HYBRID BATTERY SYSTEM, Diagnostic DTC:P31AB-123

DTC Code DTC Name
P31AB-123 Hybrid Battery Cell Low Voltage

DESCRIPTION


WIRING DIAGRAM

Refer to the wiring diagram for DTC P301A-123 Click here.

CAUTION / NOTICE / HINT

CAUTION:


  • This DTC may be stored even when the SOC is high.

  • Do not perform "HV Batt Cell Low Volt READY ON Prevention Cancel" unless specifically directed by the troubleshooting procedure. Doing so may cause a serious malfunction.

  • Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.

  • After removing the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals. After waiting for 10 minutes, check the voltage at the terminals in the inspection point in the inverter with converter assembly. The voltage should be 0 V before beginning work Click here.

    Tech Tips

    Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

  • When disposing of HV battery, make sure to return them through an authorized collection agent who is capable of handling them safely. If they are returned via the manufacturer specified route, they will be returned properly and in a safe manner by an authorized collection agent.

  • Before returning the HV battery, make sure to perform a recovery inspection Click here

  • Make a note of the output DTCs as some of them may be necessary for recovery inspection of the HV battery.

Note

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work Click here.

PROCEDURE


  1. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

    4. Read output DTCs.

      Result
      Result Proceed to
      P301B-123 is not output A
      P301B-123 is output B

    5. Turn the power switch off.


    B

    GO TO DTC CHART (P301B-123) Click here

    A

  2. SYSTEM CHECK (HYBRID CONTROL)

    CAUTION:

    Before repairing or replacing the malfunctioning part, do not perform "HV Batt Cell Low Volt READY ON Prevention Cancel".


    1. While depressing the brake pedal, press the power switch and check that the hybrid system turns on (READY).

      Note

      Do not turn the power switch on (READY) repeatedly.

      Doing so may cause a malfunction.

      Result
      Result Proceed to
      Hybrid system starts. A
      Hybrid system does not start. B

    2. Turn the power switch off.


    B

    CHECK DTC OUTPUT (HYBRID CONTROL) Click here

    A

  3. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

    4. Read output DTCs Click here.

      Result
      Result Proceed to
      P0AFC-123 is not output. A
      P0AFC-123 is also output. B

    5. Turn the power switch off.


    B

    GO TO DTC CHART (P0AFC-123) Click here

    A

  4. CHECK CONNECTOR CONNECTION CONDITION (BATTERY SMART UNIT CONNECTOR)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 1 hybrid battery shield sub-assembly Click here.

    3. B005ZO9

      Check the connections of the battery smart unit.

      OK
      The connectors are connected securely and there are no contact problems.

    4. Install the No. 1 hybrid battery shield sub-assembly.


    NG

    CONNECT SECURELY

    OK

  5. CHECK HV BATTERY (BATTERY CELL VOLTAGE)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 1 hybrid battery shield sub-assembly Click here.

    3. Disconnect the z32 battery smart unit connector.

    4. B005Z2UE02
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to Battery Smart Unit)

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

      Standard Voltage (Battery Block 0)
      Tester Connection Hybrid Battery Cell Switch Condition Specified Condition
      z32-13 (GA0) - z32-9 (VA1) 1 Power switch off 3.0 V or more
      z32-9 (VA1) -z32-5 (VA2) 2 Power switch off 3.0 V or more
      z32-5 (VA2) - z32-1 (VA3) 3 Power switch off 3.0 V or more
      z32-1 (VA3) - z32-14 (VA4) 4 Power switch off 3.0 V or more
      z32-14 (VA4) - z32-10 (VA5) 5 Power switch off 3.0 V or more
      z32-10 (VA5) - z32-6 (VA6) 6 Power switch off 3.0 V or more
      z32-6 (VA6) - z32-2 (VA7) 7 Power switch off 3.0 V or more

      Note

      Make sure to check the polarity of each terminal (positive (+) or negative (-)) before connecting a tester.

    5. B005Z4TE02
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to Battery Smart Unit)

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

      Standard Voltage (Battery Block 1)
      Tester Connection Hybrid Battery Cell Switch Condition Specified Condition
      z32-2 (VA7) - z32-15 (VA8) 8 Power switch off 3.0 V or more
      z32-15 (VA8) - z32-11 (VA9) 9 Power switch off 3.0 V or more
      z32-11 (VA9) - z32-7 (VA10) 10 Power switch off 3.0 V or more
      z32-7 (VA10) - z32-16 (VA11) 11 Power switch off 3.0 V or more
      z32-16 (VA11) - z32-12 (VA12) 12 Power switch off 3.0 V or more
      z32-12 (VA12) - z32-8 (VA13) 13 Power switch off 3.0 V or more
      z32-8 (VA13) - z32-4 (VA14) 14 Power switch off 3.0 V or more

      Note

      Make sure to check the polarity of each terminal (positive (+) or negative (-)) before connecting a tester.

    6. Reconnect the z32 battery smart unit connector.

    7. Disconnect the z33 battery smart unit connector.

    8. B005YQJE02
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to Battery Smart Unit)

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

      Standard Voltage (Battery Block 2)
      Tester Connection Hybrid Battery Cell Switch Condition Specified Condition
      z33-11 (GA1) - z33-6 (VA15) 15 Power switch off 3.0 V or more
      z33-6 (VA15) - z33-1 (VA16) 16 Power switch off 3.0 V or more
      z33-1 (VA16) - z33-12 (VA17) 17 Power switch off 3.0 V or more
      z33-12 (VA17) - z33-7 (VA18) 18 Power switch off 3.0 V or more
      z33-7 (VA18) - z33-2 (VA19) 19 Power switch off 3.0 V or more
      z33-2 (VA19) - z33-13 (VA20) 20 Power switch off 3.0 V or more
      z33-13 (VA20) - z33-8 (VA21) 21 Power switch off 3.0 V or more

      Note

      Make sure to check the polarity of each terminal (positive (+) or negative (-)) before connecting a tester.

    9. B005Y29E02
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to Battery Smart Unit)

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

      Standard Voltage (Battery Block 3)
      Tester Connection Hybrid Battery Cell Switch Condition Specified Condition
      z33-8 (VA21) - z33-3 (VA22) 22 Power switch off 3.0 V or more
      z33-3 (VA22) - z33-14 (VA23) 23 Power switch off 3.0 V or more
      z33-14 (VA23) - z33-9 (VA24) 24 Power switch off 3.0 V or more
      z33-9 (VA24) - z33-4 (VA25) 25 Power switch off 3.0 V or more
      z33-4 (VA25) - z33-15 (VA26) 26 Power switch off 3.0 V or more
      z33-15 (VA26) - z33-10 (VA27) 27 Power switch off 3.0 V or more
      z33-10 (VA27) - z33-5 (VA28) 28 Power switch off 3.0 V or more

      Note

      Make sure to check the polarity of each terminal (positive (+) or negative (-)) before connecting a tester.

    10. Reconnect the z33 battery smart unit connector.

    11. Disconnect the z30 battery smart unit connector.

    12. B005ZKAE02
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to Battery Smart Unit)

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

      Standard Voltage (Battery block 4)
      Tester Connection Hybrid Battery Cell Switch Condition Specified Condition
      z30-11 (GA2) - z30-6 (VA29) 29 Power switch off 3.0 V or more
      z30-6 (VA29) - z30-1 (VA30) 30 Power switch off 3.0 V or more
      z30-1 (VA30) - z30-12 (VA31) 31 Power switch off 3.0 V or more
      z30-12 (VA31) - z30-7 (VA32) 32 Power switch off 3.0 V or more
      z30-7 (VA32) - z30-2 (VA33) 33 Power switch off 3.0 V or more
      z30-2 (VA33) - z30-13 (VA34) 34 Power switch off 3.0 V or more
      z30-13 (VA34) - z30-8 (VA35) 35 Power switch off 3.0 V or more

      Note

      Make sure to check the polarity of each terminal (positive (+) or negative (-)) before connecting a tester.

    13. B005Z6AE02
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to Battery Smart Unit)

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

      Standard Voltage (Battery block 5)
      Tester Connection Hybrid Battery Cell Switch Condition Specified Condition
      z30-8 (VA35) - z30-3 (VA36) 36 Power switch off 3.0 V or more
      z30-3 (VA36) - z30-14 (VA37) 37 Power switch off 3.0 V or more
      z30-14 (VA37) - z30-9 (VA38) 38 Power switch off 3.0 V or more
      z30-9 (VA38) - z30-4 (VA39) 39 Power switch off 3.0 V or more
      z30-4 (VA39) - z30-15 (VA40) 40 Power switch off 3.0 V or more
      z30-15 (VA40) - z30-10 (VA41) 41 Power switch off 3.0 V or more
      z30-10 (VA41) - z30-5 (VA42) 42 Power switch off 3.0 V or more

      Note

      Make sure to check the polarity of each terminal (positive (+) or negative (-)) before connecting a tester.

    14. Reconnect the z30 battery smart unit connector.

    15. Disconnect the z31 battery smart unit connector.

    16. B005ZKSE02
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to Battery Smart Unit)

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

      Standard Voltage (Battery Block 6)
      Tester Connection Hybrid Battery Cell Switch Condition Specified Condition
      z31-13 (GA3) - z31-9 (VA43) 43 Power switch off 3.0 V or more
      z31-9 (VA43) - z31-5 (VA44) 44 Power switch off 3.0 V or more
      z31-5 (VA44) - z31-1 (VA45) 45 Power switch off 3.0 V or more
      z31-1 (VA45) - z31-14 (VA46) 46 Power switch off 3.0 V or more
      z31-14 (VA46) - z31-10 (VA47) 47 Power switch off 3.0 V or more
      z31-10 (VA47) - z31-6 (VA48) 48 Power switch off 3.0 V or more
      z31-6 (VA48) - z31-2 (VA49) 49 Power switch off 3.0 V or more

      Note

      Make sure to check the polarity of each terminal (positive (+) or negative (-)) before connecting a tester.

    17. B005XQIE02
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to Battery Smart Unit)

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

      Standard Voltage (Battery Block 7)
      Tester Connection Hybrid Battery Cell Switch Condition Specified Condition
      z31-2 (VA49) - z31-15 (VA50) 50 Power switch off 3.0 V or more
      z31-15 (VA50) - z31-11 (VA51) 51 Power switch off 3.0 V or more
      z31-11 (VA51) - z31-7 (VA52) 52 Power switch off 3.0 V or more
      z31-7 (VA52) - z31-16 (VA53) 53 Power switch off 3.0 V or more
      z31-16 (VA53) - z31-12 (VA54) 54 Power switch off 3.0 V or more
      z31-12 (VA54) - z31-8 (VA55) 55 Power switch off 3.0 V or more
      z31-8 (VA55) - z31-4 (VA56) 56 Power switch off 3.0 V or more

      Note

      Make sure to check the polarity of each terminal (positive (+) or negative (-)) before connecting a tester.

      Result
      Result Proceed to
      The difference between the highest and lowest value is less than 0.3 V and every measured value is 3.0 V or more. A
      Other than above. B

    18. Reconnect the z31 battery smart unit connector.

    19. Install the No. 1 hybrid battery shield sub-assembly.


    A

    REPLACE BATTERY SMART UNIT Click here

    B

  6. CHECK BATTERY SMART UNIT

    Note

    Make sure to use tester probes with a diameter of approximately 0.5 mm (0.0197 in.) when measuring the resistance.


    1. Remove the battery smart unit.

      Click here

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

      Tech Tips


      • If the voltage of any cell of the HV battery was less than 3.0 V, measure the resistance of the battery smart unit at the terminals which relate to that battery cell.

      • If the difference between the highest and lowest measured cell voltage of each battery block is 0.3 V or more, measure the resistance of the battery smart unit at the terminals which relate to the cell with the lowest measured voltage.

      B005ZURC03
      *a

      Component without harness connected

      (Battery Smart Unit)

      		 - -
      Standard Resistance (Battery Block 0)

      Tester Connection

      (Tester Probe Polarity)

      		 Hybrid Battery Cell Condition Specified Condition
      z32-13 (GA0) (-) - z32-9 (VA1) (+) 1 Always 50 kΩ or higher
      z32-9 (VA1) (-) - z32-5 (VA2) (+) 2 Always 50 kΩ or higher
      z32-5 (VA2) (-) - z32-1 (VA3) (+) 3 Always 50 kΩ or higher
      z32-1 (VA3) (-) - z32-14 (VA4) (+) 4 Always 50 kΩ or higher
      z32-14 (VA4) (-) - z32-10 (VA5) (+) 5 Always 50 kΩ or higher
      z32-10 (VA5) (-) - z32-6 (VA6) (+) 6 Always 50 kΩ or higher
      z32-6 (VA6) (-) - z32-2 (VA7) (+) 7 Always 50 kΩ or higher
      z32-13 (GA0) (-) -z32-2 (VA7) (+)

      • 1

      • 2

      • 3

      • 4

      • 5

      • 6

      • 7

      		 Always 350 kΩ or higher
      Standard Resistance (Battery Block 1)

      Tester Connection

      (Tester Probe Polarity)

      		 Hybrid Battery Cell Condition Specified Condition
      z32-2 (VA7) (-) - z32-15 (VA8) (+) 8 Always 50 kΩ or higher
      z32-15 (VA8) (-) - z32-11 (VA9) (+) 9 Always 50 kΩ or higher
      z32-11 (VA9) (-) - z32-7 (VA10) (+) 10 Always 50 kΩ or higher
      z32-7 (VA10) (-) - z32-16 (VA11) (+) 11 Always 50 kΩ or higher
      z32-16 (VA11) (-) - z32-12 (VA12) (+) 12 Always 50 kΩ or higher
      z32-12 (VA12) (-) - z32-8 (VA13) (+) 13 Always 50 kΩ or higher
      z32-8 (VA13) (-) - z32-4 (VA14) (+) 14 Always 50 kΩ or higher
      z32-2 (VA7) (-) - z32-4 (VA14) (+)

      • 8

      • 9

      • 10

      • 11

      • 12

      • 13

      • 14

      		 Always 350 kΩ or higher
      Standard Resistance (Battery Block 2)

      Tester Connection

      (Tester Probe Polarity)

      		 Hybrid Battery Cell Condition Specified Condition
      z33-11 (GA1) (-) - z33-6 (VA15) (+) 15 Always 50 kΩ or higher
      z33-6 (VA15) (-) - z33-1 (VA16) (+) 16 Always 50 kΩ or higher
      z33-1 (VA16) (-) - z33-12 (VA17) (+) 17 Always 50 kΩ or higher
      z33-12 (VA17) (-) - z33-7 (VA18) (+) 18 Always 50 kΩ or higher
      z33-7 (VA18) (-) - z33-2 (VA19) (+) 19 Always 50 kΩ or higher
      z33-2 (VA19) (-) - z33-13 (VA20) (+) 20 Always 50 kΩ or higher
      z33-13 (VA20) (-) - z33-8 (VA21) (+) 21 Always 50 kΩ or higher
      z33-11 (GA1) (-) - z33-8 (VA21) (+)

      • 15

      • 16

      • 17

      • 18

      • 19

      • 20

      • 21

      		 Always 350 kΩ or higher
      Standard Resistance (Battery Block 3)

      Tester Connection

      (Tester Probe Polarity)

      		 Hybrid Battery Cell Condition Specified Condition
      z33-8 (VA21) (-) - z33-3 (VA22) (+) 22 Always 50 kΩ or higher
      z33-3 (VA22) (-) - z33-14 (VA23) (+) 23 Always 50 kΩ or higher
      z33-14 (VA23) (-) - z33-9 (VA24) (+) 24 Always 50 kΩ or higher
      z33-9 (VA24) (-) - z33-4 (VA25) (+) 25 Always 50 kΩ or higher
      z33-4 (VA25) (-) - z33-15 (VA26) (+) 26 Always 50 kΩ or higher
      z33-15 (VA26) (-) - z33-10 (VA27) (+) 27 Always 50 kΩ or higher
      z33-10 (VA27) (-) - z33-5 (VA28) (+) 28 Always 50 kΩ or higher
      z33-8 (VA21) (-) - z33-5 (VA28) (+)

      • 22

      • 23

      • 24

      • 25

      • 26

      • 27

      • 28

      		 Always 350 kΩ or higher
      Standard Resistance (Battery Block 4)

      Tester Connection

      (Tester Probe Polarity)

      		 Hybrid Battery Cell Condition Specified Condition
      z30-11 (GA2) (-) - z30-6 (VA29) (+) 29 Always 50 kΩ or higher
      z30-6 (VA29) (-) - z30-1 (VA30) (+) 30 Always 50 kΩ or higher
      z30-1 (VA30) (-) - z30-12 (VA31) (+) 31 Always 50 kΩ or higher
      z30-12 (VA31) (-) - z30-7 (VA32) (+) 32 Always 50 kΩ or higher
      z30-7 (VA32) (-) - z30-2 (VA33) (+) 33 Always 50 kΩ or higher
      z30-2 (VA33) (-) - z30-13 (VA34) (+) 34 Always 50 kΩ or higher
      z30-13 (VA34) (-) - z30-8 (VA35) (+) 35 Always 50 kΩ or higher
      z30-11 (GA2) (-) - z30-8 (VA35) (+)

      • 29

      • 30

      • 31

      • 32

      • 33

      • 34

      • 35

      		 Always 350 kΩ or higher
      Standard Resistance (Battery Block 5)

      Tester Connection

      (Tester Probe Polarity)

      		 Hybrid Battery Cell Condition Specified Condition
      z30-8 (VA35) (-) - z30-3 (VA36) (+) 36 Always 50 kΩ or higher
      z30-3 (VA36) (-) - z30-14 (VA37) (+) 37 Always 50 kΩ or higher
      z30-14 (VA37) (-) - z30-9 (VA38) (+) 38 Always 50 kΩ or higher
      z30-9 (VA38) (-) - z30-4 (VA39) (+) 39 Always 50 kΩ or higher
      z30-4 (VA39) (-) - z30-15 (VA40) (+) 40 Always 50 kΩ or higher
      z30-15 (VA40) (-) - z30-10 (VA41) (+) 41 Always 50 kΩ or higher
      z30-10 (VA41) (-) - z30-5 (VA42) (+) 42 Always 50 kΩ or higher
      z30-8 (VA35) (-) - z30-5 (VA42) (+)

      • 36

      • 37

      • 38

      • 39

      • 40

      • 41

      • 42

      		 Always 350 kΩ or higher
      Standard Resistance (Battery Block 6)

      Tester Connection

      (Tester Probe Polarity)

      		 Hybrid Battery Cell Condition Specified Condition
      z31-13 (GA3) (-) - z31-9 (VA43) (+) 43 Always 50 kΩ or higher
      z31-9 (VA43) (-) - z31-5 (VA44) (+) 44 Always 50 kΩ or higher
      z31-5 (VA44) (-) - z31-1 (VA45) (+) 45 Always 50 kΩ or higher
      z31-1 (VA45) (-) - z31-14 (VA46) (+) 46 Always 50 kΩ or higher
      z31-14 (VA46) (-) - z31-10 (VA47) (+) 47 Always 50 kΩ or higher
      z31-10 (VA47) (-) - z31-6 (VA48) (+) 48 Always 50 kΩ or higher
      z31-6 (VA48) (-) - z31-2 (VA49) (+) 49 Always 50 kΩ or higher
      z31-13 (GA3) (-) - z31-2 (VA49) (+)

      • 43

      • 44

      • 45

      • 46

      • 47

      • 48

      • 49

      		 Always 350 kΩ or higher
      Standard Resistance (Battery Block 7)

      Tester Connection

      (Tester Probe Polarity)

      		 Hybrid Battery Cell Condition Specified Condition
      z31-2 (VA49) (-) - z31-15 (VA50) (+) 50 Always 50 kΩ or higher
      z31-15 (VA50) (-) - z31-11 (VA51) (+) 51 Always 50 kΩ or higher
      z31-11 (VA51) (-) - z31-7 (VA52) (+) 52 Always 50 kΩ or higher
      z31-7 (VA52) (-) - z31-16 (VA53) (+) 53 Always 50 kΩ or higher
      z31-16 (VA53) (-) - z31-12 (VA54) (+) 54 Always 50 kΩ or higher
      z31-12 (VA54) (-) - z31-8 (VA55) (+) 55 Always 50 kΩ or higher
      z31-8 (VA55) (-) - z31-4 (VA56) (+) 56 Always 50 kΩ or higher
      z31-2 (VA49) (-) - z31-4 (VA56) (+)

      • 50

      • 51

      • 52

      • 53

      • 54

      • 55

      • 56

      		 Always 350 kΩ or higher

      Note


      • Make sure to check the polarity of each terminal (positive (+) or negative (-)) before connecting a tester.

      • Read the resistance after the value has stabilized.

      • In order to avoid damaging the terminals of the battery smart unit, make sure to use tester probes with a diameter of approximately 0.5 mm (0.0197 in.) when measuring the resistance of the battery smart unit.

      Result
      Result Proceed to
      All measured values were within specified range. A
      Other than above. B

    3. Install the battery smart unit.


    A

    REPLACE HV BATTERY Click here

    B

    REPLACE BATTERY SMART UNIT Click here

  7. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

    4. Record the output DTCs.

      Note

      Make a note of the DTCs that will be used in step 10.

      Tech Tips

      The DTCs will be cleared by disconnecting the cable from the negative (-) auxiliary battery terminal in steps 8 and 9.

    5. Turn the power switch off.


    NEXT

  8. REPLACE HV BATTERY

    Click here


    NEXT

  9. REPLACE BATTERY SMART UNIT

    Click here


    NEXT

  10. RECONFIRM DTC OUTPUT (HYBRID CONTROL)


    1. Check the DTCs recorded in step 7.

      Result
      Result Proceed to
      P31B3-123 is not output. A
      DTCs shown in P31B3-123 and Table 1 are output simultaneously. B
      DTCs shown in P31B3-123 and Table 1 are not output simultaneously. C
      Table 1
      DTC No. Relevant Diagnosis
      P0A78-266, 267, 565, 586 Drive Motor "A" Inverter Performance
      P0A94-564, 585, 587, 589, 590 DC/DC Converter Performance

      Tech Tips

      DTC P31B3-123 may be output simultaneously. In this case, troubleshoot the DTCs listed above first. Then, perform a reproduction test to check that no DTCs are output.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    C

    REPLACE HYBRID VEHICLE CONTROL ECU Click here

    A

  11. Utility

    CAUTION:

    Before repairing or replacing the malfunctioning part, do not perform "HV Batt Cell Low Volt READY ON Prevention Cancel".


    1. Perform "HV Batt Cell Low Volt READY ON Prevention Cancel" Click here.


    NEXT

  12. CLEAR DTC (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

    4. Clear the DTCs and freeze frame data.

      Note

      When DTCs are cleared, freeze frame data and INF codes are also cleared.

    5. Turn the power switch off.

    6. Perform a reproduction test.


    NEXT

  13. RECONFIRM DTC OUTPUT (HYBRID CONTROL)


    1. Perform a driving test for about 10 minutes to allow the ECU to store DTCs. If the hybrid system does not start, turn the power switch off and on (READY).

      Tech Tips

      Because 2-trip detection logic is used, the DTC detection conditions need to be met twice.

    2. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

    3. Read output DTCs.

      Result
      Result Proceed to
      P31AB-123 is not output A
      P31AB-123 is output B
      P3004-131 is output C

    4. Turn the power switch off.


    A

    RETURNS TO NORMAL OPERATION

    C

    GO TO DTC CHART (P3004-131) Click here

    B

  14. CHECK CONNECTOR CONNECTION CONDITION (HYBRID VEHICLE CONTROL ECU CONNECTOR)


    1. Check the connector connections and contact pressure of the relevant terminals for the hybrid vehicle control ECU connectors Click here.

      B005ZP3E01
      Text in Illustration
      *A for LHD *B for RHD
      OK
      The connectors are connected securely and there are no contact pressure problems.

    NG

    CONNECT SECURELY

    OK

  15. CHECK FRAME WIRE (INVERTER WITH CONVERTER ASSEMBLY SIDE)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. B005XKK

      Remove the inverter cover from the inverter with converter assembly.

    3. B005ZCNE02

      Check the connection between the frame wire T1 and the inverter with converter assembly.

      Specified Condition
      Bolt A
      8.0 N*m (82 kgf*cm, 71 in.*lbf)
      Bolt B
      9.2 N*m (94 kgf*cm, 81 ft.*lbf)

    4. Check for arc marks on the terminals of the frame wire.

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B

    5. Install the inverter cover to the inverter with converter assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  16. CHECK FRAME WIRE (HYBRID BATTERY JUNCTION BLOCK ASSEMBLY SIDE)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 2 hybrid battery shield sub-assembly Click here.

    3. B005YKOE02

      Check the connection between the frame wire T5, T6 and the hybrid battery junction block assembly.

      Specified Condition
      9.0 N*m (92 kgf*cm, 80 in.*lbf)

    4. Check for arc marks on the terminals of the frame wire.

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B

    5. Install the No. 2 hybrid battery shield sub-assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  17. CHECK FRAME WIRE (INVERTER WITH CONVERTER ASSEMBLY - HYBRID BATTERY JUNCTION BLOCK ASSEMBLY)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. B005XKK

      Remove the inverter cover from the inverter with converter assembly.

    3. B005XJLE02

      Disconnect the frame wire T1 from the inverter with converter assembly.

    4. Remove the No. 2 hybrid battery shield sub-assembly Click here.

    5. B005Z46E02
      Text in Illustration
      *1

      Frame Wire

      (Inverter with Converter Assembly Side)
      *2

      Frame Wire

      (Hybrid Battery Junction Block Assembly)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      T6-1 (CBI) - T1-2 (CBI) Power switch off Below 1 Ω
      T5-1 (CEI) - T1-1 (CEI) Power switch off Below 1 Ω

    6. Install the No. 2 hybrid battery shield sub-assembly.

    7. Connect the frame wire to the inverter with converter assembly.

    8. Install the inverter cover to the inverter with converter assembly.


    NG

    REPLACE FRAME WIRE Click here

    OK

  18. CHECK CONNECTOR CONNECTION CONDITION (HV BATTERY HIGH VOLTAGE CONNECTOR)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 2 hybrid battery shield sub-assembly Click here.

    3. B005YF6E02

      Check the connections between the HV battery high voltage connectors (k3, h3) and the hybrid battery junction block assembly.

      OK
      The connectors are connected securely and not damaged.

    4. Check for arc marks on the terminals of the HV battery high voltage connectors.

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B

    5. Install the No. 2 hybrid battery shield sub-assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  19. CHECK HV BATTERY

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 2 hybrid battery shield sub-assembly Click here.

    3. B005Y8IE02

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      k3-1 (+) - 1 Power switch off 84 V or higher
      h3-1 (-) - 2 Power switch off 84 V or higher

      CAUTION:

      Do not allow the probes of the electrical tester to contact each other during this inspection.

    4. Install the No. 2 hybrid battery shield sub-assembly.


    NG

    REPLACE HV BATTERY Click here

    OK

  20. CHECK HARNESS AND CONNECTOR (HYBRID VEHICLE CONTROL ECU - HYBRID BATTERY JUNCTION BLOCK ASSEMBLY)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Disconnect the L5 hybrid vehicle control ECU connector.

    3. Remove the No. 2 hybrid battery shield sub-assembly Click here.

    4. Disconnect the c6 hybrid battery junction block assembly connector.

      Tech Tips

      Before disconnecting the connector c6 that drives the system main relay of the hybrid battery junction block assembly, make sure that the connector is securely engaged.

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

      B005ZI3E16
      Standard Resistance
      Tester Connection Condition Specified Condition
      L5-4 (SMRB) - c6-4 (SMRB) Power switch off Below 1 Ω
      L5-3 (SMRP) - c6-3 (SMRP) Power switch off Below 1 Ω
      Text in Illustration
      *a

      Rear view of wire harness connector

      (to Hybrid Vehicle Control ECU)
      *b

      Rear view of wire harness connector

      (to Hybrid Battery Junction Block Assembly)

    6. Reconnect the c6 hybrid battery junction block assembly connector.

    7. Install the No. 2 hybrid battery shield sub-assembly.

    8. Reconnect the L5 hybrid vehicle control ECU connector.


    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  21. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRB)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the hybrid battery junction block assembly Click here.

    3. B005Y7SE02
      Text in Illustration
      *a

      Component without harness connected

      (Hybrid Battery Junction Block Assembly)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      k3-1 (+) - T6-1 (CBI) Auxiliary battery voltage is applied between terminals c6-4 (SMRB) and c6-2 (GND) Below 1 Ω

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      c6-4 (SMRB) - c6-2 (GND) -40 to 80 °C (-40 to 176°F) 19.0 to 35.5 Ω

    5. Install the hybrid battery junction block assembly.


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  22. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRP)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the hybrid battery junction block assembly Click here.

    3. B005ZIME02
      Text in Illustration
      *a

      Component without harness connected

      (Hybrid Battery Junction Block Assembly)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      h3-1 (-) - T5-1 (CEI) Auxiliary battery voltage is applied between terminals c6-3 (SMRP) and c6-2 (GND) 28.5 to 31.5 Ω

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      c6-3 (SMRP) - c6-2 (GND) -40 to 80 °C (-40 to 176°F) 112 to 274 Ω

    5. Install the hybrid battery junction block assembly.


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  23. CHECK FOR INTERMITTENT PROBLEMS

    Click here


    OK

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    NG

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

  24. REPLACE BATTERY SMART UNIT

    Click here


    NEXT

    REPLACE HV BATTERY Click here