HYBRID BATTERY SYSTEM, Diagnostic DTC:P0A9B11, P0A9B15, P0AC511, P0AC515, P0ACA11, P0ACA15, P0AE811, P0AE815, P0BC211, P0BC215, P0C3311, P0C3315

DTC Code DTC Name
P0A9B11 Hybrid/EV Battery Temperature Sensor "A" Circuit Short to Ground
P0A9B15 Hybrid/EV Battery Temperature Sensor "A" Circuit Short to Auxiliary Battery or Open
P0AC511 Hybrid/EV Battery Temperature Sensor "B" Circuit Short to Ground
P0AC515 Hybrid/EV Battery Temperature Sensor "B" Circuit Short to Auxiliary Battery or Open
P0ACA11 Hybrid/EV Battery Temperature Sensor "C" Circuit Short to Ground
P0ACA15 Hybrid/EV Battery Temperature Sensor "C" Circuit Short to Auxiliary Battery or Open
P0AE811 Hybrid/EV Battery Temperature Sensor "D" Circuit Short to Ground
P0AE815 Hybrid/EV Battery Temperature Sensor "D" Circuit Short to Auxiliary Battery or Open
P0BC211 Hybrid/EV Battery Temperature Sensor "E" Circuit Short to Ground
P0BC215 Hybrid/EV Battery Temperature Sensor "E" Circuit Short to Auxiliary Battery or Open
P0C3311 Hybrid/EV Battery Temperature Sensor "F" Circuit Short to Ground
P0C3315 Hybrid/EV Battery Temperature Sensor "F" Circuit Short to Auxiliary Battery or Open

DESCRIPTION

The battery temperature sensors are provided at 6 locations of the HV battery. The resistance of the thermistor, which is built into each battery temperature sensor, varies in accordance with changes in the HV battery temperature. The lower the battery temperature, the higher the thermistor resistance. Conversely, the higher the temperature, the lower the resistance. The battery ECU assembly uses the battery temperature sensors to detect the HV battery temperature, and sends the detected value to the battery ECU assembly. Based on the results of this detection, the battery ECU assembly controls the blower fan. (The blower fan starts when the HV battery temperature rises above a predetermined level.)

Temperature Sensor Identification Cross Reference Table
DTC Title Sensor Battery Temperature Sensor GTS Display
A 0 1
B 1 2
C 2 3
D 3 4
E 4 5
F 5 6

Tech Tips

Use the reference table above to determine which battery temperature sensor corresponds to each DTC. For example, sensor A in the DTC title column is battery temperature sensor 0. This sensor is displayed as Hybrid Battery Temperature 1 in the Data List.

B004CEYE05
DTC No. Detection Item DTC Detection Condition Trouble Area MIL Warning Indicate
P0A9B11 Hybrid/EV Battery Temperature Sensor "A" Circuit Short to Ground

The battery temperature sensor is malfunctioning, its output voltage is lower than the specified value (short circuit) and the detected temperature is higher than the specified value.

(1 trip detection logic)

  • No. 1 HV supply stack sub-assembly

  • HV battery junction block assembly

  • Battery ECU assembly

  • Wire harness or connector

 Comes on

Master Warning Light:

Comes on
P0A9B15 Hybrid/EV Battery Temperature Sensor "A" Circuit Short to Auxiliary Battery or Open

The battery temperature sensor is malfunctioning, its output voltage is higher than the specified value (short to +B or open) and the detected temperature is lower than the specified value.

(1 trip detection logic)

  • No. 1 HV supply stack sub-assembly

  • HV battery junction block assembly

  • Battery ECU assembly

  • Wire harness or connector

 Comes on

Master Warning Light:

Comes on
P0AC511 Hybrid/EV Battery Temperature Sensor "B" Circuit Short to Ground

The battery temperature sensor is malfunctioning, its output voltage is lower than the specified value (short circuit) and the detected temperature is higher than the specified value.

(1 trip detection logic)

  • No. 1 HV supply stack sub-assembly

  • HV battery junction block assembly

  • Battery ECU assembly

  • Wire harness or connector

 Comes on

Master Warning Light:

Comes on
P0AC515 Hybrid/EV Battery Temperature Sensor "B" Circuit Short to Auxiliary Battery or Open

The battery temperature sensor is malfunctioning, its output voltage is higher than the specified value (short to +B or open) and the detected temperature is lower than the specified value.

(1 trip detection logic)

  • No. 1 HV supply stack sub-assembly

  • HV battery junction block assembly

  • Battery ECU assembly

  • Wire harness or connector

 Comes on

Master Warning Light:

Comes on
P0ACA11 Hybrid/EV Battery Temperature Sensor "C" Circuit Short to Ground

The battery temperature sensor is malfunctioning, its output voltage is lower than the specified value (short circuit) and the detected temperature is higher than the specified value.

(1 trip detection logic)

  • No. 1 HV supply stack sub-assembly

  • HV battery junction block assembly

  • Battery ECU assembly

  • Wire harness or connector

 Comes on

Master Warning Light:

Comes on
P0ACA15 Hybrid/EV Battery Temperature Sensor "C" Circuit Short to Auxiliary Battery or Open

The battery temperature sensor is malfunctioning, its output voltage is higher than the specified value (short to +B or open) and the detected temperature is lower than the specified value.

(1 trip detection logic)

  • No. 1 HV supply stack sub-assembly

  • HV battery junction block assembly

  • Battery ECU assembly

  • Wire harness or connector

 Comes on

Master Warning Light:

Comes on
P0AE811 Hybrid/EV Battery Temperature Sensor "D" Circuit Short to Ground

The battery temperature sensor is malfunctioning, its output voltage is lower than the specified value (short circuit) and the detected temperature is higher than the specified value.

(1 trip detection logic)

  • No. 2 HV supply stack sub-assembly

  • HV battery junction block assembly

  • Battery ECU assembly

  • Wire harness or connector

 Comes on

Master Warning Light:

Comes on
P0AE815 Hybrid/EV Battery Temperature Sensor "D" Circuit Short to Auxiliary Battery or Open

The battery temperature sensor is malfunctioning, its output voltage is higher than the specified value (short to +B or open) and the detected temperature is lower than the specified value.

(1 trip detection logic)

  • No. 2 HV supply stack sub-assembly

  • HV battery junction block assembly

  • Battery ECU assembly

  • Wire harness or connector

 Comes on

Master Warning Light:

Comes on
P0BC211 Hybrid/EV Battery Temperature Sensor "E" Circuit Short to Ground

The battery temperature sensor is malfunctioning, its output voltage is lower than the specified value (short circuit) and the detected temperature is higher than the specified value.

(1 trip detection logic)

  • No. 2 HV supply stack sub-assembly

  • HV battery junction block assembly

  • Battery ECU assembly

  • Wire harness or connector

 Comes on

Master Warning Light:

Comes on
P0BC215 Hybrid/EV Battery Temperature Sensor "E" Circuit Short to Auxiliary Battery or Open

The battery temperature sensor is malfunctioning, its output voltage is higher than the specified value (short to +B or open) and the detected temperature is lower than the specified value.

(1 trip detection logic)

  • No. 2 HV supply stack sub-assembly

  • HV battery junction block assembly

  • Battery ECU assembly

  • Wire harness or connector

 Comes on

Master Warning Light:

Comes on
P0C3311 Hybrid/EV Battery Temperature Sensor "F" Circuit Short to Ground

The battery temperature sensor is malfunctioning, its output voltage is lower than the specified value (short circuit) and the detected temperature is higher than the specified value.

(1 trip detection logic)

  • No. 2 HV supply stack sub-assembly

  • HV battery junction block assembly

  • Battery ECU assembly

  • Wire harness or connector

 Comes on

Master Warning Light:

Comes on
P0C3315 Hybrid/EV Battery Temperature Sensor "F" Circuit Short to Auxiliary Battery or Open

The battery temperature sensor is malfunctioning, its output voltage is higher than the specified value (short to +B or open) and the detected temperature is lower than the specified value.

(1 trip detection logic)

  • No. 2 HV supply stack sub-assembly

  • HV battery junction block assembly

  • Battery ECU assembly

  • Wire harness or connector

 Comes on

Master Warning Light:

Comes on
Temperature Displayed Malfunction
Below -45°C (-49°F) Open or +B short circuit
95°C (203°F) or more GND short circuit
Related Data List
DTC No. Data List
P0A9B11

Hybrid Battery Temperature 1 to 6

Hybrid Battery Current Sensor Power Supply Voltage
P0A9B15
P0AC511
P0AC515
P0ACA11
P0ACA15
P0AE811
P0AE815
P0BC211
P0BC215
P0C3311
P0C3315

Tech Tips


  • After checking for the above DTCs, check the hybrid system Data List item "Hybrid Battery Temperature" using the GTS.

  • If the vehicle as is left as is for 24 hours, the value of "Hybrid Battery Temperature" will be almost the same as the ambient temperature.

CONFIRMATION DRIVING PATTERN

Tech Tips

After repair has been completed, clear the DTC and then check that the vehicle has returned to normal by performing the following All Readiness check procedure.

Click here


  1. Connect the GTS to the DLC3.

  2. Turn the power switch on (IG) and turn the GTS on.

  3. Clear the DTCs (even if no DTCs are stored, perform the clear DTC procedure).

  4. Turn the power switch off and wait for 2 minutes or more.

  5. Turn the power switch on (IG) and turn the GTS on.

  6. With power switch on (IG) and wait for 5 seconds or more.

  7. Enter the following menus: Powertrain / HV Battery / Utility / All Readiness.

  8. Check the DTC judgment result.

    Tech Tips


    • If the judgment result shows NORMAL, the system is normal.

    • If the judgment result shows ABNORMAL, the system has a malfunction.

    • If the judgment result shows INCOMPLETE or N/A, perform driving pattern again.

WIRING DIAGRAM

B004CI6E01

CAUTION / NOTICE / HINT

CAUTION:


  • B004BJX

    Before the following operations are conducted, take precautions to prevent electric shock by turning the power switch off, wearing insulated gloves, and removing the service plug grip from HV battery.


    • Inspecting the high-voltage system

    • Disconnecting the low voltage connector of the inverter with converter assembly

    • Disconnecting the low voltage connector of the HV battery

  • B004C5R

    To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.

  • B0049VM

    After removing the service plug grip from the HV battery, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.

  • B004AZGC06
    *a Without waiting for 10 minutes

    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 and the electric vehicle charger assembly.

  • B004AA2C06
    *a Dealer
    *b Battery Collection Agent

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


    • Accidents such as electric shock may result if the HV battery is disposed of improperly or abandoned. Therefore, make sure to return all HV batteries through an authorized collection agent.

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

    Click here

  • Before returning the HV supply stack sub-assembly, 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 and HV supply stack sub-assemblies.

  • B004CBE

    After removing the HV battery, keep it away from water. Exposure to water may cause the HV battery to produce heat, resulting in a fire.

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 (HV BATTERY, HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

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

    4. Check for DTCs.


      Powertrain > HV Battery > Trouble Codes
      Powertrain > Hybrid Control > Trouble Codes
      Result
      Result Proceed to
      "P0A9B11, P0A9B15, P0AC511, P0AC515, P0ACA11, P0ACA15, P0AE811, P0AE815, P0BC211, P0BC215, P0C3311 or P0C3315" only is output, or DTCs except the ones in the table below are also output. A
      DTCs of hybrid battery system in the table below are output. B
      DTCs of hybrid control system in the table below are output. C
      System Relevant DTC
      Hybrid battery system P060A47 Hybrid/EV Battery Energy Control Module Monitoring Processor Watchdog / Safety MCU Failure
      P060B49 Hybrid/EV Battery Energy Control Module A/D Processing Internal Electronic Failure
      P060687 Hybrid/EV Battery Energy Control Module Processor to Monitoring Processor Missing Message
      Hybrid control system P0A1F94 Hybrid/EV Battery Energy Control Module Unexpected Operation

    5. Turn the power switch off.


    B

    GO TO DTC CHART (HYBRID BATTERY SYSTEM) Click here

    C

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    A

  2. READ VALUE USING GTS (HYBRID BATTERY TEMPERATURE)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / HV Battery / Data List.

    4. Read the Data List.


      Powertrain > HV Battery > Data List
      Tester Display Measurement Item Range Reference Value Diagnostic Note
      Hybrid Battery Temperature 1 HV battery temperature sensor output. -50 to 205.9°C (-58 to 402.6°F) Same as ambient temperature (left as is for 24 hours)

      • Battery temperature sensor

      • Battery ECU assembly
      Hybrid Battery Temperature 2 HV battery temperature sensor output. -50 to 205.9°C (-58 to 402.6°F) Same as ambient temperature (left as is for 24 hours)

      • Battery temperature sensor

      • Battery ECU assembly
      Hybrid Battery Temperature 3 HV battery temperature sensor output. -50 to 205.9°C (-58 to 402.6°F) Same as ambient temperature (left as is for 24 hours)

      • Battery temperature sensor

      • Battery ECU assembly
      Hybrid Battery Temperature 4 HV battery temperature sensor output. -50 to 205.9°C (-58 to 402.6°F) Same as ambient temperature (left as is for 24 hours)

      • Battery temperature sensor

      • Battery ECU assembly
      Hybrid Battery Temperature 5 HV battery temperature sensor output. -50 to 205.9°C (-58 to 402.6°F) Same as ambient temperature (left as is for 24 hours)

      • Battery temperature sensor

      • Battery ECU assembly
      Hybrid Battery Temperature 6 HV battery temperature sensor output. -50 to 205.9°C (-58 to 402.6°F) Same as ambient temperature (left as is for 24 hours)

      • Battery temperature sensor

      • Battery ECU assembly

      Powertrain > HV Battery > Data List
      Tester Display
      Hybrid Battery Temperature 1
      Hybrid Battery Temperature 2
      Hybrid Battery Temperature 3
      Hybrid Battery Temperature 4
      Hybrid Battery Temperature 5
      Hybrid Battery Temperature 6

      Tech Tips

      A malfunctioning sensor (battery temperature sensor 0, 1, 2, 3, 4 or 5) can be determined by comparing the output temperature of the 6 battery temperature sensors.

    5. Turn the power switch off.

      Result
      Proceed to
      NEXT

    NEXT

  3. CHECK FREEZE FRAME DATA


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / HV battery / Trouble Codes.

    4. Check and record the "Hybrid Battery Current Sensor Power Supply Voltage" freeze frame data.


      Powertrain > HV Battery > Trouble Codes

      Tech Tips

      Use this for reference when measuring the hybrid battery current sensor power supply voltage.

    5. Turn the power switch off.

      Result
      Proceed to
      NEXT

    NEXT

  4. CHECK DTC


    1. Check the DTCs that were output when the vehicle was brought to the workshop.

      Result
      Result Proceed to
      "P0A9B11, P0A9B15, P0AC511, P0AC515, P0ACA11 or P0ACA15" is also output. A
      "P0AE811, P0AE815, P0BC211, P0BC215, P0C3311 or P0C3315" is also output. B

    B

    CHECK CONNECTOR CONNECTION CONDITION (NO. 2 HV SUPPLY STACK SUB-ASSEMBLY CONNECTOR) Click here

    A

  5. CHECK CONNECTOR CONNECTION CONDITION (NO. 1 HV SUPPLY STACK SUB-ASSEMBLY CONNECTOR)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    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. B0049SJE01

      Check the connections of the A No. 1 HV supply stack sub-assembly connector.

      Click here

      OK
      The connector is connected securely and there are no contact problems.

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

      Result
      Result
      OK
      NG

    NG

    CONNECT SECURELY

    OK

  6. CHECK CONNECTOR CONNECTION CONDITION (BATTERY ECU ASSEMBLY CONNECTOR)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    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 upper No. 1 hybrid battery cover sub-assembly.

      Click here

    3. B004AUFE01

      Check the connections of the z31 battery ECU assembly connector.

      Click here

      OK
      The connector is connected securely and there are no contact problems.

    4. Install the upper No. 1 hybrid battery cover sub-assembly.

      Result
      Result
      OK
      NG

    NG

    CONNECT SECURELY

    OK

  7. CHECK HV BATTERY (BATTERY TEMPERATURE SENSOR 0 to 2)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    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 upper No. 1 hybrid battery cover sub-assembly.

      Click here

    3. B004AUFE01

      Disconnect the z31 battery ECU assembly connector.

      Note

      Before disconnecting the connector, check that it is not loose or disconnected.

    4. B004B3CC09
      *a

      Rear view of wire harness connector

      (to Battery ECU Assembly)

      Measure the resistance of the circuit for the malfunctioning sensor (battery temperature sensor 0 to 2).

      Tester Connection
      Tester Connection Battery Temperature Sensor
      z31-6(TB0) - z31-26(GB0) 0
      z31-25(TB1) - z31-5(GB1) 1
      z31-4(TB2) - z31-24(GB2) 2
      Standard Resistance
      Thermistor Temperature Condition Specified Condition
      20 to 30°C (68 to 86°F) Always 8.22 to 12.2 kΩ
      30 to 40°C (86 to 104°F) Always 5.74 to 8.41 kΩ
      40 to 50°C (104 to 122°F) Always 4.09 to 5.91 kΩ

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      z31-6 (TB0) - Body ground and other terminals (except z31-26 (GB0)) Always 10 kΩ or higher
      z31-26 (GB0) - Body ground and other terminals (except z31-6 (TB0)) Always 10 kΩ or higher
      z31-25 (TB1) - Body ground and other terminals (except z31-5 (GB1)) Always 10 kΩ or higher
      z31-5 (GB1) - Body ground and other terminals (except z31-25 (TB1)) Always 10 kΩ or higher
      z31-4 (TB2) - Body ground and other terminals (except z31-24 (GB2)) Always 10 kΩ or higher
      z31-24 (GB2) - Body ground and other terminals (except z31-4 (TB2)) Always 10 kΩ or higher

    6. Reconnect the z31 battery ECU assembly connector.

    7. Install the upper No. 1 hybrid battery cover sub-assembly.

      Result
      Proceed to
      OK
      NG

    OK

    GO TO STEP 12 Click here

    NG

  8. CHECK HARNESS AND CONNECTOR (BATTERY ECU ASSEMBLY - NO. 1 HV SUPPLY STACK SUB-ASSEMBLY)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    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 upper No. 1 hybrid battery cover sub-assembly.

      Click here

    3. B004AUFE01

      Disconnect the z31 battery ECU assembly connector.

      Note

      Before disconnecting the connector, check that it is not loose or disconnected.

    4. B0049SJE01

      Disconnect the A No. 1 HV supply stack sub-assembly connector.

      Note

      Before disconnecting the connector, check that it is not loose or disconnected.

    5. B004C76C03
      *a

      Rear view of wire harness connector

      (to Battery ECU Assembly)
      *b

      Front view of wire harness connector

      (to No. 1 HV Supply Stack Sub-assembly)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      z31-6 (TB0) - A-1 (TB0) Always Below 1 Ω
      z31-26 (GB0) - A-4 (GB0) Always Below 1 Ω
      z31-25 (TB1) - A-5 (TB1) Always Below 1 Ω
      z31-5 (GB1) - A-2 (GB1) Always Below 1 Ω
      z31-4 (TB2) - A-3 (TB2) Always Below 1 Ω
      z31-24 (GB2) - A-6 (GB2) Always Below 1 Ω
      Standard Resistance
      Tester Connection Condition Specified Condition
      z31-6 (TB0) or A-1 (TB0) - Body ground and other terminals Always 10 kΩ or higher
      z31-26 (GB0) or A-4 (GB0) - Body ground and other terminals Always 10 kΩ or higher
      z31-25 (TB1) or A-5 (TB1) - Body ground and other terminals Always 10 kΩ or higher
      z31-5 (GB1) or A-2 (GB1) - Body ground and other terminals Always 10 kΩ or higher
      z31-4 (TB2) or A-3 (TB2) - Body ground and other terminals Always 10 kΩ or higher
      z31-24 (GB2) or A-6 (GB2) - Body ground and other terminals Always 10 kΩ or higher

    6. Reconnect the A No. 1 HV supply stack sub-assembly connector.

    7. Reconnect the z31 battery ECU assembly connector.

    8. Install the upper No. 1 hybrid battery cover sub-assembly.

      Result
      Proceed to
      OK
      NG

    OK

    REPLACE NO. 1 HV SUPPLY STACK SUB-ASSEMBLY Click here

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  9. CHECK CONNECTOR CONNECTION CONDITION (NO. 2 HV SUPPLY STACK SUB-ASSEMBLY CONNECTOR)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    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. B004AZYE01

      Check the connections of the B No. 2 HV supply stack sub-assembly connector.

      Click here

      OK
      The connector is connected securely and there are no contact problems.

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

      Result
      Result
      OK
      NG

    NG

    CONNECT SECURELY

    OK

  10. CHECK CONNECTOR CONNECTION CONDITION (BATTERY ECU ASSEMBLY CONNECTOR)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    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 upper No. 1 hybrid battery cover sub-assembly.

      Click here

    3. B004AUFE01

      Check the connections of the z31 battery ECU assembly connector.

      Click here

      OK
      The connector is connected securely and there are no contact problems.

    4. Install the upper No. 1 hybrid battery cover sub-assembly.

      Result
      Result
      OK
      NG

    NG

    CONNECT SECURELY

    OK

  11. CHECK HV BATTERY (BATTERY TEMPERATURE SENSOR 3 to 5)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    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 upper No. 1 hybrid battery cover sub-assembly.

      Click here

    3. B004AUFE01

      Disconnect the z31 battery ECU assembly connector.

      Note

      Before disconnecting the connector, check that it is not loose or disconnected.

    4. B004B3CC11
      *a

      Rear view of wire harness connector

      (to Battery ECU Assembly)

      Measure the resistance of the circuit for the malfunctioning sensor (battery temperature sensor 3 to 5).

      Tester Connection
      Tester Connection Battery Temperature Sensor
      z31-23(TB3) - z31-3(GB3) 3
      z31-2(TB4) - z31-22(GB4) 4
      z31-21(TB5) - z31-1(GB5) 5
      Standard Resistance
      Thermistor Temperature Condition Specified Condition
      20 to 30°C (68 to 86°F) Always 8.22 to 12.2 kΩ
      30 to 40°C (86 to 104°F) Always 5.74 to 8.41 kΩ
      40 to 50°C (104 to 122°F) Always 4.09 to 5.91 kΩ

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      z31-23 (TB3) - Body ground and other terminals (except z31-3 (GB3)) Always 10 kΩ or higher
      z31-3 (GB3) - Body ground and other terminals (except z31-23 (TB3)) Always 10 kΩ or higher
      z31-2 (TB4) - Body ground and other terminals (except z31-22 (GB4)) Always 10 kΩ or higher
      z31-22 (GB4) - Body ground and other terminals (except z31-2 (TB4)) Always 10 kΩ or higher
      z31-21 (TB5) - Body ground and other terminals (except z31-1 (GB5)) Always 10 kΩ or higher
      z31-1 (GB5) - Body ground and other terminals (except z31-21 (TB5)) Always 10 kΩ or higher

    6. Reconnect the z31 battery ECU assembly connector.

    7. Install the upper No. 1 hybrid battery cover sub-assembly.

      Result
      Proceed to
      OK
      NG

    NG

    CHECK HARNESS AND CONNECTOR (BATTERY ECU ASSEMBLY - NO. 2 HV SUPPLY STACK SUB-ASSEMBLY) Click here

    OK

  12. CHECK HARNESS AND CONNECTOR (BATTERY ECU ASSEMBLY - HV BATTERY JUNCTION BLOCK ASSEMBLY)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    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 upper No. 1 hybrid battery cover sub-assembly.

      Click here

    3. B004AUFE01

      Disconnect the z31 battery ECU assembly connector.

      Note

      Before disconnecting the connector, check that it is not loose or disconnected.

    4. B004BE0E01

      Disconnect the z28 battery current sensor connector from the HV battery junction block assembly.

      Note

      Before disconnecting the connector, check that it is not loose or disconnected.

    5. B0049YFC03
      *a

      Front view of wire harness connector

      (to HV Battery Junction Block Assembly (Battery Current Sensor))
      *b

      Rear view of wire harness connector

      (to Battery ECU Assembly)

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

      Standard Resistance (Check for Open)
      Tester Connection Condition Specified Condition
      z31-19(VIB) - z28-1(VIB) Always Below 1 Ω
      z31-38(IB1) - z28-2(IB1) Always Below 1 Ω
      z31-37(GIB) - z28-3(GIB) Always Below 1 Ω
      z31-18(IB0) - z28-4(IB0) Always Below 1 Ω
      Standard Resistance (Check for Short)
      Tester Connection Condition Specified Condition
      z31-19(VIB) or z28-1(VIB) - Body ground and other terminals Always 10 kΩ or higher
      z31-38(IB1) or z28-2(IB1) - Body ground and other terminals Always 10 kΩ or higher
      z31-37(GIB) or z28-3(GIB) - Body ground and other terminals Always 10 kΩ or higher
      z31-18(IB0) - z28-4(IB0) - Body ground and other terminals Always 10 kΩ or higher

    6. Reconnect the z28 battery current sensor connector to the HV battery junction block assembly.

    7. Reconnect the z31 battery ECU assembly connector.

    8. Install the upper No. 1 hybrid battery cover sub-assembly.

      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  13. CHECK BATTERY ECU ASSEMBLY (VIB VOLTAGE)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    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 upper No. 1 hybrid battery cover sub-assembly.

      Click here

    3. B004C1XC02
      *a

      Front view of wire harness connector

      (No. 2 HV Battery Pack Wire Connector)

      Apply auxiliary battery voltage between No. 2 HV battery pack wire connector terminals X119-14 (IGCT) - X119-1 (GND).

      Note

      Make sure that the battery positive and battery negative do not contact one another.

    4. B004BAPC06
      *a

      Component with harness connected

      (to Battery ECU Assembly)

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      z31-19 (VIB) - z31-37 (GIB)

      Auxiliary battery positive (+) → X119-14 (IGCT)

      Auxiliary battery negative (-) → X119-1 (GND)

      		 4.6 to 5.4 V

    5. Disconnect the X119 connector of the No. 2 HV battery pack wire from the auxiliary battery.

    6. Install the upper No. 1 hybrid battery cover sub-assembly.

      Result
      Proceed to
      OK
      NG

    OK

    REPLACE BATTERY ECU ASSEMBLY Click here

    NG

  14. HV BATTERY JUNCTION BLOCK ASSEMBLY (BATTERY CURRENT SENSOR OUTPUT VOLTAGE)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    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 upper HV battery cover panel.

      Click here

    3. B004BE0E01

      Disconnect the z28 battery current sensor connector from the HV battery junction block assembly.

      Note

      Before disconnecting the connector, check that it is not loose or disconnected.

    4. B004C1XC02
      *a

      Front view of wire harness connector

      (No. 2 HV Battery Pack Wire Connector)

      Apply auxiliary battery voltage between No. 2 HV battery pack wire connector terminals X119-14 (IGCT) - X119-1 (GND).

      Note

      Make sure that the battery positive and battery negative do not contact one another.

    5. B004C2YC29
      *a

      Front view of wire harness connector

      (to HV Battery Junction Block Assembly (Battery Current Sensor))

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      z28-1(VIB) - z28-3 (GIB)

      Auxiliary battery positive (+) → X119-14 (IGCT)

      Auxiliary battery negative (-) → X119-1 (GND)

      		 4.6 to 5.4 V

    6. Disconnect the X119 connector of the No. 2 HV battery pack wire from the auxiliary battery.

    7. Reconnect the z28 battery current sensor connector to the HV battery junction block assembly.

    8. Install the upper HV battery cover panel.

      Result
      Proceed to
      OK
      NG

    OK

    REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY Click here

    NG

    REPLACE BATTERY ECU ASSEMBLY Click here

  15. CHECK HARNESS AND CONNECTOR (BATTERY ECU ASSEMBLY - NO. 2 HV SUPPLY STACK SUB-ASSEMBLY)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    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 upper No. 1 hybrid battery cover sub-assembly.

      Click here

    3. B004AUFE01

      Disconnect the z31 battery ECU assembly connector.

      Note

      Before disconnecting the connector, check that it is not loose or disconnected.

    4. B004AZYE01

      Disconnect the B No. 2 HV supply stack sub-assembly connector.

      Note

      Before disconnecting the connector, check that it is not loose or disconnected.

    5. B004C76C04
      *a

      Rear view of wire harness connector

      (to Battery ECU Assembly)
      *b

      Front view of wire harness connector

      (to No. 2 HV Supply Stack Sub-assembly)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      z31-23 (TB3) - B-4 (TB3) Always Below 1 Ω
      z31-3 (GB3) - B-1 (GB3) Always Below 1 Ω
      z31-2 (TB4) - B-2 (TB4) Always Below 1 Ω
      z31-22 (GB4) - B-5 (GB4) Always Below 1 Ω
      z31-21 (TB5) - B-6 (TB5) Always Below 1 Ω
      z31-1 (GB5) - B-3 (GB5) Always Below 1 Ω
      Standard Resistance
      Tester Connection Condition Specified Condition
      z31-23 (TB3) or B-4 (TB3) - Body ground and other terminals Always 10 kΩ or higher
      z31-3 (GB3) or B-1 (GB3) - Body ground and other terminals Always 10 kΩ or higher
      z31-2 (TB4) or B-2 (TB4) - Body ground and other terminals Always 10 kΩ or higher
      z31-22 (GB4) or B-5 (GB4) - Body ground and other terminals Always 10 kΩ or higher
      z31-21 (TB5) or B-6 (TB5) - Body ground and other terminals Always 10 kΩ or higher
      z31-1 (GB5) or B-3 (GB5) - Body ground and other terminals Always 10 kΩ or higher

    6. Reconnect the B No. 2 HV supply stack sub-assembly connector.

    7. Reconnect the z31 battery ECU assembly connector.

    8. Install the upper No. 1 hybrid battery cover sub-assembly.

      Result
      Proceed to
      OK
      NG

    OK

    REPLACE NO. 2 HV SUPPLY STACK SUB-ASSEMBLY Click here

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR