HYBRID BATTERY SYSTEM ECU Power Source Circuit

DESCRIPTION

If the power switch is on (IG), the hybrid vehicle control ECU assembly applies current to the MREL terminal to turn the IGCT relay on. This supplies power to the IGCT terminals.

WIRING DIAGRAM

B004AC5E01
*a IGCT NO.1 Relay
*b IGCT NO.5
*c No.2 HV Battery Pack Wire Connector
*d Battery ECU Assembly

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.

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 HARNESS AND CONNECTOR (IGCT 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 No. 4 hybrid battery intake duct.

      Click here

    3. B004BEBE01

      Disconnect the X119 No. 2 HV battery pack wire connector.

      Note

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

    4. Connect the cable to the negative (-) auxiliary battery terminal.

    5. Turn the power switch on (IG).

    6. B004BPAC04
      *a

      Front view of wire harness connector

      (No. 2 HV Battery Pack Wire Connector)

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      X119-14 (IGCT) - Body ground Power switch off 11 to 14 V

    7. Turn the power switch off.

    8. Disconnect the cable from the negative (-) auxiliary battery terminal.

    9. Reconnect the X119 No. 2 HV battery pack wire connector.

    10. Install the No. 4 hybrid battery intake duct.

      Result
      Proceed to
      OK
      NG

    NG

    CHECK FUSE (IGCT NO. 5) Click here

    OK

  2. CHECK HARNESS AND CONNECTOR (BATTERY ECU ASSEMBLY - BODY GROUND)

    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. 4 hybrid battery intake duct.

      Click here

    3. B004BEBE01

      Disconnect the X119 No. 2 HV battery pack wire connector.

      Note

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

    4. B0049SEC05
      *a

      Front view of wire harness connector

      (No. 2 HV Battery Pack Wire Connector)

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

      Standard Voltage
      Tester Connection Condition Specified Condition
      X119-1 (GND) - Body ground Always Below 1 Ω
      X119-10 (GND1) - Body ground Always Below 1 Ω

    5. Reconnect the X119 No. 2 HV battery pack wire connector.

    6. Install the No. 4 hybrid battery intake duct.

      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  3. CHECK HARNESS AND CONNECTOR (BATTERY ECU ASSEMBLY - NO. 2 HV BATTERY PACK WIRE 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

      Disconnect the z31 battery ECU assembly connector.

      Note

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

    4. B004CJ6C20
      *a

      Front view of wire harness connector

      (No. 2 HV Battery Pack Wire Connector)
      *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
      Tester Connection Condition Specified Condition
      z31-40(IGCT) - X119-14(IGCT) Always Below 1 Ω
      z31-11(GND) - X119-1(GND) Always Below 1 Ω
      z31-31(GND1) - X119-10(GND1) Always Below 1 Ω
      z31-40(IGCT) or X119-14(IGCT) - Body ground and other terminals Always 10 kΩ or more
      z31-11(GND) or X119-1(GND) - Body ground and other terminals Always 10 kΩ or more
      z31-31(GND1) or X119-10(GND1) - Body ground and other terminals Always 10 kΩ or more

    5. Reconnect the z31 battery ECU assembly connector.

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

      Result
      Proceed to
      OK
      NG

    OK

    GO TO PROBLEM SYMPTOMS TABLE Click here

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  4. CHECK FUSE (IGCT NO. 5)


    1. B004A77C02
      *1 No. 2 luggage room relay block assembly
      *a IGCT NO. 5 Fuse

      Remove the IGCT NO. 5 fuse from the No. 2 luggage room relay block assembly.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      IGCT NO. 5 fuse terminals 1 - 2 Always Below 1 Ω

    3. Install the IGCT NO. 5 fuse to the No. 2 luggage room relay block assembly.

      Result
      Proceed to
      OK
      NG

    NG

    CHECK HARNESS AND CONNECTOR (NO. 2 HV BATTERY PACK WIRE CONNECTOR - NO. 2 LUGGAGE ROOM RELAY BLOCK ASSEMBLY) Click here

    OK

  5. CHECK HARNESS AND CONNECTOR (NO. 2 HV BATTERY PACK WIRE CONNECTOR - NO. 2 LUGGAGE ROOM RELAY 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 No. 4 hybrid battery intake duct.

      Click here

    3. B004BEBE01

      Disconnect the X119 No. 2 HV battery pack wire connector.

      Note

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

    4. Remove the IGCT NO. 5 fuse from the No. 2 luggage room relay block assembly.

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

      B004A6MC02
      *1 No. 2 Luggage Room Relay Block Assembly *a IGCT NO. 5 Fuse Holder
      *b

      Front view of wire harness connector

      (No. 2 HV Battery Pack Wire Connector)

      		 - -
      Standard Voltage
      Tester Connection Condition Specified Condition
      X119-14 (IGCT) - 2 (IGCT NO. 5 fuse holder) Always Below 1 Ω

    6. Install the IGCT NO. 5 fuse to the No. 2 luggage room relay block assembly.

    7. Reconnect the X119 No. 2 HV battery pack wire connector.

    8. Install the No. 4 hybrid battery intake duct.

      Result
      Proceed to
      OK
      NG

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

    OK

  6. CHECK HARNESS AND CONNECTOR (NO. 2 LUGGAGE ROOM RELAY BLOCK ASSEMBLY)


    1. Remove the IGCT NO. 5 fuse from the No. 2 luggage room relay block assembly.

    2. Remove the IGCT NO. 1 relay from the No. 2 luggage room relay block assembly.

    3. B004AGWC02
      *1 No. 2 Luggage Room Relay Block Assembly
      *a IGCT NO. 5 Fuse Holder
      *b IGCT NO. 1 Relay Holder

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      5 (IGCT NO. 1 relay holder) - 1 (IGCT NO. 2 fuse holder) Always Below 1 Ω

    4. Install the IGCT NO. 1 relay from the No. 2 luggage room relay block assembly.

    5. Install the IGCT NO. 5 fuse from the No. 2 luggage room relay block assembly.

      Result
      Proceed to
      OK
      NG

    OK

    CHECK ECU Power Source Circuit (HYBRID CONTROL SYSTEM) Click here

    NG

    REPAIR OR REPLACE HARNESS OR CONNECTOR

  7. CHECK HARNESS AND CONNECTOR (NO. 2 HV BATTERY PACK WIRE CONNECTOR - NO. 2 LUGGAGE ROOM RELAY 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 No. 4 hybrid battery intake duct.

      Click here

    3. B004BEBE01

      Disconnect the X119 No. 2 HV battery pack wire connector.

      Note

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

    4. Remove the IGCT NO. 5 fuse from the No. 2 luggage room relay block assembly.

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

      B004A6MC02
      *1 No. 2 Luggage Room Relay Block Assembly *a IGCT NO. 5 Fuse Holder
      *b

      Front view of wire harness connector

      (No. 2 HV Battery Pack Wire Connector)

      		 - -
      Standard Voltage
      Tester Connection Condition Specified Condition
      X119-14 (IGCT) or 2 (IGCT NO. 5 fuse holder) - Body ground and other terminals Always 10 kΩ or more

    6. Install the IGCT NO. 5 fuse to the No. 2 luggage room relay block assembly.

    7. Reconnect the X119 No. 2 HV battery pack wire connector.

    8. Install the No. 4 hybrid battery intake duct.

      Result
      Proceed to
      OK
      NG

    OK

    REPLACE FUSE (IGCT NO. 5)

    NG

  8. REPAIR OR REPLACE HARNESS OR CONNECTOR

    Result
    Proceed to
    NEXT

    NEXT

    REPLACE FUSE (IGCT NO. 5)