Battery Control –
HV Battery (for Lithium-Ion Battery) – Charging
© 2024 Toyota Motor Sales, USA
T-SB-0110-20
Rev2
November 2, 2020
Page 8 of 20
High Voltage (HV) Battery Rescue Charge at Battery (HEV Workstation/GRX5100)
Rescue Charge at Battery (continued)
2020 – 2022 Corolla HV:
Engine / Hybrid System – Hybrid / Battery Control –
HV Battery (for Nickel Metal Hydride Battery) – Charging
2021 – 2022 / 2023 – 2025 Corolla HV:
Engine / Hybrid System – Hybrid / Battery Control –
HV Battery (for Lithium-Ion Battery) – Charging
2023 – 2025 Corolla Cross HV:
Engine / Hybrid System – Hybrid / Battery Control – HV Battery – Charging
2023 – 2024 / 2025 Crown:
Engine / Hybrid System – Hybrid / Battery Control – HV Battery – Charging
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TSB/Document ID: T-SB-0110-20 Rev2
Replacement Service Bulletin Number:
MFR Communication Date: 2024-12-10
MFR Internal Campaign ID/Software Version: T-SB-0110-20 Rev2
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE
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