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, EV electric battery fuse 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, 5, 6
Service plug grip Check connection condition and for open circuit. 2, 3
EV electric battery fuse Check for open circuit. 4
System Main Relay Check operation condition as relay. 7, 8

SYSTEM DESCRIPTION

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

WIRING DIAGRAM

B004OFJE03

CAUTION / NOTICE / HINT

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.

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PROCEDURE


  1. CHECK INVERTER WITH CONVERTER ASSEMBLY (HV FLOOR UNDER 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. B004QAS

      Check that the bolts for the HV floor under wire is tightened to the specified torque, the HV floor under wire is connected securely, and there are no contact problems.

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

    3. Disconnect the HV floor under wire from the inverter with converter assembly.

    4. Check for arc marks at the terminals for the HV floor under 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 connected securely and there are no contact problems. There are arc marks.
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C

    5. Reconnect the HV floor under wire.


    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 connectors, and there is no evidence of contamination.

    2. Install the service plug grip.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE SERVICE PLUG GRIP Click here

    OK

  3. INSPECT SERVICE PLUG GRIP

    CAUTION:

    Be sure to wear insulated gloves.


    1. Remove the service plug grip.

      Tech Tips

      Click here

    2. B004P62C01
      *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 grip.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE SERVICE PLUG GRIP Click here

    OK

  4. CHECK HYBRID BATTERY TERMINAL BLOCK

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. Remove the Hybrid battery terminal block.

      Tech Tips

      Click here

    2. B004QWZC01
      *1 Hybrid Battery Terminal Block

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      Hybrid battery terminal block Always Below 1 Ω

    3. Install the Hybrid battery terminal block.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE HYBRID BATTERY TERMINAL BLOCK Click here

    OK

  5. CHECK HV BATTERY JUNCTION BLOCK ASSEMBLY (HV FLOOR UNDER 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. 1 HV battery cover panel RH.

      Tech Tips

      Click here

    3. B004QYD

      Check the HV floor under wire is connected securely, and there are no contact problems.

    4. Disconnect the HV floor under wire connectors from the HV battery junction block assembly.

    5. Check for arc marks on the terminals of the HV floor wire and the HV battery junction block assembly.

      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 connected securely and there are no contact problems. There are arc marks.
      The terminals are not connected securely and there is a contact problem. There are no arc marks. C

    6. Connect the HV floor under wire connectors to the HV battery junction block assembly.

    7. Install the No. 1 HV battery cover panel RH.


    B

    REPLACE MALFUNCTIONING PARTS

    C

    CONNECT SECURELY

    A

  6. CHECK HV FLOOR UNDER 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. 1 HV battery cover panel RH.

      Tech Tips

      Click here

    3. B004QYD

      Disconnect the HV floor under wire connectors from the HV battery junction block assembly.

    4. B004QIR

      Disconnect the HV floor under wire connector from the inverter with converter assembly.

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

      B004PCBC04
      *1 Shield Ground - -
      *a

      HV Floor Under Wire

      (Inverter with Converter Assembly Side)

      		 *b

      HV Floor Under Wire

      (HV Battery Junction Block Assembly Side)
      Standard Resistance
      Tester Connection Condition Specified Condition
      S1-1 (CBI) - S4-1 (CBI) Power switch off Below 1 Ω
      S1-2 (CEI) - S3-1 (CEI) Power switch off Below 1 Ω

      Note

      Be sure not to damage or deform the terminal being inspected.

    6. 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 Condition Specified Condition
      S1-1 (CBI) or S4-1(CBI) - Body ground and shield ground Power switch off 10 MΩ or higher
      S1-2 (CEI) or S3-1(CEI) - Body ground and shield ground Power switch off 10 MΩ or higher
      S1-1 (CBI) - S1-2 (CEI) Power switch off 10 MΩ or higher
      S4-1 (CBI) - S3-1 (CEI) Power switch off 10 MΩ or higher

    7. Reconnect the HV floor under wire connector to the inverter with converter assembly.

    8. Reconnect the HV floor under wire connectors to the HV battery junction block assembly.

    9. Install the No. 1 HV battery cover panel RH.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE HV FLOOR UNDER WIRE Click here

    OK

  7. INSPECT HV 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 HV battery junction block assembly.

      Tech Tips

      Click here

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

      B004PMLC34
      *a

      Component without harness connected

      (HV Battery Junction Block Assembly)

      		 - -
      Standard Resistance
      Tester Connection Condition Specified Condition
      A-1 (+) - S4-1 (CBI) Auxiliary battery voltage not applied between terminals M37-1 (SMRB) and M37-3 (GND) 10 kΩ or higher
      A-1 (+) - S4-1 (CBI) Auxiliary battery voltage applied between terminals M37-1 (SMRB) and M37-3 (GND) Below 1 Ω

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      M37-1 (SMRB) - M37-3 (GND) -40 to 80°C (-40 to 176°F) 20.6 to 40.8 Ω

    5. Install the HV battery junction block assembly.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  8. INSPECT HV 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 HV battery junction block assembly.

      Tech Tips

      Click here

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

      B004PMLC45
      *a

      Component without harness connected

      (HV Battery Junction Block Assembly)

      		 - -
      Standard Resistance
      Tester Connection Condition Specified Condition
      z12-1 (-) - S3-1 (CEI) Auxiliary battery voltage not applied between terminals M37-4 (SMRG) and M37-3 (GND) 10 kΩ or higher
      z12-1 (-) - S3-1 (CEI) Auxiliary battery voltage applied between terminals M37-4 (SMRG) and M37-3 (GND) Below 1 Ω

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      M37-4 (SMRG) - M37-3 (GND) -40 to 80°C (-40 to 176°F) 20.6 to 40.8 Ω

    5. Install the HV battery junction block assembly.

      Result
      Proceed to
      OK
      NG

    OK

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

    NG

    REPLACE HV BATTERY JUNCTION BLOCK ASSEMBLY Click here