HYBRID CONTROL SYSTEM HV Battery High-voltage Line Circuit

DESCRIPTION

The cause of the malfunction may be the HV battery high-voltage line circuit.

Check the continuity in the high-voltage line from the HV battery to the inverter.

Check the connection condition and for an open circuit in the frame wire from the service plug grip and HV battery to the inverter and perform a function check of the system main relay.

Related Parts Check
Area Inspection Step
High-voltage circuit from HV battery to inverter Check connection condition and for open circuit. 1, 4, 5
Service plug grip Check connection condition and for open circuit. 2, 3
System Main Relay Check operation condition as relay. 6, 7

SYSTEM DESCRIPTION

The HV battery high voltage is supplied to the inverter via the system main relay operation.

WIRING DIAGRAM

A01I35OE01

INSPECTION PROCEDURE

This step is referenced from the procedures for each DTC.

If the inspection results below are normal, perform the next procedure for the referenced DTC.

CAUTION:


  • Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.

  • 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.

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 INVERTER WITH CONVERTER ASSEMBLY (NO. 4 FLOOR WIRE CONNECTOR CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. A01I5ZB

      Remove the connector cover assembly from the inverter with converter assembly.

    3. A01I4JQE01

      Check that the bolt for the No. 4 floor wire is tightened to the specified torque, the No. 4 floor wire is connected securely, and there are no contact problems.

      Specified Condition
      T=8.0 N*m (82 kgf*cm, 71 in.*lbf)

    4. Disconnect connector Q1 of the No. 4 floor wire from the inverter with converter assembly.

    5. Check for arc marks at the bolt and terminals for the No. 4 floor wire.

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B

    6. Connect the No. 4 floor wire to the inverter with converter assembly.

    7. Install the connector cover assembly.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  2. CHECK SERVICE PLUG GRIP (CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Visually check the connection of the service plug grip to the HV battery. Remove the service plug grip and check for contamination.

      OK
      Dirt or foreign matter has not entered the connection, and there is no evidence of contamination.

    2. Install the service plug grip.


    NG

    REPLACE SERVICE PLUG GRIP Click here

    OK

  3. INSPECT SERVICE PLUG GRIP


    1. Remove the service plug drip.

    2. A01I5OJE01
      Text in Illustration
      *1 Service plug grip

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      Service plug grip terminals Always Below 1 Ω

    3. Install the service plug drip.


    NG

    REPLACE SERVICE PLUG GRIP Click here

    OK

  4. CHECK HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (NO. 4 FLOOR WIRE CONNECTION CONDITION)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 4 hybrid battery shield panel Click here.

    3. A01I5G7E04

      Check that the No. 4 floor wire connectors are connected securely, and there are no contact problems.

    4. Disconnect connector Q2 and connector Q3 of the No. 4 floor wire from the hybrid battery junction block assembly.

    5. Check for arc marks on the terminals of the No. 4 floor wire.

      Result
      Result Proceed to
      The terminals are connected securely and there are no contact problems. There are no arc marks. A
      The terminals are not connected securely and there is a contact problem. There are arc marks. B
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C
      The terminals are connected securely and there are no contact problems. There are arc marks. B

    6. Connect the No. 4 floor wire to the hybrid battery junction block assembly.

    7. Install the No. 4 hybrid battery shield panel.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  5. CHECK NO. 4 FLOOR WIRE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the No. 4 hybrid battery shield panel Click here.

    3. A01I5G7E04

      Disconnect connectors Q2 and Q3 of the No. 4 floor wire from the hybrid battery junction block assembly.

    4. A01I5ZB

      Remove the connector cover assembly from the inverter with converter assembly.

    5. A01I4JQE01

      Disconnect connector Q1 of the No. 4 floor wire from the inverter with converter assembly.

    6. A01I63JE01
      Text in Illustration
      *1 Shield Ground
      *a

      No. 4 Floor Wire

      (Inverter with Converter Assembly Side)
      *b

      No. 4 Floor Wire

      (Hybrid Battery Junction Block Assembly Side)

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

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      Q1-1 (CBI) - Q2-1 (CBI) (Positive terminal) Power switch off Below 1 Ω
      Q1-2 (CEI) - Q3-1 (CEI) (Negative terminal) Power switch off Below 1 Ω

    7. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Switch Condition Specified Condition
      Q2-1 (CBI) - Body ground and shield ground Power switch off 10 MΩ or higher
      Q3-1 (CEI) - Body ground and shield ground Power switch off 10 MΩ or higher
      Q2-1 (CBI) - Q3-1 (CEI) Power switch off 10 MΩ or higher

    8. Connect the No. 4 floor wire to the hybrid battery junction block assembly.

    9. Connect the No. 4 floor wire to the inverter with converter assembly.

    10. Install the connector cover assembly.

    11. Install the No. 4 hybrid battery shield panel.


    NG

    REPLACE NO. 4 FLOOR WIRE Click here

    OK

  6. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRB)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the hybrid battery junction block assembly Click here.

    3. A01I4ZAE05
      Text in Illustration
      *a

      Component without harness connected

      (Hybrid Battery Junction Block Assembly)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      A-1 (+) - Q2-1 (CBI) Auxiliary battery voltage is not applied between terminals O9-1 (SMRB) and O9-2 (GND) 10 kΩ or higher
      A-1 (+) - Q2-1 (CBI) Auxiliary battery voltage is applied between terminals O9-1 (SMRB) and O9-2 (GND) Below 1 Ω

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      O9-1 (SMRB) - O9-2 (GND) -40 to 80°C (-40 to 176°F) 25.0 to 59.0 Ω

    5. Install the hybrid battery junction block assembly.


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  7. INSPECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY (SMRG)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the hybrid battery junction block assembly Click here.

    3. A01I4ZAE06
      Text in Illustration
      *a

      Component without harness connected

      (Hybrid Battery Junction Block Assembly)

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      q1-1 (-) - Q3-1 (CEI) Auxiliary battery voltage is not applied between terminals O9-3 (SMRG) and O9-2 (GND) 10 kΩ or higher
      q1-1 (-) - Q3-1 (CEI) Auxiliary battery voltage is applied between terminals O9-3 (SMRG) and O9-2 (GND) Below 1 Ω

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      O9-3 (SMRG) - O9-2 (GND) -40 to 80°C (-40 to 176°F) 25.0 to 59.0 Ω

    5. Install the hybrid battery junction block assembly.


    NG

    REPLACE HYBRID BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

    HV BATTERY HIGH-VOLTAGE LINE CIRCUIT NORMAL (PERFORM NEXT STEP FOR REFERENCED DTC)