HYBRID BATTERY SYSTEM, Diagnostic DTC:P31AB-123

DESCRIPTION

• The power management control ECU alerts the driver and performs fail-safe control based on error signals sent from the battery smart unit.

  DTC No.	INF Code	DTC Detection Condition	Trouble Area
  P31AB	123	When battery cells are over discharged (1 trip detection)	HV battery Battery smart unit Frame wire Wire harness or connector Hybrid battery junction block assembly Inverter with converter assembly

WIRING DIAGRAM

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

CAUTION / NOTICE / HINT

PROCEDURE

1. READ VALUE USING GTS (PM ECU - Batt Line 1 Volt and Batt Line 2 Volt)

   
   

   1. Connect the GTS to the DLC3.

   2. Turn the power switch on (IG).

   3. Enter the following menus: Powertrain / Hybrid Control / Data List / PM ECU - Batt Line 1 Volt and Batt Line 2 Volt.

      Result
      Tester Display Result Proceed to PM ECU - Batt Line 1 Volt and Batt Line 2 Volt Hi A PM ECU - Batt Line 1 Volt and Batt Line 2 Volt Lo B

   
   

   B

   CHECK DTC OUTPUT (HYBRID CONTROL) Click here

   A

2. 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

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. 

      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. 2012/05 - 2013/12:

      
      

      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 z26 battery smart unit connector.

      4. 

         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 z26-13 (GA0) - z26-9 (VA1) 1 Power switch off 3.0 V or more z26-9 (VA1) - z26-5 (VA2) 2 Power switch off 3.0 V or more z26-5 (VA2) - z26-1 (VA3) 3 Power switch off 3.0 V or more z26-1 (VA3) - z26-14 (VA4) 4 Power switch off 3.0 V or more z26-14 (VA4) - z26-10 (VA5) 5 Power switch off 3.0 V or more z26-10 (VA5) - z26-6 (VA6) 6 Power switch off 3.0 V or more z26-6 (VA6) - z26-2 (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. 

         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 z26-2 (VA7) - z26-15 (VA8) 8 Power switch off 3.0 V or more z26-15 (VA8) - z26-11 (VA9) 9 Power switch off 3.0 V or more z26-11 (VA9) - z26-7 (VA10) 10 Power switch off 3.0 V or more z26-7 (VA10) - z26-16 (VA11) 11 Power switch off 3.0 V or more z26-16 (VA11) - z26-12 (VA12) 12 Power switch off 3.0 V or more z26-12 (VA12) - z26-8 (VA13) 13 Power switch off 3.0 V or more z26-8 (VA13) - z26-4 (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 z26 battery smart unit connector.

      7. Disconnect the z27 battery smart unit connector.

      8. 

         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 z27-11 (GA1) - z27-6 (VA15) 15 Power switch off 3.0 V or more z27-6 (VA15) - z27-1 (VA16) 16 Power switch off 3.0 V or more z27-1 (VA16) - z27-12 (VA17) 17 Power switch off 3.0 V or more z27-12 (VA17) - z27-7 (VA18) 18 Power switch off 3.0 V or more z27-7 (VA18) - z27-2 (VA19) 19 Power switch off 3.0 V or more z27-2 (VA19) - z27-13 (VA20) 20 Power switch off 3.0 V or more z27-13 (VA20) - z27-8 (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. 

         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 z27-8 (VA21) - z27-3 (VA22) 22 Power switch off 3.0 V or more z27-3 (VA22) - z27-14 (VA23) 23 Power switch off 3.0 V or more z27-14 (VA23) - z27-9 (VA24) 24 Power switch off 3.0 V or more z27-9 (VA24) - z27-4 (VA25) 25 Power switch off 3.0 V or more z27-4 (VA25) - z27-15 (VA26) 26 Power switch off 3.0 V or more z27-15 (VA26) - z27-10 (VA27) 27 Power switch off 3.0 V or more z27-10 (VA27) - z27-5 (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 z27 battery smart unit connector.

      11. Disconnect the z22 battery smart unit connector.

      12. 

          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 z22-11 (GA2) - z22-6 (VA29) 29 Power switch off 3.0 V or more z22-6 (VA29) - z22-1 (VA30) 30 Power switch off 3.0 V or more z22-1 (VA30) - z22-12 (VA31) 31 Power switch off 3.0 V or more z22-12 (VA31) - z22-7 (VA32) 32 Power switch off 3.0 V or more z22-7 (VA32) - z22-2 (VA33) 33 Power switch off 3.0 V or more z22-2 (VA33) - z22-13 (VA34) 34 Power switch off 3.0 V or more z22-13 (VA34) - z22-8 (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. 

          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 z22-8 (VA35) - z22-3 (VA36) 36 Power switch off 3.0 V or more z22-3 (VA36) - z22-14 (VA37) 37 Power switch off 3.0 V or more z22-14 (VA37) - z22-9 (VA38) 38 Power switch off 3.0 V or more z22-9 (VA38) - z22-4 (VA39) 39 Power switch off 3.0 V or more z22-4 (VA39) - z22-15 (VA40) 40 Power switch off 3.0 V or more z22-15 (VA40) - z22-10 (VA41) 41 Power switch off 3.0 V or more z22-10 (VA41) - z22-5 (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 z22 battery smart unit connector.

      15. Disconnect the z23 battery smart unit connector.

      16. 

          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 z23-13 (GA3) - z23-9 (VA43) 43 Power switch off 3.0 V or more z23-9 (VA43) - z23-5 (VA44) 44 Power switch off 3.0 V or more z23-5 (VA44) - z23-1 (VA45) 45 Power switch off 3.0 V or more z23-1 (VA45) - z23-14 (VA46) 46 Power switch off 3.0 V or more z23-14 (VA46) - z23-10 (VA47) 47 Power switch off 3.0 V or more z23-10 (VA47) - z23-6 (VA48) 48 Power switch off 3.0 V or more z23-6 (VA48) - z23-2 (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. 

          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 z23-2 (VA49) - z23-15 (VA50) 50 Power switch off 3.0 V or more z23-15 (VA50) - z23-11 (VA51) 51 Power switch off 3.0 V or more z23-11 (VA51) - z23-7 (VA52) 52 Power switch off 3.0 V or more z23-7 (VA52) - z23-16 (VA53) 53 Power switch off 3.0 V or more z23-16 (VA53) - z23-12 (VA54) 54 Power switch off 3.0 V or more z23-12 (VA54) - z23-8 (VA55) 55 Power switch off 3.0 V or more z23-8 (VA55) - z23-4 (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 z23 battery smart unit connector.

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

   2. 2013/12 -:

      
      

      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. 

         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. 

         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. 

         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. 

         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. 

          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. 

          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. 

          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. 

          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. 2012/05 - 2013/12:

      
      

      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.

         

         *a

         Component without harness connected (Battery Smart Unit)

         -

         -

         Standard Resistance (Battery Block 0)

         Tester Connection (Tester Probe Polarity) Hybrid Battery Cell Condition Specified Condition z26-13 (GA0) (-) - z26-9 (VA1) (+) 1 Always 50 kΩ or higher z26-9 (VA1) (-) - z26-5 (VA2) (+) 2 Always 50 kΩ or higher z26-5 (VA2) (-) - z26-1 (VA3) (+) 3 Always 50 kΩ or higher z26-1 (VA3) (-) - z26-14 (VA4) (+) 4 Always 50 kΩ or higher z26-14 (VA4) (-) - z26-10 (VA5) (+) 5 Always 50 kΩ or higher z26-10 (VA5) (-) - z26-6 (VA6) (+) 6 Always 50 kΩ or higher z26-6 (VA6) (-) - z26-2 (VA7) (+) 7 Always 50 kΩ or higher z26-13 (GA0) (-) -z26-2 (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 z26-2 (VA7) (-) - z26-15 (VA8) (+) 8 Always 50 kΩ or higher z26-15 (VA8) (-) - z26-11 (VA9) (+) 9 Always 50 kΩ or higher z26-11 (VA9) (-) - z26-7 (VA10) (+) 10 Always 50 kΩ or higher z26-7 (VA10) (-) - z26-16 (VA11) (+) 11 Always 50 kΩ or higher z26-16 (VA11) (-) - z26-12 (VA12) (+) 12 Always 50 kΩ or higher z26-12 (VA12) (-) - z26-8 (VA13) (+) 13 Always 50 kΩ or higher z26-8 (VA13) (-) - z26-4 (VA14) (+) 14 Always 50 kΩ or higher z26-2 (VA7) (-) - z26-4 (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 z27-11 (GA1) (-) - z27-6 (VA15) (+) 15 Always 50 kΩ or higher z27-6 (VA15) (-) - z27-1 (VA16) (+) 16 Always 50 kΩ or higher z27-1 (VA16) (-) - z27-12 (VA17) (+) 17 Always 50 kΩ or higher z27-12 (VA17) (-) - z27-7 (VA18) (+) 18 Always 50 kΩ or higher z27-7 (VA18) (-) - z27-2 (VA19) (+) 19 Always 50 kΩ or higher z27-2 (VA19) (-) - z27-13 (VA20) (+) 20 Always 50 kΩ or higher z27-13 (VA20) (-) - z27-8 (VA21) (+) 21 Always 50 kΩ or higher z27-11 (GA1) (-) - z27-8 (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 z27-8 (VA21) (-) - z27-3 (VA22) (+) 22 Always 50 kΩ or higher z27-3 (VA22) (-) - z27-14 (VA23) (+) 23 Always 50 kΩ or higher z27-14 (VA23) (-) - z27-9 (VA24) (+) 24 Always 50 kΩ or higher z27-9 (VA24) (-) - z27-4 (VA25) (+) 25 Always 50 kΩ or higher z27-4 (VA25) (-) - z27-15 (VA26) (+) 26 Always 50 kΩ or higher z27-15 (VA26) (-) - z27-10 (VA27) (+) 27 Always 50 kΩ or higher z27-10 (VA27) (-) - z27-5 (VA28) (+) 28 Always 50 kΩ or higher z27-8 (VA21) (-) - z27-5 (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 z22-11 (GA2) (-) - z22-6 (VA29) (+) 29 Always 50 kΩ or higher z22-6 (VA29) (-) - z22-1 (VA30) (+) 30 Always 50 kΩ or higher z22-1 (VA30) (-) - z22-12 (VA31) (+) 31 Always 50 kΩ or higher z22-12 (VA31) (-) - z22-7 (VA32) (+) 32 Always 50 kΩ or higher z22-7 (VA32) (-) - z22-2 (VA33) (+) 33 Always 50 kΩ or higher z22-2 (VA33) (-) - z22-13 (VA34) (+) 34 Always 50 kΩ or higher z22-13 (VA34) (-) - z22-8 (VA35) (+) 35 Always 50 kΩ or higher z22-11 (GA2) (-) - z22-8 (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 z22-8 (VA35) (-) - z22-3 (VA36) (+) 36 Always 50 kΩ or higher z22-3 (VA36) (-) - z22-14 (VA37) (+) 37 Always 50 kΩ or higher z22-14 (VA37) (-) - z22-9 (VA38) (+) 38 Always 50 kΩ or higher z22-9 (VA38) (-) - z22-4 (VA39) (+) 39 Always 50 kΩ or higher z22-4 (VA39) (-) - z22-15 (VA40) (+) 40 Always 50 kΩ or higher z22-15 (VA40) (-) - z22-10 (VA41) (+) 41 Always 50 kΩ or higher z22-10 (VA41) (-) - z22-5 (VA42) (+) 42 Always 50 kΩ or higher z22-8 (VA35) (-) - z22-5 (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 z23-13 (GA3) (-) - z23-9 (VA43) (+) 43 Always 50 kΩ or higher z23-9 (VA43) (-) - z23-5 (VA44) (+) 44 Always 50 kΩ or higher z23-5 (VA44) (-) - z23-1 (VA45) (+) 45 Always 50 kΩ or higher z23-1 (VA45) (-) - z23-14 (VA46) (+) 46 Always 50 kΩ or higher z23-14 (VA46) (-) - z23-10 (VA47) (+) 47 Always 50 kΩ or higher z23-10 (VA47) (-) - z23-6 (VA48) (+) 48 Always 50 kΩ or higher z23-6 (VA48) (-) - z23-2 (VA49) (+) 49 Always 50 kΩ or higher z23-13 (GA3) (-) - z23-2 (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 z23-2 (VA49) (-) - z23-15 (VA50) (+) 50 Always 50 kΩ or higher z23-15 (VA50) (-) - z23-11 (VA51) (+) 51 Always 50 kΩ or higher z23-11 (VA51) (-) - z23-7 (VA52) (+) 52 Always 50 kΩ or higher z23-7 (VA52) (-) - z23-16 (VA53) (+) 53 Always 50 kΩ or higher z23-16 (VA53) (-) - z23-12 (VA54) (+) 54 Always 50 kΩ or higher z23-12 (VA54) (-) - z23-8 (VA55) (+) 55 Always 50 kΩ or higher z23-8 (VA55) (-) - z23-4 (VA56) (+) 56 Always 50 kΩ or higher z23-2 (VA49) (-) - z23-4 (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.

      3. Install the battery smart unit.

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

   2. 2013/12 -:

      
      

      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.

         

         *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.

      3. Install the battery smart unit.

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

   
   

   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. 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

8. 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

9. 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

10. 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. 

       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

11. CHECK HV BATTERY (BATTERY CELL VOLTAGE)

    CAUTION:

    Be sure to wear insulated gloves.

    
    

    1. 2012/05 - 2013/12:

       
       

       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 z26 battery smart unit connector.

       4. 

          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 z26-13 (GA0) - z26-9 (VA1) 1 Power switch off 3.0 V or more z26-9 (VA1) - z26-5 (VA2) 2 Power switch off 3.0 V or more z26-5 (VA2) - z26-1 (VA3) 3 Power switch off 3.0 V or more z26-1 (VA3) - z26-14 (VA4) 4 Power switch off 3.0 V or more z26-14 (VA4) - z26-10 (VA5) 5 Power switch off 3.0 V or more z26-10 (VA5) - z26-6 (VA6) 6 Power switch off 3.0 V or more z26-6 (VA6) - z26-2 (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. 

          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 z26-2 (VA7) - z26-15 (VA8) 8 Power switch off 3.0 V or more z26-15 (VA8) - z26-11 (VA9) 9 Power switch off 3.0 V or more z26-11 (VA9) - z26-7 (VA10) 10 Power switch off 3.0 V or more z26-7 (VA10) - z26-16 (VA11) 11 Power switch off 3.0 V or more z26-16 (VA11) - z26-12 (VA12) 12 Power switch off 3.0 V or more z26-12 (VA12) - z26-8 (VA13) 13 Power switch off 3.0 V or more z26-8 (VA13) - z26-4 (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 z26 battery smart unit connector.

       7. Disconnect the z27 battery smart unit connector.

       8. 

          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 z27-11 (GA1) - z27-6 (VA15) 15 Power switch off 3.0 V or more z27-6 (VA15) - z27-1 (VA16) 16 Power switch off 3.0 V or more z27-1 (VA16) - z27-12 (VA17) 17 Power switch off 3.0 V or more z27-12 (VA17) - z27-7 (VA18) 18 Power switch off 3.0 V or more z27-7 (VA18) - z27-2 (VA19) 19 Power switch off 3.0 V or more z27-2 (VA19) - z27-13 (VA20) 20 Power switch off 3.0 V or more z27-13 (VA20) - z27-8 (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. 

          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 z27-8 (VA21) - z27-3 (VA22) 22 Power switch off 3.0 V or more z27-3 (VA22) - z27-14 (VA23) 23 Power switch off 3.0 V or more z27-14 (VA23) - z27-9 (VA24) 24 Power switch off 3.0 V or more z27-9 (VA24) - z27-4 (VA25) 25 Power switch off 3.0 V or more z27-4 (VA25) - z27-15 (VA26) 26 Power switch off 3.0 V or more z27-15 (VA26) - z27-10 (VA27) 27 Power switch off 3.0 V or more z27-10 (VA27) - z27-5 (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 z27 battery smart unit connector.

       11. Disconnect the z22 battery smart unit connector.

       12. 

           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 z22-11 (GA2) - z22-6 (VA29) 29 Power switch off 3.0 V or more z22-6 (VA29) - z22-1 (VA30) 30 Power switch off 3.0 V or more z22-1 (VA30) - z22-12 (VA31) 31 Power switch off 3.0 V or more z22-12 (VA31) - z22-7 (VA32) 32 Power switch off 3.0 V or more z22-7 (VA32) - z22-2 (VA33) 33 Power switch off 3.0 V or more z22-2 (VA33) - z22-13 (VA34) 34 Power switch off 3.0 V or more z22-13 (VA34) - z22-8 (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. 

           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 z22-8 (VA35) - z22-3 (VA36) 36 Power switch off 3.0 V or more z22-3 (VA36) - z22-14 (VA37) 37 Power switch off 3.0 V or more z22-14 (VA37) - z22-9 (VA38) 38 Power switch off 3.0 V or more z22-9 (VA38) - z22-4 (VA39) 39 Power switch off 3.0 V or more z22-4 (VA39) - z22-15 (VA40) 40 Power switch off 3.0 V or more z22-15 (VA40) - z22-10 (VA41) 41 Power switch off 3.0 V or more z22-10 (VA41) - z22-5 (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 z22 battery smart unit connector.

       15. Disconnect the z23 battery smart unit connector.

       16. 

           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 z23-13 (GA3) - z23-9 (VA43) 43 Power switch off 3.0 V or more z23-9 (VA43) - z23-5 (VA44) 44 Power switch off 3.0 V or more z23-5 (VA44) - z23-1 (VA45) 45 Power switch off 3.0 V or more z23-1 (VA45) - z23-14 (VA46) 46 Power switch off 3.0 V or more z23-14 (VA46) - z23-10 (VA47) 47 Power switch off 3.0 V or more z23-10 (VA47) - z23-6 (VA48) 48 Power switch off 3.0 V or more z23-6 (VA48) - z23-2 (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. 

           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 z23-2 (VA49) - z23-15 (VA50) 50 Power switch off 3.0 V or more z23-15 (VA50) - z23-11 (VA51) 51 Power switch off 3.0 V or more z23-11 (VA51) - z23-7 (VA52) 52 Power switch off 3.0 V or more z23-7 (VA52) - z23-16 (VA53) 53 Power switch off 3.0 V or more z23-16 (VA53) - z23-12 (VA54) 54 Power switch off 3.0 V or more z23-12 (VA54) - z23-8 (VA55) 55 Power switch off 3.0 V or more z23-8 (VA55) - z23-4 (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 z23 battery smart unit connector.

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

    2. 2013/12 -:

       
       

       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. 

          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. 

          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. 

          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. 

          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. 

           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. 

           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. 

           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. 

           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

12. 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. 2012/05 - 2013/12:

       
       

       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.

          

          *a

          Component without harness connected (Battery Smart Unit)

          -

          -

          Standard Resistance (Battery Block 0)

          Tester Connection (Tester Probe Polarity) Hybrid Battery Cell Condition Specified Condition z26-13 (GA0) (-) - z26-9 (VA1) (+) 1 Always 50 kΩ or higher z26-9 (VA1) (-) - z26-5 (VA2) (+) 2 Always 50 kΩ or higher z26-5 (VA2) (-) - z26-1 (VA3) (+) 3 Always 50 kΩ or higher z26-1 (VA3) (-) - z26-14 (VA4) (+) 4 Always 50 kΩ or higher z26-14 (VA4) (-) - z26-10 (VA5) (+) 5 Always 50 kΩ or higher z26-10 (VA5) (-) - z26-6 (VA6) (+) 6 Always 50 kΩ or higher z26-6 (VA6) (-) - z26-2 (VA7) (+) 7 Always 50 kΩ or higher z26-13 (GA0) (-) -z26-2 (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 z26-2 (VA7) (-) - z26-15 (VA8) (+) 8 Always 50 kΩ or higher z26-15 (VA8) (-) - z26-11 (VA9) (+) 9 Always 50 kΩ or higher z26-11 (VA9) (-) - z26-7 (VA10) (+) 10 Always 50 kΩ or higher z26-7 (VA10) (-) - z26-16 (VA11) (+) 11 Always 50 kΩ or higher z26-16 (VA11) (-) - z26-12 (VA12) (+) 12 Always 50 kΩ or higher z26-12 (VA12) (-) - z26-8 (VA13) (+) 13 Always 50 kΩ or higher z26-8 (VA13) (-) - z26-4 (VA14) (+) 14 Always 50 kΩ or higher z26-2 (VA7) (-) - z26-4 (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 z27-11 (GA1) (-) - z27-6 (VA15) (+) 15 Always 50 kΩ or higher z27-6 (VA15) (-) - z27-1 (VA16) (+) 16 Always 50 kΩ or higher z27-1 (VA16) (-) - z27-12 (VA17) (+) 17 Always 50 kΩ or higher z27-12 (VA17) (-) - z27-7 (VA18) (+) 18 Always 50 kΩ or higher z27-7 (VA18) (-) - z27-2 (VA19) (+) 19 Always 50 kΩ or higher z27-2 (VA19) (-) - z27-13 (VA20) (+) 20 Always 50 kΩ or higher z27-13 (VA20) (-) - z27-8 (VA21) (+) 21 Always 50 kΩ or higher z27-11 (GA1) (-) - z27-8 (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 z27-8 (VA21) (-) - z27-3 (VA22) (+) 22 Always 50 kΩ or higher z27-3 (VA22) (-) - z27-14 (VA23) (+) 23 Always 50 kΩ or higher z27-14 (VA23) (-) - z27-9 (VA24) (+) 24 Always 50 kΩ or higher z27-9 (VA24) (-) - z27-4 (VA25) (+) 25 Always 50 kΩ or higher z27-4 (VA25) (-) - z27-15 (VA26) (+) 26 Always 50 kΩ or higher z27-15 (VA26) (-) - z27-10 (VA27) (+) 27 Always 50 kΩ or higher z27-10 (VA27) (-) - z27-5 (VA28) (+) 28 Always 50 kΩ or higher z27-8 (VA21) (-) - z27-5 (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 z22-11 (GA2) (-) - z22-6 (VA29) (+) 29 Always 50 kΩ or higher z22-6 (VA29) (-) - z22-1 (VA30) (+) 30 Always 50 kΩ or higher z22-1 (VA30) (-) - z22-12 (VA31) (+) 31 Always 50 kΩ or higher z22-12 (VA31) (-) - z22-7 (VA32) (+) 32 Always 50 kΩ or higher z22-7 (VA32) (-) - z22-2 (VA33) (+) 33 Always 50 kΩ or higher z22-2 (VA33) (-) - z22-13 (VA34) (+) 34 Always 50 kΩ or higher z22-13 (VA34) (-) - z22-8 (VA35) (+) 35 Always 50 kΩ or higher z22-11 (GA2) (-) - z22-8 (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 z22-8 (VA35) (-) - z22-3 (VA36) (+) 36 Always 50 kΩ or higher z22-3 (VA36) (-) - z22-14 (VA37) (+) 37 Always 50 kΩ or higher z22-14 (VA37) (-) - z22-9 (VA38) (+) 38 Always 50 kΩ or higher z22-9 (VA38) (-) - z22-4 (VA39) (+) 39 Always 50 kΩ or higher z22-4 (VA39) (-) - z22-15 (VA40) (+) 40 Always 50 kΩ or higher z22-15 (VA40) (-) - z22-10 (VA41) (+) 41 Always 50 kΩ or higher z22-10 (VA41) (-) - z22-5 (VA42) (+) 42 Always 50 kΩ or higher z22-8 (VA35) (-) - z22-5 (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 z23-13 (GA3) (-) - z23-9 (VA43) (+) 43 Always 50 kΩ or higher z23-9 (VA43) (-) - z23-5 (VA44) (+) 44 Always 50 kΩ or higher z23-5 (VA44) (-) - z23-1 (VA45) (+) 45 Always 50 kΩ or higher z23-1 (VA45) (-) - z23-14 (VA46) (+) 46 Always 50 kΩ or higher z23-14 (VA46) (-) - z23-10 (VA47) (+) 47 Always 50 kΩ or higher z23-10 (VA47) (-) - z23-6 (VA48) (+) 48 Always 50 kΩ or higher z23-6 (VA48) (-) - z23-2 (VA49) (+) 49 Always 50 kΩ or higher z23-13 (GA3) (-) - z23-2 (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 z23-2 (VA49) (-) - z23-15 (VA50) (+) 50 Always 50 kΩ or higher z23-15 (VA50) (-) - z23-11 (VA51) (+) 51 Always 50 kΩ or higher z23-11 (VA51) (-) - z23-7 (VA52) (+) 52 Always 50 kΩ or higher z23-7 (VA52) (-) - z23-16 (VA53) (+) 53 Always 50 kΩ or higher z23-16 (VA53) (-) - z23-12 (VA54) (+) 54 Always 50 kΩ or higher z23-12 (VA54) (-) - z23-8 (VA55) (+) 55 Always 50 kΩ or higher z23-8 (VA55) (-) - z23-4 (VA56) (+) 56 Always 50 kΩ or higher z23-2 (VA49) (-) - z23-4 (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.

       3. Install the battery smart unit.

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

    2. 2013/12 -:

       
       

       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.

          

          *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.

       3. Install the battery smart unit.

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

    
    

    A

    REPLACE HV BATTERY Click here

    B

    REPLACE BATTERY SMART UNIT Click here

13. 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 16.

       Tech Tips

       The DTCs will be cleared by disconnecting the cable from the negative (-) auxiliary battery terminal in steps 14 and 15.

    5. Turn the power switch off.

    
    

    NEXT

14. REPLACE HV BATTERY

    Click here

    
    

    NEXT

15. REPLACE BATTERY SMART UNIT

    Click here

    
    

    NEXT

16. RECONFIRM DTC OUTPUT (HYBRID CONTROL)

    
    

    1. Check the DTCs recorded in step 13.

       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 POWER MANAGEMENT CONTROL ECU Click here

    A

17. 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

18. 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

19. 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

20. CHECK CONNECTOR CONNECTION CONDITION (POWER MANAGEMENT CONTROL ECU CONNECTOR)

    
    

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

       

       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

21. 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. 

       Remove the inverter cover from the inverter with converter assembly.

    3. 

       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

22. 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. 

       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

23. 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. 

       Remove the inverter cover from the inverter with converter assembly.

    3. 

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

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

    5. 

       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

24. 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. 

       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

25. 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. 

       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

26. CHECK HARNESS AND CONNECTOR (POWER MANAGEMENT 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 power management 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.

       

       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 Power Management 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 power management control ECU connector.

    
    

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

27. 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. 

       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

28. 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. 

       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

29. CHECK FOR INTERMITTENT PROBLEMS

    Click here

    
    

    OK

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    NG

    REPLACE INVERTER WITH CONVERTER ASSEMBLY Click here

30. REPLACE BATTERY SMART UNIT

    Click here

    
    

    NEXT

    REPLACE HV BATTERY Click here