It goes with out saying follow this at your own risk.

It is both dangerous to you and could damage your car.

There is one important thing to understand about electric vehicles and how they work before we start.

The battereis in the pack are connected to the inverter thru relays, the inverter runs the motor

There are three relays, the Precharge relay (cont1 or SMR No. 1 Violet wire) the Positive relay Cont 2 or SMR No.2 Gray wire) and the Negative relay Cont 3 or SMR No.3Pink wire) see diagram below.

DO NOT EVER engage both the Positive relay and Negative relay with out having engaged the Precharge relay first, unless you have disconnected the Inverter and capaciors first.

The reason for this is the Inverter in all electric vehicles has a huge bank of capacitors to ensure that suffiient energy is available to the inverter circuit.

When DC voltage is applied to an uncharged capacitor it initially behaves like a short circuit and will fully charge, virtually for our purposes instantly. This inrush of current would be potentially hundereds of amps unchecked. Such an inrush  would weld (destroy) the contacts on any relay that trys to connect the battery to the capacitors before precharging the capacitors. Note the series resistor connected to SMR1 in the diagram below.

The Precharge relay is designed for thw purpose of slowly charging the capacitors. The precharge relay has a resistor in series with the relay between the capacitors and the battery. This relay allows the capacitors to charge up slowly so that when the main relays are engaged they are not subjected to destructive currents.

End or warning. This is what we are looking at.

HOTWIRE BATTERY PACK

If you find your battery is completely dead or below a voltage that the charger is unable to start charging you can try and boost the batteries a little bit or at least enough for the Battery ECU to recognize that the battery is there and connected.

As above proceed with caution there are high voltages that can hurt you, gloves and non conductive tools are a good idea.

The obective here is to turn the relays in the batteru pack on to facilitate charging the battery enough to allow the paddle charger to charge the car it's self.

The Techstream software allows you to turn on one relay at a time but not both at the same time, for the reasons noted above.

So what we need to do is manually energise one or both of the relays by applying  12 volts to the relay circuit and use the software to turn the other relay on. One could of course turn both on manually this would require two splices but increases the risk of accidently turning both on at the wrong time. Infact this patch should be temporary so it can not be triggered by someone unaware of the implications.

FIRST THING : Pull the "Prug", the safety interconnect on the floor underneath a removable cover behind the drivers seat. Pull a small flap of carpet up to access it.

STEP ONE: Disconnect the 12 volt auxilary battery.

STEP TWO: Open the suitcase and disconnect the Negative wire from the connection point at the bottom back right hand side where the power from the batteries enters the suitcase, see picture below.

Insulate the bare post, (a very large marret would work) and mechanically block the negative wire from connecting to anything at this point.

STEP THREE :  Locate the Battery ECU,front left hand side of suitcase compartment. Remove the 4 screws holding the module to the suitcase body. Ease the module away from the suitcase body to expose the wires of interest. E2 is the connector you are interested in. It is the top most one of 4 side by side connectors on the left side of the module.You may need to remove the topside connector and free the wiring harness to facilitate easier movement. Plug it back in when done. Try not to drop any screws, have a telescoping magnetic tool handy just in case.

Depending on your dexterity and comfort with splicing wires you could condut the surgery right here.

The other option is to remove the rubber boot on the outsde of the suit case, disconnect E2 and pull it out from the rubber boot where there would be more room to work. See next picture.

Step 4- Pick one of the two wires indicated above, pink or gray which ever is easier for you to access. There are a number of ways to approach this depending on skill level. You can use a crimp that allows you to add a wire to the existing wire. You can remove some of the insulation and solder an additional wire to the existing wire. Insulate carefully after. You couldl cut and splice, and then solder a new wire onto the existing wire. A novel temporary solution would be to take a very sharp pin and push it into the insulation to connect with the copper inside and then use an aligator clip jumper wire to connect to it. Once you have decided how you are going to do it, and have done it, you need to test it. To do this connect the 12 volt auxilary battery back up to the car and then run your new wire to the positive post. When you connect the wire to the post you should here a relay click. when you release the wire the relay will click again as it drops out. Step 4, Success.

Leave the wire disconnected from the battery post untill we have the rest of the set up ready.

STEP 5 Techstream

You need to run Techstream on your laptop and have it connected to the car or use the MasterTech device from Toyota, not described here.

Once you have Techstream running and are conected to the vehicle you need to go to the EV selection and then click on the active tests you will see the above list. Try it, so you are familiar with it, no harm can be done at this point.

Once you know how it works turn your mind to which wire you need to splice into. Focusing on Techsream turning on one relay and the spliced wire truning on the other.

Now for the charging set up. Go back to the suitcase. With the power supply turned off, connect your power supply to the battery pack wires as shown in the first picture. Positive to the still connected positive bolt/connector. Negative to the loose wire not the post. Make sure both wires are secure and will not fall off or move during charging.

STEP 6 : Check your work. Reconnect the PRUG and the auxilary battery.

STEP 7 : Relays on. Enage the relay connected to the wire or switch that you have set up in the suitcase. The relay should click. Nothing else should happen. With the car on turn on the "other relay" using the Techstream software. Again you should hear a click nothing else. The fans will be running in the car normally.

STEP 8: Return to the suit case and your power supply. Turn the voltage and current controls down to the bottom, rotate left or counter clock wise.

Turn the power supply on, You may get a voltage reading on the volt meter of the power supply. This would be good. adjust the voltage of the power supply up slowly and not much a few volts at a time. Ideally you will see a voltage increase. You can slowly increase the current, you should get an indication of current flow. Over a period of time adjust the voltage up and the current up. You should see indications that a charge is being taken.This can be noted by the voltage going up and the current going down. Proceed very slowly hours might be good. Do not leave it unattended, have a good book.

Over time ideally you might get somewhere close to 200 volts, I would stop there or earlier by turning the voltage and curent down and see if the battery pack voltage settles to a voltage above what you started with. If you are getting a sustained 200 volts. it would be time to see if the paddle charger will respond.

STEP 8: Turn the relays off.Turn the car off, disconnect the aux 12 volts. Disconnect the power supply. Disconnet the PRUG

STEP 9: Make sure the new wire you installed to energise the relay is diconnected  ie not connected to anything and is insulated and isolated. Reconnect the negative wire from the pack to the post. Reconnect the 12 volt aux battery, reconnect the PRUG in this order.

Run Techstream to see what it thinks of the battery. Hopefully it has improved.

STEP 10: Try the charger. Repeat the above steps as often as necessary to get the charger to start charging or the battery gets above 288 volts and there is still no action. There is no point going beyond 288 Volts. If no improvement. This would be the time to consider other steps.