HYBRID CONTROL SYSTEM, Diagnostic DTC:P0AA649, P1C7C49, P1C7D49, P1C7E49, P1C7F49, P1CF749, P33CF49

DTC Code DTC Name
P0AA649 Hybrid/EV Battery Voltage System Isolation Internal Electronic Failure
P1C7C49 Hybrid/EV Battery Voltage System Isolation (A/C Area) Internal Electronic Failure
P1C7D49 Hybrid/EV Battery Voltage System Isolation (Hybrid/EV Battery Area) Internal Electronic Failure
P1C7E49 Hybrid/EV Battery Voltage System Isolation (Transaxle Area) Internal Electronic Failure
P1C7F49 Hybrid/EV Battery Voltage System Isolation (Direct Current Area) Internal Electronic Failure
P1CF749 Hybrid/EV Battery Voltage System Isolation (Charger Area) Internal Electronic Failure
P33CF49 Hybrid/EV Battery Voltage System Isolation Internal Electronic Failure Abnormal Area Detection Failure

DESCRIPTION

The hybrid vehicle control ECU monitors the battery ECU assembly and detects insulation malfunctions in the high-voltage system.

DTC No. Detection Item DTC Detection Condition Trouble Area MIL Warning Indicate
P0AA649 Hybrid/EV Battery Voltage System Isolation Internal Electronic Failure

Insulation resistance between the high-voltage circuit and the body has decreased.*2

(1 trip detection logic)

  • Inverter with converter assembly

  • HV floor under wire

  • No. 1 HV battery junction block assembly

  • No. 2 HV battery junction block assembly

  • Battery ECU assembly

  • Hybrid battery terminal block

  • No. 1 HV supply stack sub-assembly

  • No. 2 HV supply stack sub-assembly

  • No. 3 HV supply stack sub-assembly

  • No. 4 HV supply stack sub-assembly

  • No. 5 HV supply stack sub-assembly

  • Hybrid vehicle transaxle assembly

  • Motor cable

  • HV battery charger wire

  • Air conditioning wire

  • Air conditioning system

  • Electric vehicle charger assembly

  • Solar energy control unit*1

 Does not come on

Master Warning Light:

Comes on
P1C7C49 Hybrid/EV Battery Voltage System Isolation (A/C Area) Internal Electronic Failure

Insulation resistance of the compressor with motor assembly or air conditioning inverter has decreased.*3

(1 trip detection logic)

 Air conditioning system Does not come on

Master Warning Light:

Comes on
P1C7D49 Hybrid/EV Battery Voltage System Isolation (Hybrid/EV Battery Area) Internal Electronic Failure

Insulation resistance of the HV battery, battery ECU assembly or SMR has decreased.*3

(1 trip detection logic)

  • No. 1 HV battery junction block assembly

  • No. 2 HV battery junction block assembly

  • Battery ECU assembly

  • Hybrid battery terminal block

  • No. 1 HV supply stack sub-assembly

  • No. 2 HV supply stack sub-assembly

  • No. 3 HV supply stack sub-assembly

  • No. 4 HV supply stack sub-assembly

  • No. 5 HV supply stack sub-assembly

 Comes on

Master Warning Light:

Comes on
P1C7E49 Hybrid/EV Battery Voltage System Isolation (Transaxle Area) Internal Electronic Failure

Insulation resistance of the hybrid vehicle transaxle assembly or inverter for the generator (MG1) and motor (MG2) has decreased.*3

(1 trip detection logic)

  • Inverter with converter assembly

  • Hybrid vehicle transaxle assembly

  • Motor cable

 Does not come on

Master Warning Light:

Comes on
P1C7F49 Hybrid/EV Battery Voltage System Isolation (Direct Current Area) Internal Electronic Failure

Insulation resistance of the inverter for the generator (MG1) and motor (MG2), A/C inverter, SMR or No. 2 engine room wire has decreased.*3

(1 trip detection logic)

  • Inverter with converter assembly

  • HV floor under wire

  • No. 1 HV battery junction block assembly

  • No. 2 HV battery junction block assembly

  • Hybrid vehicle transaxle assembly

  • Motor cable

  • HV battery charger wire

  • Air conditioning wire

  • Air conditioning system

 Does not come on

Master Warning Light:

Comes on
P1CF749 Hybrid/EV Battery Voltage System Isolation (Charger Area) Internal Electronic Failure

Insulation resistance of the electric vehicle charger assembly, solar energy control unit, SMR, or DC charge high-voltage wire harness has decreased.*3

(1 trip detection logic)

  • Electric vehicle charger assembly

  • No. 1 HV battery junction block assembly

  • No. 2 HV battery junction block assembly

  • HV battery charger wire

  • Solar energy control unit*1

 Comes on

Master Warning Light:

Comes on
P33CF49 Hybrid/EV Battery Voltage System Isolation Internal Electronic Failure Abnormal Area Detection Failure

Insulation resistance has decreased in an unspecified area.

(1 trip detection logic)

  • Inverter with converter assembly

  • HV floor under wire

  • No. 1 HV battery junction block assembly

  • No. 2 HV battery junction block assembly

  • Battery ECU assembly

  • Hybrid battery terminal block

  • No. 1 HV supply stack sub-assembly

  • No. 2 HV supply stack sub-assembly

  • No. 3 HV supply stack sub-assembly

  • No. 4 HV supply stack sub-assembly

  • No. 5 HV supply stack sub-assembly

  • Hybrid vehicle transaxle assembly

  • Motor cable

  • HV battery charger wire

  • Air conditioning wire

  • Air conditioning system

  • Electric vehicle charger assembly

  • Solar energy control unit*1

 Comes on

Master Warning Light:

Comes on

*1: w/ Solar Charging System

Tech Tips


  • *2: The insulation malfunction detection circuit in the battery ECU assembly monitors the insulation resistance between the high voltage circuits and body. If the insulation resistance decreases, the hybrid vehicle control ECU stores DTC P0AA649 and illuminates the master warning light first regardless of malfunction area.

    Depending on the vehicle condition, the high voltage circuit insulation resistance may return to normal. So if DTC P0AA649 outputs, complete the following steps as soon as possible.

  • *3: If the following operations are performed within the same trip after DTC P0AA649 is stored, just one of the related DTCs (P1C7C49, P1C7D49, P1C7E49, P1C7F49 or P1CF749) will be stored.


    1. Apply the parking brake firmly.

    2. Wait for 1 minute or more with the vehicle stopped, the brake pedal firmly depressed, the power switch on (READY), drive (D) selected and the air conditioning system on (Lo/MAX COOL, blower speed HI).

    3. Turn the power switch off and wait for 2 minutes or more.

    4. Connect the electric vehicle charger cable assembly, and plug-in charge the vehicle for 3 minutes or more.

      Tech Tips


      • DTCs and freeze frame data are useful information in determining the malfunctioning part. Before performing diagnosis, make sure to check and make a note of all output DTCs and freeze frame data. (Even if a high-voltage insulation malfunction cannot be reproduced, once stored, DTCs of insulation will not be cleared unless the clear operation is performed.)

      • When the insulation resistance of the HV battery area decreases and the power switch is turned on (IG), DTC P1C7D49 is stored within 2 minutes.

  • When measuring insulation resistance using a megohmmeter, measure the resistance while jiggling the high voltage wire harness.

Related Data List (Reproduction of Phenomenon and Check)
DTC No. Data List
P0AA649

  • Short Wave Highest Value Level

  • Hybrid Battery Voltage

  • VL-Voltage before Boosting

  • VH-Voltage after Boosting

  • Boost Ratio

  • A/C Consumption Power

  • SMRP Status

  • SMRB Status

  • SMRG Status

  • Generator Inverter Shutdown Status

  • Motor Inverter Shutdown Status

  • Insulation Resistance Division Check Completion using MG Inv

  • Insulation Resistance Division Check Completion using A/C Inv

  • Insulation Resistance Division Check Completion using SMR

  • Insulation Resistance Division Check Completion using AC Charging Area

  • Short Wave Highest Value Availability just after MG Inv On/Off

  • Short Wave Highest Value Availability just after A/C Inv On/Off

  • Short Wave Highest Value Availability just after SMR On/Off

  • Short Wave Highest Value Availability just after AC Charging Relay On/Off

  • AC Charging Precharge Relay Status

  • AC Charging Positive Relay Status

  • AC Charging Negative Relay Status
P1C7C49
P1C7D49
P1C7E49
P1C7F49
P1CF749
P33CF49

Use the following items as a reference when duplicating the vehicle conditions at the time when the malfunction occurred.


CONFIRMATION DRIVING PATTERN


  1. CONFIRMATION AFTER REPLACING PARTS

    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. (Do not turn the power switch off (READY off) during this inspection.)

    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. Apply the parking brake and secure the wheels using chocks.

    6. When the vehicle is stationary, turn the power switch on (READY) with park (P) selected and wait for1 minute or more.

    7. Turn the air conditioning system on (MAX COLD, blower speed HI).

    8. While depressing the brake pedal without depressing the accelerator pedal, move the shift lever to D and wait for 5 minutes.

      - If step B is performed within the same trip after DTC P0AA649 is stored, the parts with insufficient insulation resistance will be determined and a DTC (P1C7C49, P1C7D49, P1C7E49 or P1C7F49) will be stored.

      - If no DTCs are output, proceed to the step A.

    9. Drive the vehicle for approximately 5 minutes referring to the following freeze frame data items: "Vehicle Speed", "Shift Position", "Accelerator Position Sensor No.1 Voltage %", "Engine Speed", "Coolant Temperature", "Master Cylinder Control Torque", "Motor Temperature" and "Generator Temperature". (Step A)

      (If the freeze frame data item "Vehicle Speed" is 10 km/h (6 mph) or less, drive the vehicle at 10km/h (6 mph) or more.)

      - If step B is performed within the same trip after DTC P0AA649 is stored, the parts with insufficient insulation resistance will be determined and a DTC (P1C7C49, P1C7D49, P1C7E49 or P1C7F49) will be stored.

      - If DTC P0AA649 is output, complete the Step B immediately as quickly as possible.

      - If no DTCs are output, proceed to the step C.

    10. Wait for 1 minute or more with the vehicle stopped, the power switch on (READY), park (P) selected and the air conditioning system on (Lo/COOL MAX, blower speed HI), then turn the power switch off and wait for 2 minutes or more. (Step B)

    11. Turn the power switch off and connect the electric vehicle charger cable assembly, and plug-in charge the vehicle for 3 minutes or more. (step C)

      - When charging does not continue for 3 minutes with no DTC output, lower the SOC and then perform the step C again.

      - If DTC P0AA649 is output at this step, the area where the insulation resistance has decreased is specified and DTC P1C7D49, P1CF749 or P33CF49 is also output.

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

    13. Enter the following menus: Powertrain / Hybrid Control / Utility / All Readiness.

    14. 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

B006IN8C01
*A w/ Solar Charging System - -
*1 HV Battery *2 Battery ECU assembly
*3 SMRB *4 SMRG
*5 SMRP *6 System Main Resistor
*7 Service Plug Grip *8 Inverter with Converter Assembly
*9 Boost Converter *10 Inverter
*11 Generator (MG1) *12 Motor (MG2)
*13 Compressor with Motor Assembly *14 A/C Inverter
*15 A/C Motor *16 Electric Vehicle Charger Assembly
*17 CHRB *18 CHRG
*19 CHRP *20 Solar Energy Control Unit
*a High-voltage Areas *b DTC P0AA649 Vehicle Insulation Resistance Reduction Area
*c DTC P1C7C49 Air Conditioning System Area *d DTC P1C7D49 HV Battery Area
*e DTC P1C7E49 Hybrid Vehicle Transaxle Assembly Area *f DTC P1C7F49 High Voltage Direct Current Area
*g DTC P1CF749 Charger Area - -
B006HG9C01
*A w/o Solar Charging System - -
*1 HV Battery *2 Battery ECU assembly
*3 SMRB *4 SMRG
*5 SMRP *6 System Main Resistor
*7 Service Plug Grip *8 Inverter with Converter Assembly
*9 Boost Converter *10 Inverter
*11 Generator (MG1) *12 Motor (MG2)
*13 Compressor with Motor Assembly *14 A/C Inverter
*15 A/C Motor *16 Electric Vehicle Charger Assembly
*17 CHRB *18 CHRG
*19 CHRP - -
*a High-voltage Areas *b DTC P0AA649 Vehicle Insulation Resistance Reduction Area
*c DTC P1C7C49 Air Conditioning System Area *d DTC P1C7D49 HV Battery Area
*e DTC P1C7E49 Hybrid Vehicle Transaxle Assembly Area *f DTC P1C7F49 High Voltage Direct Current Area
*g DTC P1CF749 Charger Area - -
B006IX8E02
B006ILEE04
B006HPDE02

SYSTEM DESCRIPTION

Tech Tips

If a decrease in insulation resistance cannot be confirmed using a megohmmeter, check "Short Wave Highest Value Level" in the Data List.


  1. SHORT WAVE HIGHEST VALUE LEVEL


    1. "Short Wave Highest Value Level" shows a decrease in insulation resistance. When insulation resistance decreases, "Insulation Lower" will be displayed. However, even though the insulation resistance of the vehicle is normal, "Short Wave Highest Value Level" may decrease, so that "Not Judge" will be displayed for any of the following conditions.


      • Within approximately 1 minute since the power switch was turned on (IG).

      • When the system voltages ("Hybrid Battery Voltage", "VL-Voltage before Boosting" and "VH-Voltage after Boosting") are changing.

      • During boosting. If the Data List item "Boost Ratio" is not 0% or within a few seconds of it becoming 0%. (The values of "Hybrid Battery Voltage", "VL-Voltage before Boosting" and "VH-Voltage after Boosting" are about the same when not boosting.)

      • When "No" is displayed for any of the following Data List items:

        - Short Wave Highest Value Availability just after MG Inv On/Off

        - Short Wave Highest Value Availability just after A/C Inv On/Off

        - Short Wave Highest Value Availability just after SMR On/Off

        - Short Wave Highest Value Availability just after AC Charging Relay On/Off

    2. When "Short Wave Highest Value Level" shows "Insulation Lower LV3", insulation resistance will be close to 0 Ω. In this case, damage to a high-voltage cable or hybrid component (high-voltage), or a short to body ground due to intrusion of foreign matter, such as metal particles, can be suspected.


    • If problem symptoms cannot be reproduced and a malfunction still exists after replacing a part as instructed, checking the following freeze frame data can help determine a trouble area.

    Items to be Checked Using Freeze Frame Data:
    Freeze Frame Data Diagnostic Note
    Short Wave Highest Value Level Indicates that the insulation resistance has decreased.

    • VL-Voltage before Boosting

    • VH-Voltage after Boosting

    • Hybrid Battery Voltage

    • Boost Ratio

    		 During boosting (when "Boost Ratio" is not 0%), or when "VL-Voltage before Boosting", "VH-Voltage after Boosting" or "Hybrid Battery Voltage" is varying, "Short Wave Highest Value Level" may decrease even though the insulation resistance is normal.

    • SMRP Status

    • SMRB Status

    • SMRG Status

    • AC Charging Precharge Relay Status

    • AC Charging Positive Relay Status

    • AC Charging Negative Relay Status

    When "SMRP Status", "SMRB Status", "SMRG Status", "CHRP Status", "CHRB Status" and "CHRG Status" are all OFF, the insulation malfunction detection circuit detects a decrease in insulation resistance in the HV battery area ((*d) in the wiring diagram).


      Example:

    • When the power switch is turned on (IG) (not on (READY)) and the electric vehicle charger cable assembly is disconnected, and the solar charging system is not operating, all 3 system main relays and 3 charge relays are off and it is suspected that the HV battery is disconnected from the high voltage circuits.

      If "Insulation Short Wave Highest Value Level" decreases a few minutes after the power switch is turned on (IG) (not on (READY)) and the electric vehicle charger cable assembly is disconnected, the HV battery may have an insulation malfunction.
    Motor Inverter Shutdown Status

    When "Motor Inverter Shutdown Status" is ON, the insulation malfunction detection circuit cannot detect a decrease in insulation resistance in the motor system AC (alternating current) section (motor (MG2) side of (*e) in the wiring diagram).

    The motor system AC (alternating current) section includes the motor (MG2) in the hybrid vehicle transaxle assembly, motor cables and the AC (alternating current) section of the motor drive circuit in the inverter with converter assembly.
    Generator Inverter Shutdown Status

    When "Generator Inverter Shutdown Status" is ON, the insulation malfunction detection circuit cannot detect a decrease in insulation resistance in the generator system AC (alternating current) section (generator (MG1) side of (*e) in the wiring diagram).

    The generator system AC (alternating current) section includes the generator (MG1) in the hybrid vehicle transaxle assembly, generator cables and the AC (alternating current) section of the generator drive circuit in the inverter with converter assembly.
    A/C Consumption Power

    The compressor with motor assembly AC (alternating current) section ((*c) in the wiring diagram) includes the air conditioning motor, wiring between the air conditioning motor and air conditioning inverter, and the AC (alternating current) section of the air conditioning motor drive circuit in the air conditioning inverter.

    With the vehicle stopped, turn on/off the air conditioning system and observe "Short Wave Highest Value Level" to use as a diagnosis reference.

    RELATED FREEZE FRAME DATA

    Tech Tips


    • Reproducing the vehicle conditions the moment a DTC was stored according to the freeze frame data and results of the customer problem analysis helps ensure that the same DTC is stored again.

      Driving Status
      Item Diagnostic Note
      Vehicle Speed -
      Accelerator Position Sensor No.1 Voltage % -
      Engine Speed -
      Shift Position -
      Master Cylinder Control Torque -
      Coolant Temperature -
      Operation Conditions
      Item Diagnostic Note
      Motor Temperature

      If any liquid leaks into the ATF, insulation resistance may decrease only when the temperature is high.

      The motor temperature is likely to increase if the motor speed is low and output torque is high such as when cruising uphill slowly or accelerating from a low speed.
      Generator Temperature

      If any liquid leaks into the ATF, insulation resistance may decrease only when the temperature is high.

      The generator temperature is likely to increase under repeat acceleration and deceleration while the vehicle is driven in the mid speed range (60 to 80 km/h (37 to 50 mph)).

    • Customer Problem Analysis

      Ask the customer about the operating conditions and environment when the malfunction occurred.

      Item Diagnostic Note
      Driving Condition (acceleration, deceleration, turning, etc.) Changes in the insulation of the parts with insufficient insulation due to changes in G force or vibration is suspected.
      Road Condition (unpaved, etc.)
      Weather (rain, snow, etc.) Water intrusion is suspected
      Washing the vehicle (Whether the malfunction occurred after washing the vehicle?)

CAUTION / NOTICE / HINT

CAUTION:


  • B006HCX

    When troubleshooting DTC P0AA649, use either a tool wrapped with vinyl insulation tape or an insulated tool. (It is extremely dangerous when a high-voltage charge passes through a non-insulated tool causing a short.)

  • B006HUP

    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

    • Disconnecting the low voltage connector of the electric vehicle charger assembly.

    • Disconnecting the low voltage connector of the solar energy control unit

  • B006IQP

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

  • B006HQC

    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.

  • B006IVPC18
    *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.

  • 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.

  • B006I3VC06
    *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.

  • 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.

  • B006IGA

    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

Tech Tips

When measuring insulation resistance using a megohmmeter, set the megohmmeter to 500 V.

PROCEDURE


  1. CHECK DTC OUTPUT (HYBRID CONTROL, HV BATTERY)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control and HV Battery / Trouble Codes.

    4. Check for DTCs.


      Powertrain > Hybrid Control > Trouble Codes
      Powertrain > HV Battery > Trouble Codes
      Result
      Result Proceed to
      P0AA649, P1C7C49, P1C7D49, P1C7E49 or P1C7F49 only is output, or DTCs except the ones in the table below are also output. A
      DTCs of hybrid control system in the tables below are output. B
      DTCs of hybrid battery system in the tables below are output. C
      Malfunction Content System Relevant DTC
      Microcomputer malfunction Hybrid control system P060647 Hybrid/EV Powertrain Control Module Processor Watchdog / Safety MCU Failure
      P060A29 Hybrid/EV Powertrain Control Module Monitoring Processor Signal Invalid
      P060A44 Hybrid/EV Powertrain Control Module Monitoring Processor Data Memory Failure
      P060A45 Hybrid/EV Powertrain Control Module Monitoring Processor Program Memory Failure
      P060A49 Hybrid/EV Powertrain Control Module Monitoring Processor Internal Electronic Failure
      P060B1C Hybrid/EV Powertrain Control Module A/D Processing Voltage Out of Range
      P060B71 Hybrid/EV Powertrain Control Module A/D Processing Actuator Stuck
      P1CE31C Hybrid/EV Powertrain Control Module Monitoring Processor A/D Processing Voltage Out of Range
      P1CE349 Hybrid/EV Powertrain Control Module Monitoring Processor A/D Processing Internal Electronic Failure
      P1CE371 Hybrid/EV Powertrain Control Module Monitoring Processor A/D Processing Actuator Stuck
      Hybrid battery system P060687 Hybrid/EV Battery Energy Control Module Processor to Monitoring Processor Missing Message
      P060A47 Hybrid/EV Battery Energy Control Module Monitoring Processor Watchdog / Safety MCU Failure
      P060A87 Hybrid/EV Battery Energy Control Module Processor from Monitoring Processor Missing Message
      P060B49 Hybrid/EV Powertrain Control Module A/D Processing Internal Electronic Failure
      P062F46 Hybrid/EV Battery Energy Control Module EEPROM Calibration / Parameter Memory Failure
      Power Source Circuit Malfunction Hybrid control system P06881F ECM/PCM Power Relay Sense Circuit Intermittent
      System malfunction Hybrid control system P1C9E9F Hybrid/EV System Reset Stuck Off

      Tech Tips


      • P0AA649 may be output as a result of the malfunction indicated by the DTCs above.


        1. The chart above is listed in inspection order of priority.

        2. Check DTCs that are output at the same time by following the listed order. (The main cause of the malfunction can be determined without performing unnecessary inspections.)

    5. Turn the power switch off.


    B

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

    C

    GO TO DTC CHART (HYBRID BATTERY SYSTEM) Click here

    A

  2. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

    4. Check for DTCs.


      Powertrain > Hybrid Control > Trouble Codes

      Note


      • DTC P1C7C49, P1C7D49, P1C7E49, P1C7F49, P1CF749 and P33CF49 are not stored with P0AA649 at the same time. If a decrease in insulation resistance is detected and DTC P0AA649 is output, wait for 5 minutes with the power switch on (READY), the shift lever in D and the air conditioning system on within the same trip, then turn the power switch off and wait for 2 minutes to determine the DTC (P1C7C49, P1C7D49, P1C7E49 or P1C7F49).

        If a decrease in insulation resistance is detected during plug-in charge, wait for 3 minutes after connecting the electric vehicle charger cable assembly and conducting plug-in charge to determine the DTC (P1CF749 or P1CF49).

      • When any other DTC indicating parts which the insulation resistance dropped are output, perform the diagnostic procedure for each DTC.

      Result
      Result Proceed to
      P0AA649 (decrease in the insulation resistance of the high-voltage circuit) only or P0AA649 and P33CF49 (abnormal area detection failure) are output. A
      P0AA649 and P1C7C49 (decrease in the insulation resistance of the air conditioning system area) are output. B
      P0AA649 and P1C7D49 (decrease in the insulation resistance of the HV battery area) are output. C
      P0AA649 and P1C7E49 (decrease in the insulation resistance of the hybrid vehicle transaxle assembly area) are output. D
      P0AA649 and P1C7F49 (decrease in the insulation resistance of the high-voltage direct current area) are output. E
      P0AA649 and P1CF749 (decrease in the insulation resistance of the charger area) are output. F

    5. Turn the power switch off.


    B

    GO TO AIR CONDITIONING SYSTEM (P1C7C49) Click here

    C

    GO TO STEP 19 Click here

    D

    CHECK INVERTER WITH CONVERTER ASSEMBLY Click here

    E

    CHECK HIGH VOLTAGE DIRECT CURRENT AREA Click here

    F

    CHECK NO. 2 HV BATTERY JUNCTION BLOCK ASSEMBLY Click here

    A

  3. CLEAR DTC

    Result
    Proceed to
    NEXT

    1. Connect the GTS to the DLC3.

    2. Turn the power switch on (IG).

    3. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

    4. Read and record the DTCs and freeze frame data.


      Powertrain > Hybrid Control > Trouble Codes

    5. Clear the DTCs and freeze frame data.


      Powertrain > Hybrid Control > Clear DTCs

    6. Turn the power switch off.

      Result
      Proceed to
      NEXT

    NEXT

  4. SIMULATION TEST


    1. Connect the GTS to the DLC3.

    2. Turn the power switch off and wait for 2 minutes or more.

    3. Apply the parking brake and secure the wheels using chocks.

    4. When the vehicle is stationary, turn the power switch on (READY) with park (P) selected and wait for1 minute or more.

    5. Turn the air conditioning system on (MAX COLD, blower speed HI).

    6. While depressing the brake pedal without depressing the accelerator pedal, move the shift lever to D and wait for 5 minutes.

    7. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

    8. Check for DTCs.


      • If step B is performed within the same trip after DTC P0AA649 is stored, the parts with insufficient insulation resistance will be determined and a DTC (P1C7C49, P1C7D49, P1C7E49 or P1C7F49) will be stored.

      • If no DTCs are output, proceed to the step A.


      Powertrain > Hybrid Control > Trouble Codes

    9. Drive the vehicle for approximately 5 minutes referring to the following freeze frame data items:"Vehicle Speed", "Shift Position", "Accelerator Position Sensor No.1 Voltage %", "Engine Speed","Coolant Temperature", "Master Cylinder Control Torque", "Motor Temperature" and "Generator Temperature".(Step A)

      (If the freeze frame data item "Vehicle Speed" is 10 km/h (6 mph) or less, drive the vehicle at 10km/h (6 mph) or more.)

    10. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

    11. Check for DTCs.


      • If step B is performed within the same trip after DTC P0AA649 is stored, the parts with insufficient insulation resistance will be determined and a DTC (P1C7C49, P1C7D49, P1C7E49 or P1C7F49) will be stored.

      • If DTC P0AA649 is output, complete the Step B immediately as quickly as possible.

      • If no DTCs are output, proceed to the step C.


      Powertrain > Hybrid Control > Trouble Codes

    12. Wait for 1 minute or more with the vehicle stopped, the power switch on (READY), park (P) selected and the air conditioning system on (Lo/COOL MAX, blower speed HI), then turn the power switch off and wait for 2 minutes or more. (Step B)

    13. Turn the power switch off and connect the electric vehicle charger cable assembly, and plug-in charge the vehicle for 3 minutes or more. (step C)

    14. Enter the following menus: Powertrain / Hybrid Control / Trouble Codes.

    15. Check for DTCs.


      • When charging does not continue for 3 minutes with no DTC output, lower the SOC and then perform the step C again.

      • If DTC P0AA649 is output at this step, the area where the insulation resistance has decreased is specified and DTC P1C7D49, P1CF749 or P33CF49 is also output.


      Powertrain > Hybrid Control > Trouble Codes
      Result
      Result Proceed to
      P0AA649 (decrease in the insulation resistance of the high-voltage circuit) and P33CF49 (abnormal area detection failure) are output. A
      P0AA649 and P1C7C49 (decrease in the insulation resistance of the air conditioning system area) are output. B
      P0AA649 and P1C7D49 (decrease in the insulation resistance of the HV battery area) are output. C
      P0AA649 and P1C7E49 (decrease in the insulation resistance of the hybrid vehicle transaxle assembly area) are output. D
      P0AA649 and P1C7F49 (decrease in the insulation resistance of the high-voltage direct current area) are output. E
      P0AA649 and P1CF749 (decrease in the insulation resistance of the charger area) are output. F

    B

    GO TO AIR CONDITIONING SYSTEM (P1C7C49) Click here

    C

    GO TO STEP 19 Click here

    D

    GO TO STEP 38 Click here

    E

    GO TO STEP 44 Click here

    F

    GO TO STEP 53 Click here

    A

  5. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE (FOR MG2))

    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. B006HL6

      Disconnect the motor cable from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter, coolant or water enters the inverter with converter assembly.

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

      Tech Tips

      As the insulation resistance may vary when motor (MG2) rotates, perform this inspection while rotating the front wheels.

    4. Turn the power switch on (IG).

      Note

      Turning the power switch on (IG) with the service plug grip removed causes DTCs to be stored. Clear the DTCs after performing this inspection.

    5. Move the shift lever to N and lift the vehicle.

    6. B006J2GC19
      *1 Shield Ground
      *a

      Motor Cable (for MG2)

      (Inverter with Converter Assembly Side)

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below while rotating the front wheels 2 revolutions in the same direction simultaneously.

      Note


      • Carefully perform this inspection as the motor (MG2) may generate current when the front wheels are rotated by hand.

      • 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
      g2-2 (U) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher
      g2-3 (V) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher
      g2-1 (W) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher

    7. Lower the vehicle and push the P position switch (transmission shift main switch).

    8. Turn the power switch off.

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

      Result
      Proceed to
      OK
      NG

    NG

    CHECK MOTOR CABLE (FOR MG2) Click here

    OK

  6. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MOTOR CABLE (FOR MG1))

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

      Tech Tips

      As the insulation resistance may vary when generator (MG1) rotates, perform this inspection while rotating the front wheels.

    3. Turn the power switch on (IG).

      Note

      Turning the power switch on (IG) with the service plug grip removed causes DTCs to be stored. Clear the DTCs after performing this inspection.

    4. Move the shift lever to N and lift the vehicle.

    5. B006J2GC20
      *1 Shield Ground
      *a

      Motor Cable (for MG1)

      (Inverter with Converter Assembly Side)

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below while rotating the front wheels 2 revolutions in the same direction simultaneously.

      Note


      • Carefully perform this inspection as the generator (MG1) may generate current when the front wheels are rotated by hand.

      • 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
      g2-5 (U) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher
      g2-6 (V) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher
      g2-4 (W) - Body ground and shield ground Power switch on (IG) 100 MΩ or higher

    6. Lower the vehicle and push the P position switch (transmission shift main switch).

    7. Turn the power switch off.

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

      Result
      Proceed to
      OK
      NG

    NG

    CHECK MOTOR CABLE (FOR MG1) Click here

    OK

  7. CHECK AIR CONDITIONING 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. B006HWA

      Disconnect the air conditioning wire connector from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the air conditioning wire.

    3. B006J7BC04
      *1 Shield Ground
      *a

      Air conditioning wire

      (Inverter with Converter Assembly Side)
      *b Tip of Terminal

      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.

      • Be sure to inspect with connecting the tester probes to the tips of the terminal.

      Standard Resistance
      Tester Connection Condition Specified Condition
      T2-1 (ACPB) - Body ground and shield ground Power switch off 3 MΩ or higher
      T2-2 (ACPE) - Body ground and shield ground Power switch off 3 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    GO TO STEP 49 Click here

    OK

  8. 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. B006ISD

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

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the HV floor under wire.

    3. B006J02C04
      *1 Shield Ground
      *a

      HV Floor Under Wire

      (Inverter with Converter Assembly Side)

      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.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      S1-1 (CBI) - Body ground and shield ground Power switch off 10 MΩ or higher
      S1-2 (CEI) - Body ground and shield ground Power switch off 10 MΩ or higher

      Tech Tips

      Visually inspect the HV floor under wire for damage. If there is any damage, then this is the likely cause of low insulation resistance.

      Result
      Proceed to
      OK
      NG

    NG

    GO TO STEP 47 Click here

    OK

  9. CHECK INVERTER WITH CONVERTER ASSEMBLY

    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. B006ISD

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

    3. B006HVTC02
      *a High Voltage Terminal

      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
      High voltage terminal - Body ground Power switch off 1 MΩ or higher

      Tech Tips

      Perform this inspection with the motor cable and air conditioning wire disconnected from the inverter with converter assembly.

      Result
      Proceed to
      OK
      NG

    NG

    GO TO STEP 46 Click here

    OK

  10. CHECK NO. 2 HV BATTERY JUNCTION 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 upper hybrid battery cover sub-assembly.

    3. B006IYZ

      Disconnect the HV battery charger wire connector from the No. 2 HV battery junction block assembly.

    4. B006J5NC02
      *a

      Component without harness connected

      (No. 2 HV Battery Junction Block Assembly)

      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
      U9-1 (DCHB) - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    GO TO STEP 58 Click here

    OK

  11. CHECK NO. 1 HV BATTERY JUNCTION 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. B006J3Q

      Disconnect the HV battery charger wire connector from the No. 1 HV battery junction block assembly.

    3. B006I08C02
      *a

      Component without harness connected

      (No. 1 HV Battery Junction Block Assembly)

      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
      U10-1 (DCHG) - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK (w/ Solar Charging System)
      OK (w/o Solar Charging System)
      NG

    OK (w/o Solar Charging System)

    CHECK ELECTRIC VEHICLE CHARGER ASSEMBLY Click here

    NG

    GO TO STEP 66 Click here

    OK (w/ Solar Charging System)

  12. CHECK SOLAR ENERGY CONTROL UNIT

    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 rear seat console box assembly.

      Click here

    3. B006IB2N02

      Disconnect the N73 solar energy control unit connector.

    4. B006IM3N02

      Disconnect the N71 and N72 solar energy control unit connectors.

    5. B006HUMN02

      Disconnect the U11 solar energy control unit connector.

    6. B006HEFC01
      *a

      Component without harness connected

      (Solar Energy Control Unit)

      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
      U11-1 (DPLB) - Body ground Power switch off 10 MΩ or higher
      U11-2 (DPLG) - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    GO TO STEP 59 Click here

    OK

  13. CHECK ELECTRIC VEHICLE CHARGER ASSEMBLY

    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. B006IRSC03
      *a

      HV Battery Charger Wire

      (Solar Energy Control Unit Side)

      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
      U11-1 (DPLB) - Body ground Power switch off 10 MΩ or higher
      U11-2 (DPLG) - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    OK

    GO TO STEP 19 Click here

    NG

    GO TO STEP 56 Click here

  14. GO TO AIR CONDITIONING SYSTEM (P1C7C49)

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  15. GO TO AIR CONDITIONING SYSTEM (P1C7C49)

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  16. CHECK MOTOR CABLE (FOR MG2)

    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 motor cable from the hybrid vehicle transaxle assembly.

      Click here

    3. B006J2GC22
      *1 Shield Ground
      *a

      Motor Cable (for MG2)

      (Inverter with Converter Assembly Side)

      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
      g2-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      g2-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      g2-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      Result
      Proceed to
      OK
      NG

    OK

    GO TO STEP 41 Click here

    NG

    GO TO STEP 42 Click here

  17. CHECK MOTOR CABLE (FOR MG1)

    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 motor cable from the hybrid vehicle transaxle assembly.

      Click here

    3. B006J2GC23
      *1 Shield Ground
      *a

      Motor Cable (for MG1)

      (Inverter with Converter Assembly Side)

      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
      g2-5 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      g2-6 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      g2-4 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      Result
      Proceed to
      OK
      NG

    OK

    GO TO STEP 41 Click here

    NG

    GO TO STEP 43 Click here

  18. CHECK ELECTRIC VEHICLE CHARGER 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. B006IYBC10
      *a

      HV Battery Charger Wire

      (HV Battery Junction Block Assembly Side)

      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
      U9-1 (DCHB) - Body ground Power switch off 10 MΩ or higher
      U10-1 (DCHG) - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    GO TO STEP 63 Click here

    OK

  19. CHECK HV BATTERY (HIGH VOLTAGE CABLE)

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.

    Tech Tips

    Make sure that no foreign matter or water has entered the HV battery.


    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. B006IEL

      Disconnect the battery ECU assembly connectors.

      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. B006IJZC03
      *a

      Service Plug Grip Removed

      (Service Plug Grip Connecting Terminals)

      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
      1 - Body ground Power switch off 10 MΩ or higher
      2 - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    CHECK ELECTRIC VEHICLE BATTERY PLUG Click here

    OK

  20. REPLACE BATTERY ECU ASSEMBLY

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  21. CHECK ELECTRIC VEHICLE BATTERY PLUG

    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. B006IG0

      Disconnect the electric vehicle battery plug connector.

    3. B006IJZC04
      *a

      Service Plug Grip Removed

      (Service Plug Grip Connecting Terminals)

      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
      1 - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

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

    OK

  22. CHECK NO. 2 HV BATTERY JUNCTION 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. B006HO7

      Disconnect the high voltage cable connector of the HV battery from the No. 2 HV battery junction block assembly.

      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. B006I2FC02
      *a

      Component without harness connected

      (No. 2 HV Battery Junction Block Assembly)

      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
      j1-1 (+) - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    GO TO STEP 58 Click here

    OK

  23. CHECK NO. 1 HV BATTERY JUNCTION 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. B006I2W

      Disconnect the high voltage cable connector of the HV battery from the No. 1 HV battery junction block assembly.

      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. B006HO2C02
      *a

      Component without harness connected

      (No. 1 HV Battery Junction Block Assembly)

      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
      i1-1 (-) - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    GO TO STEP 66 Click here

    OK

  24. CHECK HV BATTERY

    CAUTION:

    Be sure to wear insulated gloves and protective goggles.


    1. Check that no electrolyte is leaking from each HV supply stack sub-assembly.

      Click here

      Result
      Result Proceed to
      Electrolyte is not leaking from the HV supply stack sub-assembly. A
      Electrolyte is leaking from the HV supply stack sub-assembly. B

    B

    REPLACE HV BATTERY (HV supply stack sub-assembly that has a leak of electrolyte) Click here

    A

  25. CHECK NO. 5 HV SUPPLY STACK SUB-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. B006HCY

      Disconnect the HV battery high voltage connector from the hybrid battery terminal block.

      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. B006J34C04
      *a

      Component without harness connected

      (Hybrid Battery Terminal Block Side)

      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 - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE NO. 5 HV SUPPLY STACK SUB-ASSEMBLY Click here

    OK

  26. CHECK HYBRID BATTERY TERMINAL BLOCK

    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. B006I4B

      Disconnect the HV battery high voltage connector from the hybrid battery terminal block.

      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. B006IKUC03
      *a

      Component without harness connected

      (Hybrid Battery Terminal Block)

      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 - Body ground Power switch off 10 MΩ or higher
      r1-1 - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE HYBRID BATTERY TERMINAL BLOCK Click here

    OK

  27. CHECK NO. 4 HV SUPPLY STACK SUB-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. B006IGON03

      Disconnect the pq1 HV battery high voltage connector.

      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. B006HQ6C02
      *a

      Component without harness connected

      (No. 4 HV Supply Stack Sub-assembly Side)

      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
      pq1-1 - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE NO. 4 HV SUPPLY STACK SUB-ASSEMBLY Click here

    OK

  28. CHECK NO. 3 HV SUPPLY STACK SUB-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. B006HNLC02
      *a

      Component without harness connected

      (No. 3 HV Supply Stack Sub-assembly Side)

      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
      A-1 - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE NO. 3 HV SUPPLY STACK SUB-ASSEMBLY Click here

    OK

  29. CHECK NO. 2 HV SUPPLY STACK SUB-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. B006HLNN03

      Disconnect the nm1 HV battery high voltage connector.

      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. B006J34C05
      *a

      Component without harness connected

      (No. 2 HV Supply Stack Sub-assembly Side)

      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
      nm1-1 - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

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

    OK

  30. REPLACE NO. 1 HV SUPPLY STACK SUB-ASSEMBLY

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  31. REPLACE NO. 2 HV SUPPLY STACK SUB-ASSEMBLY

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  32. REPLACE HV BATTERY (HV supply stack sub-assembly that has a leak of electrolyte)

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  33. REPLACE NO. 5 HV SUPPLY STACK SUB-ASSEMBLY

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  34. REPLACE HYBRID BATTERY TERMINAL BLOCK

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  35. REPLACE NO. 4 HV SUPPLY STACK SUB-ASSEMBLY

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  36. REPLACE NO. 3 HV SUPPLY STACK SUB-ASSEMBLY

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  37. REPLACE NO. 2 HV SUPPLY STACK SUB-ASSEMBLY

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  38. CHECK INVERTER WITH CONVERTER ASSEMBLY

    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. B006HL6

      Disconnect the motor cable from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter, coolant or water enters the inverter with converter assembly.

    3. B006IAAC01
      *a High Voltage Terminal

      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
      High voltage terminal - Body ground Power switch off 1 MΩ or higher

      Tech Tips

      Perform this inspection with the motor cable disconnected from the inverter with converter assembly.

      Result
      Proceed to
      OK
      NG

    NG

    GO TO STEP 46 Click here

    OK

  39. CHECK MOTOR CABLE (FOR MG2)

    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 motor cable from the hybrid vehicle transaxle assembly.

      Click here

    3. B006J2GC21
      *1 Shield Ground
      *a

      Motor Cable (for MG2)

      (Inverter with Converter Assembly Side)

      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
      g2-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      g2-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      g2-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE MOTOR CABLE Click here

    OK

  40. CHECK MOTOR CABLE (FOR MG1)

    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 motor cable from the hybrid vehicle transaxle assembly.

      Click here

    3. B006J2GC20
      *1 Shield Ground
      *a

      Motor Cable (for MG1)

      (Inverter with Converter Assembly Side)

      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
      g2-5 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      g2-6 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      g2-4 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE MOTOR CABLE Click here

    OK

  41. REPLACE HYBRID VEHICLE TRANSAXLE ASSEMBLY

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  42. REPLACE MOTOR CABLE

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  43. REPLACE MOTOR CABLE

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  44. CHECK HIGH VOLTAGE DIRECT CURRENT AREA

    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. B006H8X

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

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the HV floor under wire.

    3. B006J02C04
      *1 Shield Ground
      *a

      HV Floor Under Wire

      (Inverter with Converter Assembly Side)

      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.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      S1-1 (CBI) - Body ground and shield ground Power switch off 10 MΩ or higher
      S1-2 (CEI) - Body ground and shield ground Power switch off 10 MΩ or higher

      Tech Tips

      Visually inspect the HV floor under wire for damage. If there is any damage, then this is the likely cause of low insulation resistance.

      Result
      Proceed to
      OK
      NG

    NG

    CHECK HV FLOOR UNDER WIRE Click here

    OK

  45. CHECK AIR CONDITIONING 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. B006HWA

      Disconnect the air conditioning wire connector from the inverter with converter assembly.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the air conditioning wire.

    3. B006J7BC04
      *1 Shield Ground
      *a

      Air conditioning wire

      (Inverter with Converter Assembly Side)
      *b Tip of Terminal

      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.

      • Be sure to inspect with connecting the tester probes to the tips of the terminal.

      Standard Resistance
      Tester Connection Condition Specified Condition
      T2-1 (ACPB) - Body ground and shield ground Power switch off 3 MΩ or higher
      T2-2 (ACPE) - Body ground and shield ground Power switch off 3 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    CHECK AIR CONDITIONING WIRE Click here

    OK

  46. REPLACE INVERTER WITH CONVERTER ASSEMBLY

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  47. CHECK HV FLOOR UNDER WIRE

    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 hybrid battery cover sub-assembly.

      Click here

    3. B006IGF

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

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the HV floor under wire.

    4. B006J02C04
      *1 Shield Ground
      *a

      HV Floor Under Wire

      (Inverter with Converter Assembly Side)

      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.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      S1-1 (CBI) - Body ground Power switch off 10 MΩ or higher
      S1-2 (CEI) - Body ground Power switch off 10 MΩ or higher

      Tech Tips

      Visually inspect the HV floor under wire for damage. If there is any damage, then this is the likely cause of low insulation resistance.

      Result
      Proceed to
      OK
      NG

    NG

    REPLACE HV FLOOR UNDER WIRE Click here

    OK

  48. CHECK NO. 2 HV BATTERY JUNCTION 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. B006IBQC02
      *a

      Component without harness connected

      (No. 2 HV Battery Junction Block Assembly)

      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
      S3-1 (CBI) - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    OK

    GO TO STEP 66 Click here

    NG

    GO TO STEP 58 Click here

  49. CHECK AIR CONDITIONING 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. B006I2H

      Disconnect the air conditioning wire from the compressor with motor assembly.

      Click here

    3. B006J7BC04
      *1 Shield Ground
      *a

      Air conditioning wire

      (Inverter with Converter Assembly Side)
      *b Tip of Terminal

      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.

      • Be sure to inspect with connecting the tester probes to the tips of the terminal.

      Standard Resistance
      Tester Connection Condition Specified Condition
      T2-1 (ACPB) - Body ground and shield ground Power switch off 10 MΩ or higher
      T2-2 (ACPE) - Body ground and shield ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE AIR CONDITIONING WIRE Click here

    OK

  50. GO TO AIR CONDITIONING SYSTEM (P1C7C49)

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  51. REPLACE AIR CONDITIONING WIRE

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  52. REPLACE HV FLOOR UNDER WIRE

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  53. CHECK NO. 2 HV BATTERY JUNCTION 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 upper hybrid battery cover sub-assembly.

    3. B006IYZ

      Disconnect the HV battery charger wire connector from the No. 2 HV battery junction block assembly.

    4. B006J5NC03
      *a

      Component without harness connected

      (No. 2 HV Battery Junction Block Assembly)

      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
      U9-1 (DCHB) - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE NO. 2 HV BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK

  54. CHECK NO. 1 HV BATTERY JUNCTION 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. B006J3Q

      Disconnect the HV battery charger wire connector from the No. 1 HV battery junction block assembly.

    3. B006I08C03
      *a

      Component without harness connected

      (No. 1 HV Battery Junction Block Assembly)

      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
      U10-1 (DCHG) - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK (w/ Solar Charging System)
      OK (w/o Solar Charging System)
      NG

    OK (w/o Solar Charging System)

    CHECK HV BATTERY CHARGER WIRE Click here

    NG

    REPLACE NO. 1 HV BATTERY JUNCTION BLOCK ASSEMBLY Click here

    OK (w/ Solar Charging System)

  55. CHECK SOLAR ENERGY CONTROL UNIT

    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 rear seat console box assembly.

      Click here

    3. B006IB2N02

      Disconnect the N73 solar energy control unit connector.

    4. B006IM3N02

      Disconnect the N71 and N72 solar energy control unit connectors.

    5. B006HUMN02

      Disconnect the U11 solar energy control unit connector.

    6. B006HEFC01
      *a

      Component without harness connected

      (Solar Energy Control Unit)

      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
      U11-1 (DPLB) - Body ground Power switch off 10 MΩ or higher
      U11-2 (DPLG) - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    CHECK HV BATTERY CHARGER WIRE Click here

    OK

  56. CHECK HV BATTERY CHARGER 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. B006HUKN02

      Disconnect the U12 electric vehicle charger assembly connector.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the HV floor under wire.

    3. B006IRSC04
      *a

      HV Battery Charger Wire

      (Electric Vehicle Charger Assembly Side)

      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.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      U11-1 (DPLB) - Body ground Power switch off 10 MΩ or higher
      U11-2 (DPLG) - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE HV BATTERY CHARGER WIRE Click here

    OK

  57. REPLACE ELECTRIC VEHICLE CHARGER ASSEMBLY

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  58. REPLACE NO. 2 HV BATTERY JUNCTION BLOCK ASSEMBLY

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  59. CHECK HV BATTERY CHARGER 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. B006J9IN01

      Disconnect the U13 solar energy control unit connector.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the HV floor under wire.

    3. B006J8NC02
      *a

      HV Battery Charger Wire

      (Solar Energy Control Unit Side)

      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.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      U13-1 (DCHB) - Body ground Power switch off 10 MΩ or higher
      U13-2 (DCHG) - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE HV BATTERY CHARGER WIRE Click here

    OK

  60. REPLACE SOLAR ENERGY CONTROL UNIT

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  61. REPLACE HV BATTERY CHARGER WIRE

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  62. REPLACE HV BATTERY CHARGER WIRE

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  63. CHECK HV BATTERY CHARGER WIRE

    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. B006HUKN02

      Disconnect the U12 electric vehicle charger assembly connector.

      Tech Tips

      Make sure that no foreign matter has entered or contaminated the HV floor under wire.

    3. B006IYBC11
      *a

      HV Battery Charger Wire

      (HV Battery Junction Block Assembly Side)

      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.

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      U9-1 (DCHB) - Body ground Power switch off 10 MΩ or higher
      U10-1 (DCHG) - Body ground Power switch off 10 MΩ or higher
      Result
      Proceed to
      OK
      NG

    NG

    REPLACE HV BATTERY CHARGER WIRE Click here

    OK

  64. REPLACE ELECTRIC VEHICLE CHARGER ASSEMBLY

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  65. REPLACE HV BATTERY CHARGER WIRE

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here

  66. REPLACE NO. 1 HV BATTERY JUNCTION BLOCK ASSEMBLY

    Click here

    Result
    Proceed to
    NEXT

    NEXT

    PERFORM CONFIRMATION AFTER REPLACING PARTS Click here