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HYBRID BATTERY SYSTEM, Diagnostic DTC:P1CC81E, P1CC91E

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DTC Code DTC Name
P1CC81E Hybrid/EV Battery Stack 1 Voltage Difference Out of Range
P1CC91E Hybrid/EV Battery Stack 2 Voltage Difference Out of Range
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DESCRIPTION

The HV battery is composed of 84 cells (3.7 V each) in series. The battery ECU assembly monitors difference in voltage of each HV battery cell to detect malfunctions of the HV battery.

DTC No. Detection Item DTC Detection Condition Trouble Area MIL Warning Indicate
P1CC81E Hybrid/EV Battery Stack 1 Voltage Difference Out of Range

The difference in voltage of each cell of the No. 1 HV supply stack sub-assembly exceeds the specified value.

(1 trip detection logic)

  • No. 1 HV supply stack sub-assembly

  • Hybrid battery terminal block

  • Battery voltage sensor (for upper side)

 Comes on

Master Warning Light:

Comes on
P1CC91E Hybrid/EV Battery Stack 2 Voltage Difference Out of Range

The difference in voltage of each cell of the No. 2 HV supply stack sub-assembly exceeds the specified value.

(1 trip detection logic)

  • No. 2 HV supply stack sub-assembly

  • Hybrid battery terminal block

  • Battery voltage sensor (for lower side)

 Comes on

Master Warning Light:

Comes on
Table 1. Related Data List
DTC No. Data List
P1CC81E Hybrid Battery Cell 1 to 84 Voltage*1
P1CC91E
*1
No. 1 HV Supply Stack Sub-assembly:
Hybrid Battery Cell 1 to 42 Voltage
No. 2 HV Supply Stack Sub-assembly:
Hybrid Battery Cell 43 to 84 Voltage

The following items can be helpful when performing repairs:


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CONFIRMATION DRIVING PATTERN

Tip:

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.

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  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 1 hour 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. Drive the vehicle on urban roads for approximately 10 minutes.

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

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

  10. Check the DTC judgment result.

    Tip:

    • 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, perform driving pattern again.

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CAUTION / NOTICE / HINT

CAUTION:

  • B004STG

    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

  • B004Y5N

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

  • B004SX1

    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.

  • B004W3JC06
    *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.

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    Tip:

    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.

  • Make sure to insulate the high-voltage connectors and terminals of the HV battery with insulating tape after removing it.

    If the HV battery stored without insulating the connectors and terminals, electric shock or fire may result.

  • B004SCIC06
    *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.

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  • Before returning the HV supply stack sub-assembly, make sure to perform a recovery inspection.

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  • 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.

  • B004X4P

    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.

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PROCEDURE


  1. Click here

    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.


      1. Powertrain > HV Battery > Trouble Codes



      1. Powertrain > Hybrid Control > Trouble Codes


      Result
      Result Proceed to
      "P1CC81E or P1CC91E" 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.


  2. Click here

    CHECK ODOMETER


    1. Check and record the total distance traveled of the vehicle.

      Result
      Proceed to
      NEXT

  3. Click here

    CHECK DTC


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

      Result
      Result Proceed to
      "P1CC81E" is also output. A
      "P1CC91E" is also output. B

  4. Click here

    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 P1CC81E and make a note if the value of any is the lowest voltage value.


      1. Powertrain > HV Battery > Trouble Codes


      Tip:

      Use this for reference when measuring the battery voltage sensor resistance.

    5. Turn the power switch off.

      Result
      Proceed to
      NEXT

  5. Click here

    CHECK CONNECTOR CONNECTION CONDITION (BATTERY VOLTAGE SENSOR (for Upper Side) CONNECTOR)

    Result
    Result Proceed to
    OK A
    Not connected securely The terminals are not damaged or corroded B
    Either connector z14 or z15 was not connected securely The terminals are damaged or corroded C
    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. B004RVON03

      Check the connections of the z14 and z15 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 z14 or z15 was not connected securely The terminals are damaged or corroded C

  6. Click here

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

    Result
    Result Proceed to
    The voltage between the terminals is 50 kΩ or more. A
    Other than above B
    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:
      B004V6WN02

      When disconnecting connector d1 of the battery voltage sensor (for upper side), first disconnect connector z14 and z15 from the battery voltage sensor (for upper side).

      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. B004UEFC06
      *a

      Component without harness connected

      (Battery Voltage Sensor (for Upper Side))

      		 - -

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

      Tip:

      Only inspect the terminals of the battery ECU assembly which correspond to the HV battery cells which measured the lowest voltage value in the previous step.

      Standard Resistance
      Hybrid Battery Cell

      Tester Connection

      (Tester Probe Polarity)

      		 Condition Specified Condition
      1 z14-10(GA0) (-) - z14-24(VA1) (+) Always 50 kΩ or more
      2 z14-24(VA1) (-) - z14-9(VA2) (+) Always 50 kΩ or more
      3 z14-9(VA2) (-) - z14-23(VA3) (+) Always 50 kΩ or more
      4 z14-23(VA3) (-) - z14-8(VA4) (+) Always 50 kΩ or more
      5 z14-8(VA4) (-) - z14-7(VA5) (+) Always 50 kΩ or more
      6 z14-7(VA5) (-) - z14-22(VA6) (+) Always 50 kΩ or more
      7 z14-22(VA6) (-) - z14-6(VA7) (+) Always 50 kΩ or more
      8 z14-6(VA7) (-) - z14-21(VA8) (+) Always 50 kΩ or more
      9 z14-21(VA8) (-) - z14-20(VA9) (+) Always 50 kΩ or more
      10 z14-20(VA9) (-) - z14-19(VA10) (+) Always 50 kΩ or more
      11 z14-19(VA10) (-) - z14-18(VA11) (+) Always 50 kΩ or more
      12 z14-18(VA11) (-) - z14-17(VA12) (+) Always 50 kΩ or more
      13 z14-17(VA12) (-) - z14-16(VA13) (+) Always 50 kΩ or more
      14 z14-16(VA13) (-) - z14-15(VA14) (+) Always 50 kΩ or more
      15 z14-15(VA14) (-) - z14-14(VA15) (+) Always 50 kΩ or more
      16 z14-14(VA15) (-) - z14-5(VA16) (+) Always 50 kΩ or more
      17 z14-5(VA16) (-) - z14-13(VA17) (+) Always 50 kΩ or more
      18 z14-13(VA17) (-) - z14-4(VA18) (+) Always 50 kΩ or more
      19 z14-4(VA18) (-) - z14-3(VA19) (+) Always 50 kΩ or more
      20 z14-3(VA19) (-) - z14-12(VA20) (+) Always 50 kΩ or more
      21 z14-12(VA20) (-) - z14-2(VA21) (+) Always 50 kΩ or more
      22 z14-2(VA21) (-) - z14-11(VA22) (+) Always 50 kΩ or more
      23 z15-23(GA1) (-) - z15-8(VA23) (+) Always 50 kΩ or more
      24 z15-8(VA23) (-) - z15-7(VA24) (+) Always 50 kΩ or more
      25 z15-7(VA24) (-) - z15-22(VA25) (+) Always 50 kΩ or more
      26 z15-22(VA25) (-) - z15-6(VA26) (+) Always 50 kΩ or more
      27 z15-6(VA26) (-) - z15-21(VA27) (+) Always 50 kΩ or more
      28 z15-21(VA27) (-) - z15-20(VA28) (+) Always 50 kΩ or more
      29 z15-20(VA28) (-) - z15-19(VA29) (+) Always 50 kΩ or more
      30 z15-19(VA29) (-) - z15-18(VA30) (+) Always 50 kΩ or more
      31 z15-18(VA30) (-) - z15-17(VA31) (+) Always 50 kΩ or more
      32 z15-17(VA31) (-) - z15-16(VA32) (+) Always 50 kΩ or more
      33 z15-16(VA32) (-) - z15-15(VA33) (+) Always 50 kΩ or more
      34 z15-15(VA33) (-) - z15-14(VA34) (+) Always 50 kΩ or more
      35 z15-14(VA34) (-) - z15-5(VA35) (+) Always 50 kΩ or more
      36 z15-5(VA35) (-) - z15-13(VA36) (+) Always 50 kΩ or more
      37 z15-13(VA36) (-) - z15-4(VA37) (+) Always 50 kΩ or more
      38 z15-4(VA37) (-) - z15-3(VA38) (+) Always 50 kΩ or more
      39 z15-3(VA38) (-) - z15-12(VA39) (+) Always 50 kΩ or more
      40 z15-12(VA39) (-) - z15-2(VA40) (+) Always 50 kΩ or more
      41 z15-2(VA40) (-) - z15-11(VA41) (+) Always 50 kΩ or more
      42 z15-11(VA41) (-) - z15-1(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:
      B004V6WN02

      When disconnecting connector d1 of the battery voltage sensor (for upper side), first disconnect connector z14 and z15 from the battery voltage sensor (for upper side).


  7. Click here

    CHECK TOTAL DISTANCE DRIVEN


    1. Check the recorded total distance traveled of the vehicle.

      Result
      Result Proceed to
      Total distance driven is less than 200000 km (124280 mile) A
      Total distance driven is 200000 km (124280 mile) or more Current total distance driven - total distance driven when hybrid battery terminal block replaced = less than 200000 km (124280 mile) *1
      Other than above B
      Tip:

      *1: If the hybrid battery terminal block has been replaced, use the total distance driven since it was replaced.


  8. Click here

    REPLACE NO. 1 HV SUPPLY STACK SUB-ASSEMBLY

    Click here

    Result
    Proceed to
    NEXT

    • NEXT

      REPLACE HYBRID BATTERY TERMINAL BLOCKClick here

  9. Click here

    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 P1CC91E and make a note if the value of any is the lowest voltage value.


      1. Powertrain > HV Battery > Trouble Codes


      Tip:

      Use this for reference when measuring the battery voltage sensor resistance.

    5. Turn the power switch off.

      Result
      Proceed to
      NEXT

  10. Click here

    CHECK CONNECTOR CONNECTION CONDITION (BATTERY VOLTAGE SENSOR (for Lower Side) CONNECTOR)

    Result
    Result Proceed to
    OK A
    Not connected securely The terminals are not damaged or corroded B
    Either connector z16 or z17 was not connected securely The terminals are damaged or corroded C
    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. B004T7KN04

      Check the connections of the z16 and z17 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 z16 or z17 was not connected securely The terminals are damaged or corroded C

  11. Click here

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

    Result
    Result Proceed to
    The voltage between the terminals is 50 kΩ or more. A
    Other than above B
    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:
      B004RSTN02

      When disconnecting connector d3 of the battery voltage sensor (for lower side), first disconnect connector z16 and z17 from the battery voltage sensor (for lower side).

      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. B004UEFC07
      *a

      Component without harness connected

      (Battery Voltage Sensor (for Lower Side))

      		 - -

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

      Tip:

      Only inspect the terminals of the battery ECU assembly which correspond to the HV battery cells which measured the lowest voltage value in the previous step.

      Standard Resistance
      Hybrid Battery Cell

      Tester Connection

      (Tester Probe Polarity)

      		 Condition Specified Condition
      43 z16-10(GA2) (-) - z16-24(VA43) (+) Always 50 kΩ or more
      44 z16-24(VA43) (-) - z16-9(VA44) (+) Always 50 kΩ or more
      45 z16-9(VA44) (-) - z16-23(VA45) (+) Always 50 kΩ or more
      46 z16-23(VA45) (-) - z16-8(VA46) (+) Always 50 kΩ or more
      47 z16-8(VA46) (-) - z16-7(VA47) (+) Always 50 kΩ or more
      48 z16-7(VA47) (-) - z16-22(VA48) (+) Always 50 kΩ or more
      49 z16-22(VA48) (-) - z16-6(VA49) (+) Always 50 kΩ or more
      50 z16-6(VA49) (-) - z16-21(VA50) (+) Always 50 kΩ or more
      51 z16-21(VA50) (-) - z16-20(VA51) (+) Always 50 kΩ or more
      52 z16-20(VA51) (-) - z16-19(VA52) (+) Always 50 kΩ or more
      53 z16-19(VA52) (-) - z16-18(VA53) (+) Always 50 kΩ or more
      54 z16-18(VA53) (-) - z16-17(VA54) (+) Always 50 kΩ or more
      55 z16-17(VA54) (-) - z16-16(VA55) (+) Always 50 kΩ or more
      56 z16-16(VA55) (-) - z16-15(VA56) (+) Always 50 kΩ or more
      57 z16-15(VA56) (-) - z16-14(VA57) (+) Always 50 kΩ or more
      58 z16-14(VA57) (-) - z16-5(VA58) (+) Always 50 kΩ or more
      59 z16-5(VA58) (-) - z16-13(VA59) (+) Always 50 kΩ or more
      60 z16-13(VA59) (-) - z16-4(VA60) (+) Always 50 kΩ or more
      61 z16-4(VA60) (-) - z16-3(VA61) (+) Always 50 kΩ or more
      62 z16-3(VA61) (-) - z16-12(VA62) (+) Always 50 kΩ or more
      63 z16-12(VA62) (-) - z16-2(VA63) (+) Always 50 kΩ or more
      64 z16-2(VA63) (-) - z16-11(VA64) (+) Always 50 kΩ or more
      65 z17-23(GA3) (-) - z17-8(VA65) (+) Always 50 kΩ or more
      66 z17-8(VA65) (-) - z17-7(VA66) (+) Always 50 kΩ or more
      67 z17-7(VA66) (-) - z17-22(VA67) (+) Always 50 kΩ or more
      68 z17-22(VA67) (-) - z17-6(VA68) (+) Always 50 kΩ or more
      69 z17-6(VA68) (-) - z17-21(VA69) (+) Always 50 kΩ or more
      70 z17-21(VA69) (-) - z17-20(VA70) (+) Always 50 kΩ or more
      71 z17-20(VA70) (-) - z17-19(VA71) (+) Always 50 kΩ or more
      72 z17-19(VA71) (-) - z17-18(VA72) (+) Always 50 kΩ or more
      73 z17-18(VA72) (-) - z17-17(VA73) (+) Always 50 kΩ or more
      74 z17-17(VA73) (-) - z17-16(VA74) (+) Always 50 kΩ or more
      75 z17-16(VA74) (-) - z17-15(VA75) (+) Always 50 kΩ or more
      76 z17-15(VA75) (-) - z17-14(VA76) (+) Always 50 kΩ or more
      77 z17-14(VA76) (-) - z17-5(VA77) (+) Always 50 kΩ or more
      78 z17-5(VA77) (-) - z17-13(VA78) (+) Always 50 kΩ or more
      79 z17-13(VA78) (-) - z17-4(VA79) (+) Always 50 kΩ or more
      80 z17-4(VA79) (-) - z17-3(VA80) (+) Always 50 kΩ or more
      81 z17-3(VA80) (-) - z17-12(VA81) (+) Always 50 kΩ or more
      82 z17-12(VA81) (-) - z17-2(VA82) (+) Always 50 kΩ or more
      83 z17-2(VA82) (-) - z17-11(VA83) (+) Always 50 kΩ or more
      84 z17-11(VA83) (-) - z17-1(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:
      B004RSTN02

      When connecting connectors z16 and z17 of the battery voltage sensor (for lower Side), first connect connector d3 to the battery voltage sensor (for lower Side).


  12. Click here

    CHECK TOTAL DISTANCE DRIVEN


    1. Check the recorded total distance traveled of the vehicle.

      Result
      Result Proceed to
      Total distance driven is less than 200000 km (124280 mile) A
      Total distance driven is 200000 km (124280 mile) or more Current total distance driven - total distance driven when hybrid battery terminal block replaced = less than 200000 km (124280 mile) *1
      Other than above B
      Tip:

      *1: If the hybrid battery terminal block has been replaced, use the total distance driven since it was replaced.


  13. Click here

    REPLACE NO. 2 HV SUPPLY STACK SUB-ASSEMBLY

    Click here

    Result
    Proceed to
    NEXT

    • NEXT

      REPLACE HYBRID BATTERY TERMINAL BLOCKClick here