HYBRID BATTERY SYSTEM, Diagnostic DTC:P33EC16, P33ED16

DTC Code DTC Name
P33EC16 (Extreme) Hybrid/EV Battery Stack 1 Cell Circuit Voltage Below Threshold
P33ED16 (Extreme) Hybrid/EV Battery Stack 2 Cell Circuit Voltage Below Threshold

DESCRIPTION

When a certain amount of time passes during which the HV battery cell voltage is below the specified value, the battery voltage sensor informs the battery ECU assembly of any malfunctions. The battery ECU assembly stores this DTC.

DTC No. Detection Item DTC Detection Condition Trouble Area MIL Warning Indicate
P33EC16 (Extreme) Hybrid/EV Battery Stack 1 Cell Circuit Voltage Below Threshold

The voltage of any cell of the No. 1 HV supply stack sub-assembly has decreased excessively.

(1 trip detection logic)

  • No. 1 HV supply stack sub-assembly

  • Battery ECU assembly

  • Battery voltage sensor (for upper side)

 Comes on

Master Warning Light:

Comes on
P33ED16 (Extreme) Hybrid/EV Battery Stack 2 Cell Circuit Voltage Below Threshold

The voltage of any cell of the No. 2 HV supply stack sub-assembly has decreased excessively.

(1 trip detection logic)

  • No. 2 HV supply stack sub-assembly

  • Battery ECU assembly

  • battery voltage sensor (for lower side)

 Comes on

Master Warning Light:

Comes on

CAUTION:

Do not charge the HV battery using the THS charger if DTC P33EC16 or P33ED16 is output.

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 10 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

Refer to the wiring diagram for DTC P1A001C.

Click here

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
      "P33EC16 or P33ED16" 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
      P0E2D00 Hybrid/EV Battery Energy Control Module Hybrid/EV Battery Monitor Performance
      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. CHECK DTC


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

      Result
      Result Proceed to
      "P33EC16" is also output. A
      "P33ED16" is also output. B

    B

    CHECK FREEZE FRAME DATA Click here

    A

  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. Read the value of freeze frame data items "HV battery cell 1 voltage" through "HV battery cell 42 voltage" for DTC P33EC16 and make a note if the value of any is 1.2 V or less.


      Powertrain > HV Battery > Trouble Codes

      Tech Tips

      Use this for reference when measuring the HV battery cell voltage.

    5. Turn the power switch off.

      Result
      Proceed to
      NEXT

    NEXT

  4. CHECK CONNECTOR CONNECTION CONDITION (BATTERY VOLTAGE SENSOR (for Upper Side) 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.1 HV battery protector (for upper side).

      Click here

    3. B004BY4E01

      Check the connections of the z7 and z8 battery voltage sensor (for upper side) connector.

      Click here

      OK
      The connector is connected securely and there are no contact problems.
      Result
      Result Proceed to
      OK A
      Not connected securely The terminals are not damaged or corroded B
      Either connector z7 or z8 was not connected securely The terminals are damaged or corroded C

    B

    CONNECT SECURELY

    C

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

    A

  5. CHECK NO. 1 HV SUPPLY STACK SUB-ASSEMBLY (HYBRID BATTERY CELL VOLTAGE)

    CAUTION:


    • Be sure to wear insulated gloves and protective goggles.

    • Disconnect only the connector corresponding to the HV battery cell to be checked. Do not disconnect the other connectors.

    Note

    Make sure to use tester probes with a diameter of approximately 0.5 mm (0.0197 in.) when measuring the voltage of each HV battery cell.


    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 HV battery protector (for upper side).

      Click here

    3. The value of any of the freeze frame data items "HV battery cell 1 voltage" through "HV battery cell 22 voltage" is 1.2 V or less.


      1. Disconnect the z7 battery voltage sensor (for upper side) connector.

        B004A3CE01

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

        Tech Tips

        Measure the voltage of the HV battery cells whose value in the freeze frame data was 1.2 V or less only.

        Standard Voltage
        Hybrid Battery Cell Tester Connection Condition
        1 z7-10(GA0) - z7-24(VA1) Always
        2 z7-24(VA1) - z7-9(VA2) Always
        3 z7-9(VA2) - z7-23(VA3) Always
        4 z7-23(VA3) - z7-8(VA4) Always
        5 z7-8(VA4) - z7-7(VA5) Always
        6 z7-7(VA5) - z7-22(VA6) Always
        7 z7-22(VA6) - z7-6(VA7) Always
        8 z7-6(VA7) - z7-21(VA8) Always
        9 z7-21(VA8) - z7-20(VA9) Always
        10 z7-20(VA9) - z7-19(VA10) Always
        11 z7-19(VA10) - z7-18(VA11) Always
        12 z7-18(VA11) - z7-17(VA12) Always
        13 z7-17(VA12) - z7-16(VA13) Always
        14 z7-16(VA13) - z7-15(VA14) Always
        15 z7-15(VA14) - z7-14(VA15) Always
        16 z7-14(VA15) - z7-5(VA16) Always
        17 z7-5(VA16) - z7-13(VA17) Always
        18 z7-13(VA17) - z7-4(VA18) Always
        19 z7-4(VA18) - z7-3(VA19) Always
        20 z7-3(VA19) - z7-12(VA20) Always
        21 z7-12(VA20) - z7-2(VA21) Always
        22 z7-2(VA21) - z7-11(VA22) Always

        CAUTION:

        Make sure not to cross the electrodes of an electrical tester measurement terminals.

        Note

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

        B004A7NC05
        *a

        Rear view of wire harness connector

        (to Battery Voltage Sensor (for Upper Side))

      3. Reconnect the z7 battery voltage sensor (for upper side) connector.

    4. The value of any of the freeze frame data items "HV battery cell 23 voltage" through "HV battery cell 42 voltage" is 1.2 V or less.


      1. Disconnect the z8 battery voltage sensor (for upper side) connector.

        B004B6ME01

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

        Tech Tips

        Measure the voltage of the HV battery cells whose value in the freeze frame data was 1.2 V or less only.

        Standard Voltage
        Hybrid Battery Cell Tester Connection Condition
        23 z8-23(GA1) - z8-8(VA23) Always
        24 z8-8(VA23) - z8-7(VA24) Always
        25 z8-7(VA24) - z8-22(VA25) Always
        26 z8-22(VA25) - z8-6(VA26) Always
        27 z8-6(VA26) - z8-21(VA27) Always
        28 z8-21(VA27) - z8-20(VA28) Always
        29 z8-20(VA28) - z8-19(VA29) Always
        30 z8-19(VA29) - z8-18(VA30) Always
        31 z8-18(VA30) - z8-17(VA31) Always
        32 z8-17(VA31) - z8-16(VA32) Always
        33 z8-16(VA32) - z8-15(VA33) Always
        34 z8-15(VA33) - z8-14(VA34) Always
        35 z8-14(VA34) - z8-5(VA35) Always
        36 z8-5(VA35) - z8-13(VA36) Always
        37 z8-13(VA36) - z8-4(VA37) Always
        38 z8-4(VA37) - z8-3(VA38) Always
        39 z8-3(VA38) - z8-12(VA39) Always
        40 z8-12(VA39) - z8-2(VA40) Always
        41 z8-2(VA40) - z8-11(VA41) Always
        42 z8-11(VA41) - z8-1(VA42) Always

        CAUTION:

        Make sure not to cross the electrodes of an electrical tester measurement terminals.

        Note

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

        B004B26C05
        *a

        Rear view of wire harness connector

        (to Battery Voltage Sensor (for Upper Side))

      3. Reconnect the z8 battery voltage sensor (for upper side) connector.

      Result
      Result Proceed to
      The voltage between the terminals is 1.2 V or less. A
      Other than above B

    B

    REPLACE BATTERY VOLTAGE SENSOR (for Upper Side) Click here

    A

  6. CHECK BATTERY VOLTAGE SENSOR (for Upper Side) (VA1 - VA42)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.

    Note

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


    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 battery voltage sensor (for upper side).

      Click here

      CAUTION:

      When disconnecting connector O1 of the battery voltage sensor (for upper side), first disconnect connector z7 and z8 from the battery voltage sensor (for upper side).

      B004BP0E01

      Note

      Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

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

      Tech Tips

      Only inspect the terminals of the battery ECU assembly which correspond to the HV battery cells which measured 1.2 V or less in the previous step.

      B004A5XC04
      *a

      Component without harness connected

      (Battery Voltage Sensor (for Upper Side))

      		 - -
      Standard Resistance
      Hybrid Battery Cell

      Tester Connection

      (Tester Probe Polarity)

      		 Condition Specified Condition
      1 z7-10(GA0) (-) - z7-24(VA1) (+) Always 50 kΩ or more
      2 z7-24(VA1) (-) - z7-9(VA2) (+) Always 50 kΩ or more
      3 z7-9(VA2) (-) - z7-23(VA3) (+) Always 50 kΩ or more
      4 z7-23(VA3) (-) - z7-8(VA4) (+) Always 50 kΩ or more
      5 z7-8(VA4) (-) - z7-7(VA5) (+) Always 50 kΩ or more
      6 z7-7(VA5) (-) - z7-22(VA6) (+) Always 50 kΩ or more
      7 z7-22(VA6) (-) - z7-6(VA7) (+) Always 50 kΩ or more
      8 z7-6(VA7) (-) - z7-21(VA8) (+) Always 50 kΩ or more
      9 z7-21(VA8) (-) - z7-20(VA9) (+) Always 50 kΩ or more
      10 z7-20(VA9) (-) - z7-19(VA10) (+) Always 50 kΩ or more
      11 z7-19(VA10) (-) - z7-18(VA11) (+) Always 50 kΩ or more
      12 z7-18(VA11) (-) - z7-17(VA12) (+) Always 50 kΩ or more
      13 z7-17(VA12) (-) - z7-16(VA13) (+) Always 50 kΩ or more
      14 z7-16(VA13) (-) - z7-15(VA14) (+) Always 50 kΩ or more
      15 z7-15(VA14) (-) - z7-14(VA15) (+) Always 50 kΩ or more
      16 z7-14(VA15) (-) - z7-5(VA16) (+) Always 50 kΩ or more
      17 z7-5(VA16) (-) - z7-13(VA17) (+) Always 50 kΩ or more
      18 z7-13(VA17) (-) - z7-4(VA18) (+) Always 50 kΩ or more
      19 z7-4(VA18) (-) - z7-3(VA19) (+) Always 50 kΩ or more
      20 z7-3(VA19) (-) - z7-12(VA20) (+) Always 50 kΩ or more
      21 z7-12(VA20) (-) - z7-2(VA21) (+) Always 50 kΩ or more
      22 z7-2(VA21) (-) - z7-11(VA22) (+) Always 50 kΩ or more
      23 z8-23(GA1) (-) - z8-8(VA23) (+) Always 50 kΩ or more
      24 z8-8(VA23) (-) - z8-7(VA24) (+) Always 50 kΩ or more
      25 z8-7(VA24) (-) - z8-22(VA25) (+) Always 50 kΩ or more
      26 z8-22(VA25) (-) - z8-6(VA26) (+) Always 50 kΩ or more
      27 z8-6(VA26) (-) - z8-21(VA27) (+) Always 50 kΩ or more
      28 z8-21(VA27) (-) - z8-20(VA28) (+) Always 50 kΩ or more
      29 z8-20(VA28) (-) - z8-19(VA29) (+) Always 50 kΩ or more
      30 z8-19(VA29) (-) - z8-18(VA30) (+) Always 50 kΩ or more
      31 z8-18(VA30) (-) - z8-17(VA31) (+) Always 50 kΩ or more
      32 z8-17(VA31) (-) - z8-16(VA32) (+) Always 50 kΩ or more
      33 z8-16(VA32) (-) - z8-15(VA33) (+) Always 50 kΩ or more
      34 z8-15(VA33) (-) - z8-14(VA34) (+) Always 50 kΩ or more
      35 z8-14(VA34) (-) - z8-5(VA35) (+) Always 50 kΩ or more
      36 z8-5(VA35) (-) - z8-13(VA36) (+) Always 50 kΩ or more
      37 z8-13(VA36) (-) - z8-4(VA37) (+) Always 50 kΩ or more
      38 z8-4(VA37) (-) - z8-3(VA38) (+) Always 50 kΩ or more
      39 z8-3(VA38) (-) - z8-12(VA39) (+) Always 50 kΩ or more
      40 z8-12(VA39) (-) - z8-2(VA40) (+) Always 50 kΩ or more
      41 z8-2(VA40) (-) - z8-11(VA41) (+) Always 50 kΩ or more
      42 z8-11(VA41) (-) - z8-1(VA42) (+) Always 50 kΩ or more

      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 voltage sensor, make sure to use tester probes with a diameter of approximately 0.5 mm (0.0197 in.) when measuring the resistance of the battery voltage sensor.

      Result
      Result Proceed to
      The voltage between the terminals is 50 kΩ or more. A
      Other than above B

    4. Install the battery voltage sensor (for upper side).

      CAUTION:

      When connecting connectors z7 and z8 of the battery voltage sensor (for upper Side), first connect connector O1 to the battery voltage sensor (for upper Side).

      B004BP0E01

    A

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

    B

    REPLACE BATTERY VOLTAGE SENSOR (for Upper Side) Click here

  7. 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. Read the value of freeze frame data items "HV battery cell 43 voltage" through "HV battery cell 84 voltage" for DTC P33ED16 and make a note if the value of any is 1.2 V or less.


      Powertrain > HV Battery > Trouble Codes

      Tech Tips

      Use this for reference when measuring the HV battery cell voltage.

    5. Turn the power switch off.

      Result
      Proceed to
      NEXT

    NEXT

  8. CHECK CONNECTOR CONNECTION CONDITION (BATTERY VOLTAGE SENSOR (for Lower Side) 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.1 HV battery protector (for lower side).

      Click here

    3. B004B8LE01

      Check the connections of the z9 and z10 battery voltage sensor (for lower side) connector.

      Click here

      OK
      The connector is connected securely and there are no contact problems.
      Result
      Result Proceed to
      OK A
      Not connected securely The terminals are not damaged or corroded B
      Either connector z9 or z10 was not connected securely The terminals are damaged or corroded C

    B

    CONNECT SECURELY

    C

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

    A

  9. CHECK NO. 2 HV SUPPLY STACK SUB-ASSEMBLY (HYBRID BATTERY CELL VOLTAGE)

    CAUTION:


    • Be sure to wear insulated gloves and protective goggles.

    • Disconnect only the connector corresponding to the HV battery cell to be checked. Do not disconnect the other connectors.

    Note

    Make sure to use tester probes with a diameter of approximately 0.5 mm (0.0197 in.) when measuring the voltage of each HV battery cell.


    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 HV battery protector (for lower side).

      Click here

    3. The value of any of the freeze frame data items "HV battery cell 43 voltage" through "HV battery cell 64 voltage" is 1.2 V or less.


      1. Disconnect the z9 battery voltage sensor (for lower side) connector.

        B0049Z4E01

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

        Tech Tips

        Measure the voltage of the HV battery cells whose value in the freeze frame data was 1.2 V or less only.

        Standard Voltage
        Hybrid Battery Cell Tester Connection Condition
        43 z9-10(GA2) - z9-24(VA43) Always
        44 z9-24(VA43) - z9-9(VA44) Always
        45 z9-9(VA44) - z9-23(VA45) Always
        46 z9-23(VA45) - z9-8(VA46) Always
        47 z9-8(VA46) - z9-7(VA47) Always
        48 z9-7(VA47) - z9-22(VA48) Always
        49 z9-22(VA48) - z9-6(VA49) Always
        50 z9-6(VA49) - z9-21(VA50) Always
        51 z9-21(VA50) - z9-20(VA51) Always
        52 z9-20(VA51) - z9-19(VA52) Always
        53 z9-19(VA52) - z9-18(VA53) Always
        54 z9-18(VA53) - z9-17(VA54) Always
        55 z9-17(VA54) - z9-16(VA55) Always
        56 z9-16(VA55) - z9-15(VA56) Always
        57 z9-15(VA56) - z9-14(VA57) Always
        58 z9-14(VA57) - z9-5(VA58) Always
        59 z9-5(VA58) - z9-13(VA59) Always
        60 z9-13(VA59) - z9-4(VA60) Always
        61 z9-4(VA60) - z9-3(VA61) Always
        62 z9-3(VA61) - z9-12(VA62) Always
        63 z9-12(VA62) - z9-2(VA63) Always
        64 z9-2(VA63) - z9-11(VA64) Always

        CAUTION:

        Make sure not to cross the electrodes of an electrical tester measurement terminals.

        Note

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

        B004A7NC06
        *a

        Rear view of wire harness connector

        (to Battery Voltage Sensor (for Lower Side))

      3. Reconnect the z9 battery voltage sensor (for lower side) connector.

    4. The value of any of the freeze frame data items "HV battery cell 65 voltage" through "HV battery cell 84 voltage" is 1.2 V or less.


      1. Disconnect the z10 battery voltage sensor (for lower side) connector.

        B004BS0E01

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

        Tech Tips

        Measure the voltage of the HV battery cells whose value in the freeze frame data was 1.2 V or less only.

        Standard Voltage
        Hybrid Battery Cell Tester Connection Condition
        65 z10-23(GA3) - z10-8(VA65) Always
        66 z10-8(VA65) - z10-7(VA66) Always
        67 z10-7(VA66) - z10-22(VA67) Always
        68 z10-22(VA67) - z10-6(VA68) Always
        69 z10-6(VA68) - z10-21(VA69) Always
        70 z10-21(VA69) - z10-20(VA70) Always
        71 z10-20(VA70) - z10-19(VA71) Always
        72 z10-19(VA71) - z10-18(VA72) Always
        73 z10-18(VA72) - z10-17(VA73) Always
        74 z10-17(VA73) - z10-16(VA74) Always
        75 z10-16(VA74) - z10-15(VA75) Always
        76 z10-15(VA75) - z10-14(VA76) Always
        77 z10-14(VA76) - z10-5(VA77) Always
        78 z10-5(VA77) - z10-13(VA78) Always
        79 z10-13(VA78) - z10-4(VA79) Always
        80 z10-4(VA79) - z10-3(VA80) Always
        81 z10-3(VA80) - z10-12(VA81) Always
        82 z10-12(VA81) - z10-2(VA82) Always
        83 z10-2(VA82) - z10-11(VA83) Always
        84 z10-11(VA83) - z10-1(VA84) Always

        CAUTION:

        Make sure not to cross the electrodes of an electrical tester measurement terminals.

        Note

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

        B004B26C08
        *a

        Rear view of wire harness connector

        (to Battery Voltage Sensor (for Lower Side))

      3. Reconnect the z10 battery voltage sensor (for lower side) connector.

      Result
      Result Proceed to
      The voltage between the terminals is 1.2 V or less. A
      Other than above B

    B

    REPLACE BATTERY VOLTAGE SENSOR (for Lower Side) Click here

    A

  10. CHECK BATTERY VOLTAGE SENSOR (for Lower Side) (VA43 - VA84)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.

    Note

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


    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 battery voltage sensor (for lower side).

      Click here

      CAUTION:

      When disconnecting connector O3 of the battery voltage sensor (for lower side), first disconnect connector z9 and z10 from the battery voltage sensor (for lower side).

      B004CP1E01

      Note

      Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector.

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

      Tech Tips

      Only inspect the terminals of the battery ECU assembly which correspond to the HV battery cells which measured 1.2 V or less in the previous step.

      B004A5XC05
      *a

      Component without harness connected

      (Battery Voltage Sensor (for Lower Side))

      		 - -
      Standard Resistance
      Hybrid Battery Cell

      Tester Connection

      (Tester Probe Polarity)

      		 Condition Specified Condition
      43 z9-10(GA2) (-) - z9-24(VA43) (+) Always 50 kΩ or more
      44 z9-24(VA43) (-) - z9-9(VA44) (+) Always 50 kΩ or more
      45 z9-9(VA44) (-) - z9-23(VA45) (+) Always 50 kΩ or more
      46 z9-23(VA45) (-) - z9-8(VA46) (+) Always 50 kΩ or more
      47 z9-8(VA46) (-) - z9-7(VA47) (+) Always 50 kΩ or more
      48 z9-7(VA47) (-) - z9-22(VA48) (+) Always 50 kΩ or more
      49 z9-22(VA48) (-) - z9-6(VA49) (+) Always 50 kΩ or more
      50 z9-6(VA49) (-) - z9-21(VA50) (+) Always 50 kΩ or more
      51 z9-21(VA50) (-) - z9-20(VA51) (+) Always 50 kΩ or more
      52 z9-20(VA51) (-) - z9-19(VA52) (+) Always 50 kΩ or more
      53 z9-19(VA52) (-) - z9-18(VA53) (+) Always 50 kΩ or more
      54 z9-18(VA53) (-) - z9-17(VA54) (+) Always 50 kΩ or more
      55 z9-17(VA54) (-) - z9-16(VA55) (+) Always 50 kΩ or more
      56 z9-16(VA55) (-) - z9-15(VA56) (+) Always 50 kΩ or more
      57 z9-15(VA56) (-) - z9-14(VA57) (+) Always 50 kΩ or more
      58 z9-14(VA57) (-) - z9-5(VA58) (+) Always 50 kΩ or more
      59 z9-5(VA58) (-) - z9-13(VA59) (+) Always 50 kΩ or more
      60 z9-13(VA59) (-) - z9-4(VA60) (+) Always 50 kΩ or more
      61 z9-4(VA60) (-) - z9-3(VA61) (+) Always 50 kΩ or more
      62 z9-3(VA61) (-) - z9-12(VA62) (+) Always 50 kΩ or more
      63 z9-12(VA62) (-) - z9-2(VA63) (+) Always 50 kΩ or more
      64 z9-2(VA63) (-) - z9-11(VA64) (+) Always 50 kΩ or more
      65 z10-23(GA3) (-) - z10-8(VA65) (+) Always 50 kΩ or more
      66 z10-8(VA65) (-) - z10-7(VA66) (+) Always 50 kΩ or more
      67 z10-7(VA66) (-) - z10-22(VA67) (+) Always 50 kΩ or more
      68 z10-22(VA67) (-) - z10-6(VA68) (+) Always 50 kΩ or more
      69 z10-6(VA68) (-) - z10-21(VA69) (+) Always 50 kΩ or more
      70 z10-21(VA69) (-) - z10-20(VA70) (+) Always 50 kΩ or more
      71 z10-20(VA70) (-) - z10-19(VA71) (+) Always 50 kΩ or more
      72 z10-19(VA71) (-) - z10-18(VA72) (+) Always 50 kΩ or more
      73 z10-18(VA72) (-) - z10-17(VA73) (+) Always 50 kΩ or more
      74 z10-17(VA73) (-) - z10-16(VA74) (+) Always 50 kΩ or more
      75 z10-16(VA74) (-) - z10-15(VA75) (+) Always 50 kΩ or more
      76 z10-15(VA75) (-) - z10-14(VA76) (+) Always 50 kΩ or more
      77 z10-14(VA76) (-) - z10-5(VA77) (+) Always 50 kΩ or more
      78 z10-5(VA77) (-) - z10-13(VA78) (+) Always 50 kΩ or more
      79 z10-13(VA78) (-) - z10-4(VA79) (+) Always 50 kΩ or more
      80 z10-4(VA79) (-) - z10-3(VA80) (+) Always 50 kΩ or more
      81 z10-3(VA80) (-) - z10-12(VA81) (+) Always 50 kΩ or more
      82 z10-12(VA81) (-) - z10-2(VA82) (+) Always 50 kΩ or more
      83 z10-2(VA82) (-) - z10-11(VA83) (+) Always 50 kΩ or more
      84 z10-11(VA83) (-) - z10-1(VA84) (+) Always 50 kΩ or more

      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 voltage sensor, make sure to use tester probes with a diameter of approximately 0.5 mm (0.0197 in.) when measuring the resistance of the battery voltage sensor.

      Result
      Result Proceed to
      The voltage between the terminals is 50 kΩ or more. A
      Other than above B

    4. Install the battery voltage sensor (for lower side).

      CAUTION:

      When connecting connectors z9 and z10 of the battery voltage sensor (for lower Side), first connect connector O3 to the battery voltage sensor (for lower Side).

      B004CP1E01

    A

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

    B

    REPLACE BATTERY VOLTAGE SENSOR (for Lower Side) Click here