Heavy charging cable fails to connect Bz4X?

[PaulZimbardo]

I tried charging yesterday my Bz4x at an MFG charge point and it failed several times.  Eventually with the help of the phone guy I charged it by holding the very heavy cable/plug combination into the socket long enough for it to connect.  I've charged successfully before without doing that.  Does anyone think there might be a tolerance problem with the communication contacts in the socket, which the guy suggested might be the problem, with the heavy cable pulling down lightly on the plug?

[G S]

This has happened to me on a few occasions but as you say, easily negated by holding the cable during the connection process. I would say about 5 times in 13000 miles which doesn't sound bad but I mainly charge at home with a lighter cable.

At a guess, I have probably charged on the road 50 times in my year of ownership so this equates to a 10% occurrence which makes it sound more of a problem but I would describe it as a mild inconvenience given away by repeated clicking and easily solved. 

[bZ4X]

23 hours ago, PaulZimbardo said:

I tried charging yesterday my Bz4x at an MFG charge point and it failed several times.  Eventually with the help of the phone guy I charged it by holding the very heavy cable/plug combination into the socket long enough for it to connect.  I've charged successfully before without doing that.  Does anyone think there might be a tolerance problem with the communication contacts in the socket, which the guy suggested might be the problem, with the heavy cable pulling down lightly on the plug?

This is bZ4X plug problem. There is a locking pin design problem. I took my car to my delaer for this problem created a ticket and still wiating for solution. If I don't hold it until locks, fails. I will share a picture u will understand the problem more clearly. 

[Cyker]

My washing machine's like that - I have to hold the door in or the electronic latch won't.... latch.  

 

[bZ4X]

Alright, the issue is that the X equals Y because the cable is quite heavy and it's causing it to sag.

Car port:

Cable:

Take a close look at the cable, and you'll notice that the locking pin has left a mark on it when attempting to secure it.

Please see the picture:

[bZ4X]

I opted for the original lightweight Mercedes EV cable, and since then, the car mostly locks without any trouble. The problem has significantly reduced since I got the new cable. However, I still encounter occasional issues, especially when using public rapid chargers. Toyota must fix this design flaw and consider replacing our car's plugs.

Not: Note: My dealer mentioned that Toyota is aware of the issue.

[gingertips]

On 12/6/2023 at 10:55 AM, bZ4X said:

This is bZ4X plug problem. There is a locking pin design problem. I took my car to my delaer for this problem created a ticket and still wiating for solution. If I don't hold it until locks, fails. I will share a picture u will understand the problem more clearly. 

Same here.   Get this all the time.  Key is to hold and wait until it locks. But it’s definitely a design issue 

[JonathanP]

When I picked up my car on Friday the dealer said to make sure to hold the cable until you hear the click.

[bZ4X]

On 3/3/2024 at 8:34 PM, JonathanP said:

When I picked up my car on Friday the dealer said to make sure to hold the cable until you hear the click.

bZ4X is the only EV in the market where we gotta hold the cable to make sure it's locked. 😂 Shame Toyota!

[gingertips]

Agree with this.  Have been caught out a few times with the charger failing to charge due to this. In some car parks you get fined if you’re not charging 

[Mcdonaj]

Hi picked up a 9 month old BZ4X yesterday. Only 8,000 miles AWD and just what I wanted.

BUT

i have attempted to charge it at 5 different public charging points using the CCS connection and made about 15 attempts to charge. I only have achieved 2 successful charges and have had to make 3 calls to separate charger providers. This is in one day.

it would appear that the car has difficulty making a successful connection resulting in “clicking” sounds from the charging port and failed charges.

On searching the internet it would appear that this is a known  issue and the solution is for the user to retry and hold and reposition the charging plug until a successful connection is made.

We have a Kia Soul EV and have been charging it on public chargers for 7 years and have never had this problem.

So we have paid £40k for a car that we cannot “trust” will reliably charge and ut is down to the customer to manage around the issue.

This is not good enough

I would be interested if anybody else has suffered this issue and how it was resolved.

[FROSTYBALLS]

Similar topics merged.

[Cyker]

It still baffles me how they've managed to take something we pretty much mastered decades ago - Plugging something into a socket to create an electrical contact - and make it not work  

 

[ernieb]

7 hours ago, Cyker said:

It still baffles me how they've managed to take something we pretty much mastered decades ago - Plugging something into a socket to create an electrical contact - and make it not work  

 

Possibly because every manufacturer has different systems, plugs and internal protocols. IF they had agreed at the start a universal system I'm sure virtually none of this would be an issue. It's also probably that there could be adequate training with one standard interface rather than multiple.

[Andy BZ4x]

I get the issue occasionally (had mine 16 months), I just hold it in place firmly & the clicking stops & locks into place - it very rarely happens though

[Kopper Bopper]

im having the same problem and thought it might be down to wear and tear on public charging plugs the it worked holding the cable up .

I have today came of the phone to Toyota and the guy said he has the same problem and to said to hold plug till it clicks in 

so obvious Toyota know about the problem so we will have to wait till they get their finger out to solve the problem

  

[bZ4X]

On 7/25/2024 at 10:08 PM, Mcdonaj said:

Hi picked up a 9 month old BZ4X yesterday. Only 8,000 miles AWD and just what I wanted.

BUT

i have attempted to charge it at 5 different public charging points using the CCS connection and made about 15 attempts to charge. I only have achieved 2 successful charges and have had to make 3 calls to separate charger providers. This is in one day.

it would appear that the car has difficulty making a successful connection resulting in “clicking” sounds from the charging port and failed charges.

On searching the internet it would appear that this is a known  issue and the solution is for the user to retry and hold and reposition the charging plug until a successful connection is made.

We have a Kia Soul EV and have been charging it on public chargers for 7 years and have never had this problem.

So we have paid £40k for a car that we cannot “trust” will reliably charge and ut is down to the customer to manage around the issue.

This is not good enough

I would be interested if anybody else has suffered this issue and how it was resolved.

It's quite embarrassing. We have all sorts of EVs at my office because my company provides a free EV charging station. I'm the only one who has to rush back to the car to hold the cable after swiping my BP charging card at the wall-mounted charging port. Otherwise, the car makes five attempts to lock the charging cable and fails. 🚗🔌. I have had a ticket open since the beginning of 2023, still waiting for Toyota to decide on a fix. I guess I will be going to the Motor Ombudsman for this defect next year.

[Cyker]

On 7/26/2024 at 6:50 AM, ernieb said:

Possibly because every manufacturer has different systems, plugs and internal protocols. IF they had agreed at the start a universal system I'm sure virtually none of this would be an issue. It's also probably that there could be adequate training with one standard interface rather than multiple.

If they'd made this when it was all new that might wash, but by the time they made the bz4x the CCS standard was well established and has very clear specs, dimensions and tolerances for everything including the connectors, so this is inexcusable. They also clearly didn't do enough real-world testing too!

But this is not super surprising given their recalcitrance to make an EV in the first place when they believe, as I do, that the tech is not ready, and it's also Version 1 vehicle (Never buy a Version 1 anything unless you're an early adopter type and willing to deal with the inevitable Version 1 jank  )

 

[bz4xuserSLO]

Hello from Slovenia. We have a similar and bigger problem on the 12/23 BZ4x Awd: the connection on fast charging station does not start and holding the cable does not seem to help. It seems a mere coincidence results in charging but it stops for no reason after 1-3 percent of charging. So the car goes to a Toyota service center on Monday and we hope they find and solve the problem. I have had 6 Toyota cars so far, very satisfied but this car is a shame for the company.

[bz4xuserSLO]

And we got the car back: as expected the tests at the service showed no flaws and they took it to a fast charger and it was working. They suggested to charge it after the doors are locked?! So it is now up to us to record every fast charging to prove Toyota that something is not working properly. I will be more than happy if this stress never happens again, but we will take the car to longer journeys because of the warranty. Please let me know if anyone finds a solution. Kindest regards.

[bZ4X]

58 minutes ago, bz4xuserSLO said:

And we got the car back: as expected the tests at the service showed no flaws and they took it to a fast charger and it was working. They suggested to charge it after the doors are locked?! So it is now up to us to record every fast charging to prove Toyota that something is not working properly. I will be more than happy if this stress never happens again, but we will take the car to longer journeys because of the warranty. Please let me know if anyone finds a solution. Kindest regards.

I have documented this issue with multiple video recordings, and my dealer has also recorded a video of the problem. I have shared all of this video evidence with Toyota. It is clear that there is a design flaw, but Toyota is refusing to acknowledge it. I will be forced to escalate this matter to the Motor Ombudsman next year if it is not resolved. This is a serious defect that needs to be addressed.